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• CARBON content in Low Carbon Steel is generally 0.05-0.15%.
• Carbon content in MILD Steel is generally 0.16-0.29%. & DENSITY is 7.85 g/cubic CM.
• Carbon content in High Carbon Steel is generally 0.3-1.7%.
• Carbon content is PIG Iron is generally 3.5-4.5%.

A gear RATIO is a direct MEASURE of ratio of the rotational SPEEDS of two or more INTERLOCKING GEARS.

A gear ratio is a direct measure of ratio of the rotational speeds of two or more interlocking gears.

Digital TWIN Spark Ignition. This is used for a better FUEL combustion in the cylinder head which helps provide better efficiency and OPTIMUM USE of fuel.

Digital Twin Spark Ignition. This is used for a better fuel combustion in the cylinder head which helps provide better efficiency and optimum use of fuel.

• MCPHERSON STRUTS
• Leaf spring
• Coil spring
• TORSION beam
• Wishbone
• AIR Suspension

The IDEAL shape would be a sphere. The container must have the capacity to withstand the extremely HIGH PRESSURE of liquefied gas. A SPHERICAL shape helps in distributing these FORCES uniformly.

The ideal shape would be a sphere. The container must have the capacity to withstand the extremely high pressure of liquefied gas. A spherical shape helps in distributing these forces uniformly.

• Temperature Sensor:- This DEVICE collects information about the temperature from a source and converts it to a form which is understandable by another device or person. Glass thermometer is the best example where mercury acts as the temperature sensor.
• IR Sensors:- This device detects and/or emits infrared RADIATION to sense a particular phase in the environment. Mostly thermal radiation is emitted by all the objects in the infrared spectrum. This type of radiation is not visible to the human eye but the infrared sensor detects it.
• UV Sensors:- These sensors measure the INTENSITY of the ULTRAVIOLET radiation. This form of electromagnetic radiation has wavelengths which are longer than x-rays yet shorter than visible radiation. UV sensors can discover the exposure of environment to ultraviolet radiation.
• Touch Sensor:- A touch sensor acts as a variable resistor based on the location where it is sensed.
• Proximity Sensor:- A proximity sensor detects the PRESENCE of objects that are placed in close proximity without any point of contact.

The COMPRESSION RATIO of diesel engine is HIGHER than the petrol engine, the reason for producing higher torque. The EFFICIENCY of diesel engine INCREASES with load. Diesel produces slow energy on burning of fuel and the efficiency of the engine increases with load which is why diesel engine is suitable and largely used for heavy vehicles.

The compression ratio of diesel engine is higher than the petrol engine, the reason for producing higher torque. The efficiency of diesel engine increases with load. Diesel produces slow energy on burning of fuel and the efficiency of the engine increases with load which is why diesel engine is suitable and largely used for heavy vehicles.

Each power stroke in a PETROL engine releases more heat and is converted into mechanical energy due to a HIGHER rate of burning. This is the reason petrol engine has higher power and acceleration.

DIESEL engine is a compression ignition engine with higher compression ratio, therefore EXTREME pressure is high. Since the piston of a diesel engine is larger, more torque is delivered in PRODUCED.

Each power stroke in a petrol engine releases more heat and is converted into mechanical energy due to a higher rate of burning. This is the reason petrol engine has higher power and acceleration.

Diesel engine is a compression ignition engine with higher compression ratio, therefore extreme pressure is high. Since the piston of a diesel engine is larger, more torque is delivered in produced.

TORQUE is the force that CAUSES rotation. It is a MEASURE of how much force is ACTING on an object MAKING it rotate.

Torque is the force that causes rotation. It is a measure of how much force is acting on an object making it rotate.

While power determines the speed of a vehicle, torque determines the TIMES in which that speed can be REACHED. The greater the torque figure, the faster the acceleration. The more torque in the engine, the faster you ACCELERATE. Power is the rate at which WORK is DONE, so it is basically the potential of the engine.

While power determines the speed of a vehicle, torque determines the times in which that speed can be reached. The greater the torque figure, the faster the acceleration. The more torque in the engine, the faster you accelerate. Power is the rate at which work is done, so it is basically the potential of the engine.

A PIPE is measured based on its inner DIAMETER (ID) whereas a tube is measured based on the OUTER diameter (OD). Other than the dimensions there is no MAJOR DIFFERENCE between the two.

A pipe is measured based on its inner diameter (ID) whereas a tube is measured based on the outer diameter (OD). Other than the dimensions there is no major difference between the two.

Pressure and temperature are TWO of the most important factors to be considered before selecting the type of material to be used. STEAM is a compressible gas due to which the CAPACITY of the pipe line depends on the size of the pipes and pressure of the steam. Since steam at even low pressure can be dangerous, extra care is to be taken. GALVANIZED pipes are usually not used for steam. Pipes made of mild steel with welded fittings are instead largely used.

Pressure and temperature are two of the most important factors to be considered before selecting the type of material to be used. Steam is a compressible gas due to which the capacity of the pipe line depends on the size of the pipes and pressure of the steam. Since steam at even low pressure can be dangerous, extra care is to be taken. Galvanized pipes are usually not used for steam. Pipes made of mild steel with welded fittings are instead largely used.

Diamond is currently the hardest material, MADE up of carbon atoms which cannot move. Carbon is the only atom that can have four electrons in the second SHELL surrounding the carbon NUCLEUS, precisely why making a diamond the hardest material. However, there also are claims by a few to a new RARE material called Wurtzite Boron Nitride which has a structure SIMILAR to a diamond but has some other atoms in place of carbon.

Diamond is currently the hardest material, made up of carbon atoms which cannot move. Carbon is the only atom that can have four electrons in the second shell surrounding the carbon nucleus, precisely why making a diamond the hardest material. However, there also are claims by a few to a new rare material called Wurtzite Boron Nitride which has a structure similar to a diamond but has some other atoms in place of carbon.

A Process FLOW Diagram is a user friendly, simplified sketch which illustrates general plant streams, major EQUIPMENTS and key central loops and SHOWS the relationship between major components in the system. By using symbols to identify instruments and vessels it DESCRIBES the primary flow course. They also provide e detail of mass/energy balance data along with stream composition and physical properties, however do not show MINOR components.

A Process Flow Diagram is a user friendly, simplified sketch which illustrates general plant streams, major equipments and key central loops and shows the relationship between major components in the system. By using symbols to identify instruments and vessels it describes the primary flow course. They also provide e detail of mass/energy balance data along with stream composition and physical properties, however do not show minor components.

BEARING is a device that helps smoother movement with minimal friction which in turn helps enhances efficiency and speed. Considering two types of loading, radial and thrust, there are different types of bearings which help HANDLE these loads. The basic difference in the types of loads is essentially due to their ability to handle weight and different KINDS of loads for various applications.

Different types of bearings are:

• Ball bearing
• Roller bearing
• Ball Thrust bearing
• Roller thrust bearing
• Tapered roller bearing
• Magnetic bearings
• GIANT Roller Bearing

Bearing is a device that helps smoother movement with minimal friction which in turn helps enhances efficiency and speed. Considering two types of loading, radial and thrust, there are different types of bearings which help handle these loads. The basic difference in the types of loads is essentially due to their ability to handle weight and different kinds of loads for various applications.

Different types of bearings are:

• For Conventional MACHINES such as Lathe, milling machine, drilling machine, grinders company use the TWIST drill , twist drill bit with morse TAPER shank drills of HSS ( High Speed STEEL ) MATERIAL.
• For CNC Machines like CNC Lathe, VMC, company use the bits of carbide material. Bits are made from the high carbon steel, HSS, Carbide. Carbide is used for very hard material.
• HSS drills in sizes such as M2, M35, M42 Grades.
• Carbide tip tools as per ISO standards are in K10,K20,P10,P20, P30 & P40.

RAKE angle is the angle between the FACE of the CUTTING tool ( Rake Face ) and the NORMAL to the cutting direction.

Rake angle is the angle between the face of the cutting tool ( Rake Face ) and the normal to the cutting direction.

INTERNAL GEAR can be made by SHAPING with the pioneer cutter.

Internal Gear can be made by shaping with the pioneer cutter.

5S DESCRIBES how to describe a work space for efficiency and effectiveness by identifying and STORING the items.

1S -Sorting – To eliminate all the unnecessary tools, parts and instructions.

2S -Setting in order – Everything should be in its place and the place for each item should be CLEARLY labeled.

3S- Sweeping – Keep the workplace tidy and organized.

4S- Standardizing – Work place and tools should be consistent and standardized.

5S- Self Discipline – Maintain the self discipline on the FLOOR for effective efficiency. 

5S describes how to describe a work space for efficiency and effectiveness by identifying and storing the items.

1S -Sorting – To eliminate all the unnecessary tools, parts and instructions.

2S -Setting in order – Everything should be in its place and the place for each item should be clearly labeled.

3S- Sweeping – Keep the workplace tidy and organized.

4S- Standardizing – Work place and tools should be consistent and standardized.

5S- Self Discipline – Maintain the self discipline on the floor for effective efficiency. 

DIAMOND > Carbide > HSS ( HIGH Speed Steel ) > MILD Steel > Low Carbon Steel

Diamond > Carbide > HSS ( High Speed Steel ) > Mild Steel > Low Carbon Steel

Kanban is SCHEDULING system which advises manufacturers about how MUCH to produce, what to produce and when to produce. In this system, inventory is re-filled only when visual cues LIKE an empty BIN or cart is seen.

Kanban is scheduling system which advises manufacturers about how much to produce, what to produce and when to produce. In this system, inventory is re-filled only when visual cues like an empty bin or cart is seen.

DCR STANDS for Document Change Request, a change request which addresses about a PROBLEM with a document, SOP (standard operating PROCEDURE) or specification and PROPOSE a change to fix it.

DCR stands for Document Change Request, a change request which addresses about a problem with a document, SOP (standard operating procedure) or specification and propose a change to fix it.

BOM stands for Bill Of MATERIALS; it is a list of item or parts that makeup a product assembly. For example, a LAWN mower requires a HANDLE assembly, METAL deck assembly, a CONTROL assembly, motor and blade assembly.

BOM stands for Bill Of Materials; it is a list of item or parts that makeup a product assembly. For example, a lawn mower requires a handle assembly, metal deck assembly, a control assembly, motor and blade assembly.

MES stands for a system that manages and controls the PRODUCTION on the FACTORY floor with the motive of reducing the TOTAL TIME required to produce an order.

MES stands for a system that manages and controls the production on the factory floor with the motive of reducing the total time required to produce an order.

Six SIGMA is a data-driven methodology and APPROACH for eliminating DEFECTS in any process from manufacturing to transactional and from product to SERVICE.

Six sigma is a data-driven methodology and approach for eliminating defects in any process from manufacturing to transactional and from product to service.

The factors affect the MANUFACTURING process are:

Supplies: A well-managed supply and inventory is very crucial in order to run manufacturing process smoothly. The manufacturers must brace themselves up and ready to overcome any unexpected delays in supplies DUE to weather or transportation hindrance.

Equipment: Equipment’s are the central unit for any manufacturing plant; regular maintenance are utmost necessary to avoid a breakdown in the middle of PRODUCTION. IDENTIFY the means of improving the efficiency of every part of the equipment.

Factory Overhead: Without power supply, manufacturing is not possible. Always keep plan B ready in case of temporary power cut down.

Special Parts: Replacing any special SPARE parts with different specification may slow down your production, so before ordering any special spare parts ensure it fits your demand especially if it is imported from long distance.

Work Force: Human resource is equally important and plays a major role in manufacturing unit.

The factors affect the manufacturing process are:

Supplies: A well-managed supply and inventory is very crucial in order to run manufacturing process smoothly. The manufacturers must brace themselves up and ready to overcome any unexpected delays in supplies due to weather or transportation hindrance.

Equipment: Equipment’s are the central unit for any manufacturing plant; regular maintenance are utmost necessary to avoid a breakdown in the middle of production. Identify the means of improving the efficiency of every part of the equipment.

Factory Overhead: Without power supply, manufacturing is not possible. Always keep plan B ready in case of temporary power cut down.

Special Parts: Replacing any special spare parts with different specification may slow down your production, so before ordering any special spare parts ensure it fits your demand especially if it is imported from long distance.

Work Force: Human resource is equally important and plays a major role in manufacturing unit.

MANUFACTURING WORK in progress is when manufacturing firm transforms material into the work in process which includes raw material, labour and factory overhead. You can calculate all the below factors to know the costing for the manufacturing work in progress.

• Labour COSTS
• Raw material inventory costs
• Production cost
• Cost of ending work in process for the ACCOUNTING PERIOD.

Manufacturing work in progress is when manufacturing firm transforms material into the work in process which includes raw material, labour and factory overhead. You can calculate all the below factors to know the costing for the manufacturing work in progress.

A PRODUCT REPORT is a general TERM used to represent design, manufacturing, QUALITY, sales and repair information about a product.

A product report is a general term used to represent design, manufacturing, quality, sales and repair information about a product.

In MANUFACTURING unit, software that can be useful are Manufacturing ERP and Material Management. Some of the COMPANIES that provide the manufacturing software solution are SAP, Oracle ERP SYSTEM, ETC.

In manufacturing unit, software that can be useful are Manufacturing ERP and Material Management. Some of the companies that provide the manufacturing software solution are SAP, Oracle ERP system, etc.

Main challenge in MANUFACTURING is to develop better PRODUCTION processes, ensure the RIGHT MATERIAL and component supplies at the LEAST cost, decrease production time, eliminate wastage and maintain quality in the final product.

Main challenge in manufacturing is to develop better production processes, ensure the right material and component supplies at the least cost, decrease production time, eliminate wastage and maintain quality in the final product.

QMS stands for QUALITY Management System; it documents all necessary information about company’s design and OPERATIONAL controls, including ISSUE reporting, monitoring, continuous IMPROVEMENT and training, to make sure that company delivers continuous product.

QMS stands for Quality Management System; it documents all necessary information about company’s design and operational controls, including issue reporting, monitoring, continuous improvement and training, to make sure that company delivers continuous product.

A) VERNIER CALIPER Least Count

LC = ( Value of 1 Main Scale DIVISION ) / ( Total NUMBER of vernier scale divisions )

LC = 0.1 mm = ( 1 mm / 10 divisions )

LC of Vernier Caliper = 0.1 mm

B) Micrometer are also called SCREW Gauge. 

Least count of Micrometer 

Least count of Micrometer

Least Count of Micrometer= 0.01 mm

A) Vernier Caliper Least Count

LC = ( Value of 1 Main Scale Division ) / ( Total number of vernier scale divisions )

LC = 0.1 mm = ( 1 mm / 10 divisions )

LC of Vernier Caliper = 0.1 mm

B) Micrometer are also called Screw Gauge. 

Least count of Micrometer 

Least count of Micrometer

Least Count of Micrometer= 0.01 mm

Lean Manufacturing: It takes the CONCEPT of JIT and re-examines it from the CUSTOMER point of view. Anything that is produced should add something of valuable to the customer’s requirement. For example, if you are making stereo system for a luxury car, you will think from the customer point of view like sound quality, durability, space occupancy, loud or medium sound, ETC.

JIT (Just-in-Time): This methodology is designed to ensure that a product or part would arrive just in time to be USED. This technique saves the cost behind the unused inventory, and eliminating the need of piling up inventory.

Lean Manufacturing: It takes the concept of JIT and re-examines it from the customer point of view. Anything that is produced should add something of valuable to the customer’s requirement. For example, if you are making stereo system for a luxury car, you will think from the customer point of view like sound quality, durability, space occupancy, loud or medium sound, etc.

JIT (Just-in-Time): This methodology is designed to ensure that a product or part would arrive just in time to be used. This technique saves the cost behind the unused inventory, and eliminating the need of piling up inventory.

I am WORKING as production ENGINEER or supervisor. Around 40/50 workers are REPORTING to me in my line. We have 2/3 GET and DET those are getting training under me.

I am working as production engineer or supervisor. Around 40/50 workers are reporting to me in my line. We have 2/3 GET and DET those are getting training under me.

I reduced the cycle TIME of machines by using following methods:-

• Replace old machines with new one or giving servicing to the old machines on time.
• By using of good quality of tools, coolant and raw material.
• With the selection of active WORKERS and IMPART training to them.
• By MAKING the time study REPORT of all components those are running on machines.

I reduced the cycle time of machines by using following methods:-

Firstly, we make the process plan of the components and according to it, I draw the layout of the machines and make sure that machines should be in arrangement according to the next PROCESSES.

Then, I also CHECK to MAINTAIN the distance between the machines. We install the machines for maximum time SAVING and provide proper safety to the workers.

Firstly, we make the process plan of the components and according to it, I draw the layout of the machines and make sure that machines should be in arrangement according to the next processes.

Then, I also check to maintain the distance between the machines. We install the machines for maximum time saving and provide proper safety to the workers.

We get the weekly/monthly basis schedule from our customers. After getting the same schedule from PPC department, I do PLAN for various shifts and report to workers by displaying on the NOTICE board after the approval of the production manager. I PROVIDE DAILY target sheets to the workers and also check the sufficient raw material, tools, coolant & UNREPAIRED machine on the workshop.

We get the weekly/monthly basis schedule from our customers. After getting the same schedule from PPC department, I do plan for various shifts and report to workers by displaying on the notice board after the approval of the production manager. I provide daily target sheets to the workers and also check the sufficient raw material, tools, coolant & unrepaired machine on the workshop.

 I have made a good communication channel between the WORKERS and me. I give the daily production target to the workers which make them busy to complete their work. I give my full attention on shop FLOOR and we take strict ACTION if any worker starts gossiping during WORKING hours.

 I have made a good communication channel between the workers and me. I give the daily production target to the workers which make them busy to complete their work. I give my full attention on shop floor and we take strict action if any worker starts gossiping during working hours.

I improve the quality during production by using following steps:-

• By checking the components after every half hour.
• By checking the accuracy of tools & quality of material used for manufacturing the products.
• By giving run CHARTS to the workers so they can CHECK as they are GOING to be within tolerance. Run chart provides them continuous production with quality.
• By using good quality of coolant/cutting fluid for manufacturing process.
• By giving good COMMUNICATION channel between the workers and me.

I improve the quality during production by using following steps:-

Manufacturing MEANS a process of converting raw material into finish PRODUCTS by using various processes on MACHINE.

PRODUCTION means a process of converting INPUTS into outputs.

Manufacturing means a process of converting raw material into finish products by using various processes on machine.

Production means a process of converting inputs into outputs.

 I reduced downtime & INCREASE the production by using following steps:-

• By providing the maintenance activity on time if the problem comes arise on any machine.
• By providing sufficient raw material/tools/bits on machine.
• I made the BEST PLANT LAYOUT for machines and arranging them in line according to the next process.
• And, By making time study report of all COMPONENTS those are being manufactured on the machines. After then, I fixed the target for making these components.
• By using Manpower accurately & removing useless work. Also, implementing 5S, Kaizen activities to increase the production and reduce the down time.

 I reduced downtime & increase the production by using following steps:-

Jigs and fixtures are the DEVICES used to manufacture large AMOUNT of duplicate parts accurately.

Jigs:- A device that does both functions such as holding the work and guiding a tool is called Jigs. Types – Drill Jigs and Boring Jigs. 

Fixtures:- It is a production tool that holds, locates and SUPPORT the work securely so that required machining operations can be PERFORMED. Types – Milling Fixture, Profile Fixture.

Jigs and fixtures are the devices used to manufacture large amount of duplicate parts accurately.

Jigs:- A device that does both functions such as holding the work and guiding a tool is called Jigs. Types – Drill Jigs and Boring Jigs. 

Fixtures:- It is a production tool that holds, locates and support the work securely so that required machining operations can be performed. Types – Milling Fixture, Profile Fixture.

Production Engineering:– It is a branch of engineering which is a combination of manufacturing TECHNOLOGY with management service.

Industrial Engineering:– It is a branch of engineering dealing with the OPTIMIZATION of complex PROCESSES such as improvement, development , implementation of INTEGRATED systems.

Production Engineering:– It is a branch of engineering which is a combination of manufacturing technology with management service.

Industrial Engineering:– It is a branch of engineering dealing with the optimization of complex processes such as improvement, development , implementation of integrated systems.