ACE DESIGNERS - REPORT

Internship Report Bindagi, Anuj
ACE Designers Ltd. July 11, 2014
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INTERNSHIP REPORT – ACE DESIGNERS LTD.
A brief description of ACE Designers Ltd. and its associated companies is given below:
1. Ace Designers: Parent company manufacturing CNC turning machines
2. Auto CNC Machining Pvt. Ltd.: Component manufacturing unit
3. Micromatic Machine tools Pvt. Ltd.: Sales and service of machines
4. Pragati Automation: Manufacturer and exporter of tool turrets, auto tool changers etc.
5. Micromatic Grinding (MG) Technologies Ltd.: Manufacturer of cylindrical grinding
machines
6. Pioneer Computing Technologies: Manufacturer of productivity monitoring software for
machine tools.
All divisions of ACE Designers.
 Metrology
 CSG-Customer Service Group
 SMD-Sheet Metal Division
 Hydraulics
 Paint Shop
 Marketing
 QA-Quality Assurance & Quality Analysis
 Tool Room
 CMD-Component Manufacturing Division
 Purchase & Vendor
 Assembly
 Human Resource (HR)
METROLOGY
Metrology is the science of measurement. All measurement activities in ACE are carried
out at the Metrology Lab. It is the standards lab at ACE. Calibration of measuring instruments
and other high-precision measurements are the specialization of this department.
Constructional Features of the Metrology Lab.
 Vibration isolated floor for stable measurement. Standard flooring is 20” thick concrete
base.
 Temperature is controlled between 19-21 C
 Humidity is maintained between 40% RH – 60%RH
 ISO Class-8 Clean room

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 Light Intensity is 300 lux to 500 lux.
The various machines and their specifications:
 Ballbar-QC20
 Roundness Tester
 Co-Ordinate Measuring Machine (CMM)
 Laser Interferometer
 Profile Projector
 Roundness Tester (Taylor Hobson)
 Smart Balancer
 Electronic Level Blue Level
 Surface Roughness Testing Machine

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CUSTOMER SERVICE GROUP (CSG)
CSG acts as an interface between the Micromatics (MMT) throughout India and the
technical part of ACE itself.
Two important jobs of MMT:
 Install the machines in the customer factories
 In case of malfunction, the customer contact the MMT’s and they act as the customer
care center.
Operation Strategies
 Make to Order
 Make to Stock
 Assemble to Order
 Engineer to Order
Organization Structure of CSG
General Manager
Executive Technical
Engineers Assistants
Processes under CSG:
 Service Support
 Repair Services
 Customer Complaint Analysis
 Customer Training
 Free Replacement Item Control
SHEET METAL DIVISION (SMD)
The outer metal covered on a machine is manufactured in Sheet Metal Division. Huge metal
sheets will be cut and made in proper required shape. This department is concerned with all
work done on sheet metal which is used in manufacture of parts like the housing, doors and all
other sheet metal parts used on the CNC.

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The main objectives of SMD
 Controlling quality by process
 Manufacturing initiatives like Kaizen, CIP ,5S
 Adaptation of new techniques and technology
 Grinding and Painting (for finishing)
The two types of sheets used are:
1. HRCA – Hot Rolled Closed Annealed
The material used for HRCA is stainless steel SS-304 Grade
2. CRCA - Cold Rolled Closed Annealed
The material used for CRCA is mild steel of different grades
 Commercial quality grade
 Drawing grade -D Grade
 Deep drawing -DD Grade
 Extra deep drawing -EDD Grade
Manufacturing Practices
 Material Selection
 Cutting
 Forming
 Metal Joining
 Finishing
 Material Handling
Metal Joining:
Joining of the sheet metals is done in one of the following ways
 Thermal
 Adhesive
 Mechanical
 Welding
Material Selection:
The material used for sheet metal manufacturing is selected based on the following categories:
 Flatness

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 Uniform sheet thickness
 Wrinkle free sheets
 It is free from rust
 Mechanical and chemical properties as per 513 standard
Cutting:
Different cutting operations employed are:
 Shearing: This process utilizes shearing forces to cut. The length of cutting can be
controlled in this process using a back gauge. The accuracy obtained is within +/- 0.50
mm per meter
 Notching: Corner profile cutting using templates or over marking
 Punching: Used to cut holes and slots
 CNC Punching: HRCA- 4mm & SS- 2mm
 Water jet Cutting
 Plasma Cutting

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Finishing:
Types of processes:
 Rough grinding
 Finish Sandering
 Final finishing
 Buffing for SS material
 Painting or powder coating for MS material
HYDRAULICS
Hydraulic engineering is concerned with the flow and conveyance of fluids, principally
water. However, the fluid used in mechanical application is oil.
The primary components of basic hydraulic assembly are:
1. Power Pack: It is the power unit driving a hydraulic system. Its main function is to
pressurize the oil in the system using a pump and other control accessories and
collect it on return. The parts of the power pack are as follows:
 Tank
 Pump

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 Filter
 Air breather
 Accumulator
 Check Valve
 Fluid Level Gauge
2. Hydraulic Elements : It consists of all the elements that directly or indirectly help in
the control of flow of fluid and hence, transfer of energy. The different parts in
hydraulic elements are :
 Direction control valve
 Pressure reducer
 Pressure switch
 Gauge isolator
 Distribution box
The basic principle on which hydraulics works is:
The motor converts electrical energy into mechanical energy. This is the first energy
conversion that takes place. The pump converts the mechanical energy into pressure energy of
the oil.
Electrical Mechanical Pressure
Energy Energy Energy
Pump Motor

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PAINT SHOP
The primary concern of this department is cleaning of castings and sheet metal works
and painting them to prevent rust and also to give the machine aesthetic looks.
For sheet metal works the material used are:
 CRCA Sheet: Cold rolled closed annealed
 HRCA Sheet: Hot rolled closed annealed
The process of painting is as follows:
1. The dust settled on the component is cleaned and the grease is removed using
suitable cleansing agents.
2. The component is then rinsed with soft water
3. De-rusting – there are two ways of doing this:
a. Using phosphoric acid base- this cannot remove black scales
b. Using hydrochloric acid base- this removes the black scales
4. Activation: the metal surface is activated i.e. it is given a charge so as to aid
phosphating such that it adheres to the metal surface.
5. Phosphating: Phosphate coatings are used on steel parts for corrosion resistance,
lubricity, or as a foundation for subsequent coatings or painting. The main types of
phosphate coatings are manganese, iron and zinc.
Most phosphate coatings serve as a surface preparation for other coating and/or
painting. It has many features like electric isolation, excellent adhesion, porosity,
dielectric nature etc.
The whole process is carried out in phosphating tanks.
6. The work is then double rinsed using de-mineralized water.
7. It is then taken to a water drier oven which dries the component.
8. Powder Coating: It is applied as a free-flowing, dry powder. It does not require a
solvent to keep the binder and filler parts in a liquid suspension form. The coating is
typically applied electrostatically and is then cured under heat to allow it to flow and
form a “skin”. The powder may be a thermoplastic or a thermoset polymer. For this
process, the metal is placed on a conveyor which is earthed. The most common way
of applying the powder coating is to spray the powder using an electrostatic gun, or
Corona gun. The gun imparts a positive electric charge on the powder, which is then
sprayed towards the grounded object by mechanical or compressed air spraying and
then accelerated towards the work piece by the powerful electrostatic charge. The
object is then heated, and the powder melts into a uniform film, and is then cooled
to form a hard coating.

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For castings the method of liquid painting is used.
1. Blasting the casting so as to remove oil and other contaminants.
2. Primer is applied onto the casting
3. Putty is applied to fill deep holes which give the casting a smooth finish.
4. An epoxy primer is again applied onto the surface
5. Sandering is now done. It is the process wherein the roughening of surface is
carried out using emery paper so as to help the paint adhere to the casting
surface.
6. A masking tape is used to cover machine areas which are not to be painted from
paint deposition.
7. Paint is now applied onto the casting.
MARKETING
Marketing department is also known as Technical Service Group (TSG). It acts as a link
between the customer and ACE so as to get all the technical requirements from the customer
and to take the respective course of action. In ACE Designers Sales and Marketing activities are
handled by a separate subsidiary unit called Micromatic Machine Tools Pvt. Ltd., (MMT). MMT
acts as the interface between the customer and all ACE companies. MMT takes care of Indian
and non-US markets.
The main functions of the marketing department are:
Pre-Sales:
 Enquiry
 Lead
 Contact generation
 Opportunity
 Quotation
Post-Sales:
 OA
 PI
 Inspection
 Minutes of Meeting (MoM)
 Dispatch
 Tax Invoice

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Generation of Leeds: It involves finding a suitable customer whose application matches ACE
Designers product range and manufacturing abilities. Advertising in different industry based
magazines, participating in exhibitions and trade shows held all over the world, conducting
seminars and workshops are some of the main strategies that ACE Designers use to catch new
opportunities for business.
Handling Enquiries and Request for Quotation (RFQ): Customer sends an enquiry if he is
interested in buying the product. The marketing team discuss on the feasibility of the enquiry.
Once if proved feasible, Request for Quotation (RFQ) will be generated.
Some of the marketing strategies used by ACE are:
 Tech centers
 Exhibitions
 Road Shows
 Seminars and Workshops
 Industrial trade magazines
ACE Designers has 32 % of the total market share of all the machine tools across India. ACE
Designers marketing team use the concept of Just-In-Time (JIT).
MMT oversees all sales and service activities. They get an enquiry from the customer
which is forwarded to the TSG which then makes a quotation depending on what the
requirements are i.e. if it is a standard model or is customized.
This quote is sent to MMT which then sends it to the customer. Once all negotiations
are done the purchase order is given by the customer and the advance payment is finished,
MMT issues an order forwarding format to start the production of the machine to ACE. In case
of customized models separate component drawings are issued and the work begins.
QUALITY ASSURANCE (QA)
It exists to measure, evolve, analyze and feed in the data to facilitate process
improvements in the department. This department deals with:
 Inspection of incoming items
 Performing tests on machines such as Ball bar test and Laser test
 Metrology and calibration of measuring instruments
In-House Manufacturing QA
This is involving the inspection of those components that are manufactured in-house.

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After the manufacture of the first component, the operator inspects it himself and the
dimensions are recorded. Depending on the complexity, there is a secondary inspection
conducted. Inspection is conducted by the operator at every stage of the manufacture of the
component. Upon the completion of all these processes, the results are entered into SAP. After
the complete manufacture of the component, the component is stored in stores.
Items/Components are classified into 3 categories:
1. Most critical items
2. Less critical items
3. Least critical items
For most critical items, almost all components are inspected.
For other categories batch inspection is carried out. The department has a chart stating how
many components are to be inspected per 1000 components and depending on the number
of components complying with the quality standards the whole lot is either accepted or
rejected.
In case of continuous supply of faulty items corrective and preventive action (CAPA) is carried
out.
TOOL ROOM
Tool room is where machining of components takes place.
Principles of work holding:
 Wedge action
 Taper
 Helical
 Collets
 Pin arbor chuck
 2 Jaw chuck
 3 Jaw chuck
Chuck
A chuck is a specialized type of clamp used to hold rotating tools or materials.
A self-centering chuck uses jaws, interconnected via a scroll gear, to hold onto a tool or
work piece. Because they most often have three jaws, the term three-jaw chuck without

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other qualification is understood by machinists to mean a self-centering three jaw chuck. The
term universal chuck also refers to this type.
On an independent jaw chuck, each jaw can be moved independently. Because they
most often have four jaws, the term four-jaw chuck is understood. The independence of the
jaws makes the chuck ideal for gripping non-circular and circular cross-sections with extreme
precision. The non-self-centering action of the independent jaws makes centering highly
controllable.
Collets
A collet is a holding device that forms a collar around the object to be held and exerts a
strong clamping force on the object when it is tightened via a tapered outer collar. It may be
used to hold a work piece or a tool.
Each collet generally has only a narrow clamping range, which means that many collets
are required to hold a given range of materials in the chuck, unlike with many other types of
chuck that will generally cover a wide range of sizes.
The space clamping works on the helical principle.
Pin Arbor Chuck size- 80

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Chuck Collet
Different exclusive tools at ACE
COMPONENT MANUFACTURING DIVISION (CMD)
CMD is a department where singular batch components are manufactured and are
further forwarded to the stores where it gets stored and can be obtained by the assembly unit
as and when required. It is the in-house machining division, where the machinable assembly
items of a machine like bearing housing, saddle, top tables etc. are manufactured. This division
comprises machining centers, turning centers, grinding machines and special lathes to machine
the components.
Here, certain raw materials are brought in from outside. All components are
manufactured according to their process drawings specific to each component. The raw
materials are then processed according to their concerned drawings. A process drawing is
extremely important for the manufacture of any component because it contains the step by
step procedure to machine the component after the proof machining by the vendor and plays a
major role in defining the final dimensional accuracy of the completed component.
In CMD, batch manufacturing of component takes place. This sort of manufacturing
takes immense amount of planning since excess processing will take more lead time. Initially
the batch size is identified and depending upon the criticality of the component a batch size is
decided upon. The number per batch manufactured is specified by the vendor where the
vendor manages the heat treatment process. Excess components are stored for future use.
A specific routing sequence is followed in CMD. A routing sequence is a manufacturing
sequence for any component. Also, it is component specific.

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CMD undertakes a few processes. It has 5 sub-divisions in itself mentioned as follows:
1. Planning: It handles all the planning of the manufacturing of components required by
the assembly division. The software SAP takes care of all the preparation and planning.
2. Manufacturing: The component manufacturing is according to their importance. The
work centers are termed as critical and non-critical based on the quality and quantity of
the operation.
3. Quality Assurance: It exists to measure, evolve, analyze and feed in the data top
facilitate process improvements in the department.
4. Methods: This division provides for process improvements like jigs and fixtures
developments and tooling requirements.
5. Vendor department: It involves inspection of those components that are manufactured
by vendors.
One of the modern concepts used in CMD goes by the name Lean Manufacturing. Using this
concept a lot of improvements are seen it the department.
Just In Time (JIT) concept is implemented for obtaining standard components from in-group
companies.
MACHINE ASSEMBLY
The machine assembly division is one which concerns the assembly of the entire vendor,
bought-out and in-house manufactured items.
The assembly starts off with Axis alignment and Assembly division. The machined
surface is kept clean using kerosene. The guide ways, Linear Motion (LM) or Box/Hardened
Guide-ways are used. LM guide ways are used for higher precision but cannot take deeper cuts
whereas box guides can take deeper cuts but comparatively less precise. Using a spirit-level, the
guide-ways are leveled. The guides are tightened to the Guide-ways such that there is complete
contact with the bed.
The next step in the machine assembly is the assembly of the housing and greasing of
bearings for the re-circulating ball screw arrangement. The ball screw is then assembled on the
machine in between the two rails. This arrangement is used for both the axes. The cross-slide is
now assembled on top of the ball screw arrangement. LM guides are inherently friction-free to
a certain degree.
The headstock is fastened onto the bed. The pulleys are mounted onto the motor shaft
and spindle. The motor is then mounted onto its position. Belts are wrapped around these
pulleys and tensioned to a pre-determined value. This is called belt tensioning.

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Now the axes arrangement is checked for the accuracy of its motion with respect to the
spindle assembly. There are two tests:
1. Primary: A dial gauge is used to check the parallelism between the mandrel and the
cross-slide. A maximum variation of 15 microns is permissible.
2. Secondary: Plane normal to the cutting plane is called Secondary plane. A maximum
variation of 25 microns is permissible.
3. Squareness: The degree of perpendicularity of cross-slide movement with respect to the
spindle axis is referred to as squareness. A special fixture designed by ACE themselves iu
used to check this parameter.
This is followed by tail stock assembly. The assembly of axes, tailstock and motor is called as
Carcass assembly. This is then shifted to the flow line. The flow line concept is one where the
machine is indexed while the work-center is stationary. This helps in belter time-management,
resource planning and improves the overall efficiency of the assembly function. The flow line at
ACE has 8 major station and a 9th idle station. Some of the assembly procedures taking place in
each is as stated below:
Station 1: Guarding Assembly 1
 Motor Bracket
 Lubrication Unit
 Cabinet frame
 Motor guard
 Coolant junction box
 Center Guard
 Power chucking cylinder cover (PCC)
 Cabinet Conduits
 Hydraulic hose connections
 Console assembly
 Coolant channel
Station4: Electrical Assembly 1
 Lubrication power, pressure switches, front switch
 Spindle motor wiring
 AC Wiring

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Station 5: Electrical Assembly 2
 Hydraulics motor wiring
 Cable Shielding
 Input power connection
Station 6: Geometrical Testing and turret mounting
 Bed leveling
 Turret height plate check
 Turret mounting
Station 7: Coolant Running
 Mount face plate
 Chuck
 Fitting of jaws
 Turret alignment
Station 8: Cutting Test and Dispatch
 Machine Inspection
 Electrical Inspection
 Dry run for 8 hours
 Standard Cutting tests
After successful tests, the machine is ready for dispatch and is shipped to the customer.
HUMAN RESOURCE (HR)
Functions of HR:
 Time office management
Entry & exit time, working hours
 Attendance administration
 Salary and wage administration
 Training
 Man power handling
 Employee counseling and guidelines
 Overseas deputation and sponsorship

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 Innovative HR practices
 Feedback system management
 Compensation policy
Common H.R activities
Recruitment, training, payroll administration and performance management
Welfare and Safety activities
Ace being a heavy machinery manufacturing company takes care about the safety aspects of
each individual. Safety of the working environment is better maintained and the workers are
well trained regarding the essence of usage safety precautionary items. Gangways, sideboard,
emergency equipment, first aid boxes, fire extinguishers were some of the safety measures
observed.
Recreational Activities
Ace organizes annual recreational activities such as sports and cultural activities, bringing all the
employees under one roof. This helps to create a strong social relationship between employees
irrespective of their occupation.
Apprenticeship training program
In Ace designers, people with requisite qualification undergo apprenticeship training for one
year in line with the Apprenticeship program. During this period, Ace provides all facilities to
the employee.
Employee training
In Ace need for training of every employee is identified by his immediate superior. The same
will be conveyed to the HR department. The HR department organizes the common training
program for all the employees to whom it was suggested by his superior.

ACE DESIGNERS - REPORT

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