MSME INNOVATION

PROJECT REPORT
Implemented Under “Industry-Academia Collaboration” Initiative In Year 2020

Submitted By
Industry Institute Interaction Cell (IIIC)
Jawaharlal Nehru Engineering College Aurangabad

Supported By Industry Partner

“MSME INNO Project”, GIZ India
JAWAHARLAL NEHRU ENGINEERING COLLEGE
MGM Campus, N-6, CIDCO, Aurangabad- 431003, Maharashtra, India
www.jnec.org | Telephone- 0240-2481434/2481433/2482236
Projects
20

MSMEs
13

MSME Live
Project
Implemented Under
“Industry-Academia Collaboration”
Initiative in year 2020

Students
90

Mentors
18
Industry Academia Collaboration is indeed a key to success in this globally
competitive era and hence it is an integral part of MGM’s JNEC as it provides
necessary inputs to build the competencies required by our faculties and students.
JNEC is driven by a shared purpose, to make a better world through education,
research, and innovation. Engraving the multifaceted technical expertise with
human values is the well-known motto of JNEC, and this doesn’t need any
introduction here or overseas. At JNEC, our mentors believe in training the human
senses, mind, behavior, and skills in a constructive manner so as to impart it in
social benefit. The success of the program that we see today is a result of sincere & dedicated efforts of our
mentor & student teams. I congratulate all the beneficiaries & hope the beneficial collaboration of Industry
& Academia nurtures in the future.
Dr. H. H. Shinde
Principal

The initiative from GIZ & MASSIA marks the milestone towards the greater
and most essential collaboration between Industry and Academia because when
Industries and Academia work in tandem they become a powerful engine for the
economic growth of the Nation. During visits & interactions with industry partners
during the course of these projects, I personally witnessed the tremendous growth
of our student as professionals & can proudly say that the students have come up
with many creative and innovative solutions for the industrial problems. I commend
the efforts of all the teams and convey my best wishes.
Dr. M. S. Kadam
Professor & Head
Mechanical Engineering

With more than 7000 registered industrial unit in Aurangabad, industrial sector
has become growth engine of not only Aurangabad district, but also of Marathwada
economy. Collaboration between academia and industry is considered as vital
pillar for promoting startup culture. Well designed collaborative initiatives with
systematic efforts and clearly defined roles and responsibilities hold the key in the
success of these initiatives to bridge the gap between industry academia. GIZ and
Marathwada Association of Small Scale Industries (MASSIA) have provided the
platform to JNEC students for developing innovative solutions to solve problems
faced by industries. This innovation ecosystem is helping to develop problem solving skill among participated
students and further augment entrepreneurship skill. JNEC is proud partner of this program since its inception
in year 2016. Industry Institute Interaction Cell congratulates all the stakeholders for their concerted effort.
This program will surely act as benchmark for industry academia collaboration in coming days.

Prof. S. B. Pawar
Incharge, Industry Institute Interaction Cell (IIIC)
Preface
Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH, has been working jointly with
partners in India for sustainable economic, ecological, and social development and with its “MSME INNO
Project” their prime focus is on endorsing Industry-Academia Collaboration and promoting innovations
in Micro, Small and Medium Enterprises (MSME). The partnership between MGM’s Jawaharlal Nehru
Engineering College Aurangabad and GIZ started out in the year 2016 where JNEC hosted “Industry-
Academia Summit 2016” and started working in close collaboration with GIZ & Marathwada Association of
Small Scale Industries & Agriculture (MASSIA) on 5 live industrial Projects which included 10 students and
6 faculty members, this turned out to be very beneficial alliance for our students. In its second year we kept
the momentum by involving 10 students and 07 faculty members with industry projects and academic year
2018-19 witnessed 55 students and 15 faculties working on 17 Projects with 14 industries.

We are very proud to say that in academic year 2019-20, JNEC under its newly established Industry
Institute Interaction Cell (IIIC) has taken the legacy gracefully forward as 96 Students & 18 Faculty Members
of our Institute has successfully worked on 21 Live Industrial Projects with 15 Industry Partners. Here in this
report we are presenting the fabulous work done by our dedicated student-mentor teams in their respective
projects which helped the MSME to resolve their problems with low-cost innovative solutions.

I personally feel Industry academia interaction is an important aspect which should be an integral part
of technical education as it provides necessary inputs to institutes to build the competencies required by
faculties and students and this collaboration between JNEC and GIZ is a prime example of the same. We
are thankful to GIZ, India & MASSIA for this opportunity, looking forward to extend this fruitful collaboration
further and hope this collaboration grows many folds in future.

Sarfraz Ali Quadri

College Co-ordinator,
MSME Innovation Projects,
MGM’s Jawaharlal Nehru Engineering College Aurangabad
Index of Live Industrial Projects
Sr. No. Particulars Page. No.

1 Design and development of NIYO Agro spray pump 1

2 Material handling & storing adjustable trolley 3

3 esign and manufacturing of a grinding machine setup to estimate the material

D 5
removal rate of abrasive wheel for quality check

4 Design and Manufacturing of Food vending machine 7

5 Optimization of plant layout in Abhijay Autoparts 9

6 Design & development of rolling and unrolling setup for textile industries 11

7 Design of fixture for spot welding machine 13

8 Design and development of auto-collector mechanism for press machine 15

9 Design and manufacturing a fixture for WEDM of relieve tool and steady rest for 17
thread mill operation

10 Semi-Automatic Deburring Machine 19

11 Online Human Resource management system 21

12 Online Process Management System 23

13 Vibration monitoring of plastic injection moulding machine 25

14 Development and automation of sheet metal cutting machine 27

15 Facing and Centring of Special Purpose Machine 29

16 Design and development of welding fixture for shock absorber bracket 31

17 Improvement in effectiveness of VMC machine (OEE) 33

18 Design and development of automatic packaging machine 35

19 Design and development of staircase lift 37

20 Welding defect detection in silencer 39

Agriculture equipment

Design and development of NIYO

Agro spray pump
MSME : NIYO INNOVATIVE SOLUTIONS LLP| Waluj, Aurangabad
Project Category : Product Development
Academic Mentor : Prof. S.B. Salvi
Student Team : Talokar Akash, Yevale Vaibhav, Bari Manali, Wankhade Smita

Background and Objective:

NIYO innovative solutions llp., manufacture of
Pesticide spray pump for the agricultural as well as
for social purpose. Their main product are pumps
mainly for agricultural use for spraying pesticides
on the crops. Company wanted the operators or
farmers to be happy while spraying. So, company
decided to make a model which reduce the stress,
body pain and time of spraying of the operator.
From then the journey of company has started by
introducing innovative model of NIYO agro spray
pump. The company were getting the complaints
Manual NIYO spray pump.
from the customers regarding efforts required to
Idea:
push the pump, non-uniform spray through nozzle. In
In order to achieve the desired result by improving
order to improve the performance of the model, NIYO
model spraying method and new design of the
Innovative Solutions LLP decided to put the challenge
model which can reduce the human effort required
to student to suggest modifications in design.
for pushing the spray pump. Then students came
up with an idea about the electric wheel to the new
Challenge: spray pump model which can eliminate the force
Company required Design and development of required to push the spray pump. Then they focused
on how they can improve uniform pesticides spraying
new battery-operated Pesticide spray pump for
method. The solution came in form of electric
improving the efficiency of spray pump and to
knapsack pump which is used for the pumping the
reduce the customer complaints about heavy effort
pesticides and get the uniform spraying of pesticides
requirement in the company’s previous model. in farm. They also designed more balanced design
Improving the performance of the model was one of for the new pump.
the main challenges for company. The nozzle was
not spraying the pesticides uniformly, pushing efforts
required was more and also balancing was another
Implementation:
factor responsible for these problems. For such The suggested improvements in the design was very
well received by the industry and they fabricated
improvement of model NIYO Innovative Solutions
the new model in collaboration with project team’s
LLP company decided to take over those challenges
suggestions. The modified designed eliminated all
to the students of Jawaharlal Nehru Engineering
the issues with the previous design and provided
College of Mechanical Engineering department to improved performance with reduced efforts. The
develop new model which avoid all the problems new design will be in production as per requirement
which had in existing one or old model. of the customers.

1
Agriculture equipment

Newly Developed NIYO Battery operated Spray Pump

Results and Saving:

The newly developed battery operated NIYO Agro
Spray Pump Model has reduced the spraying time Mr. Yogesh Gawande, MD, NIYO Innovative
from 30min. to almost 20min. per acre which is solutions llp. With project team
almost the reduction of 10min. than time required
with the old model. The spraying has been improved
greatly, the absolute utilization of pesticide in tank
can be observed and the improved balancing gave a
better robustness to the model for heavy agricultural
work.

Feedback from MSME:

Mr. Yogesh Gawande, Managing Director of NIYO
innovative solutions llp. appreciated the efforts and
creativity of mentor and student team of Jawaharlal
Nehru engineering college
New NIYO Battery operated Spray Pump in Action

“Students have showcased great creativity and

dedication in developing this Battery operated Learnings:
model, which helped us in reducing the Operator This project helped students’ team and MSME
effort, saving time and solved the balancing problem representatives to learn many new things, students
by designing the new battery operated model, we first time worked in cross function team and got
are thankful to GIZ for coordinating the project and acquainted with industry culture. Students enhanced
looking forward to working with academia in coming their technical and practical knowledge while working
years” on live project which will be helpful to get the good
employment opportunity for them.

2
Textile

Material handling & storing

adjustable trolley
MSME : Vatan Textiles pvt ltd| Beed By-pass, Aurangabad
Project Category : Process Improvement
Academic Mentor : Prof. Sarfraz Ali Quadri
Student Team : Dhiraj Ramrao Chavan, Mayur Ashok Jadhav

Background and Objective: on that machine to move freely. The lying cones get
Vatan Textiles Ltd. is one of the oldest textiles damaged sometimes or get dirt on them easily which
industry in the region. They manufacture various degrades their shine and affects the finishing of the
types of clothing for multiple reputed brands. They final cloth. They are also occupying the major part of
have around 10 Major and small power looms the floor area unnecessarily. These were the major
working 20 to 22 hours a day. For these machines, challenges in front of the project team.
two to three Bobbins (cones) of different colours
are required as per cloth design, which are rolled
with thread. These cones continuously rotate as
per requirement of machine when they are fit in to
the loom. Each cone takes around 1-2 hours to be
utilised completely. So generally, for a day there are
nearly 18 to 20 cones required on each machine.
The handling of the cone was done manually and
the storing them on floor affects their quality. So
the industry needed a material handling and storing
system for these cones.

Challenge:
After thorough study of all the industrial operations
Cones waiting near Power Looms
and their working, discussions were held with the
concerned workers, their supervisor and the Director
of the industry accordingly. Idea:
Bobbins weighs 1.5kg to 3kg based on thread In order to achieve the desired, students team
wounded, they are stacked at Inventory in Stocks in understood the manual process very carefully and
irregular manner to be used on different workstations designed a low-cost mechanism which involves
as per requirement. As of now Individual loom an adjustable trolley which can handle around 30
worker were keeping the number of required cones number of bobbins of different size & weight and can
on the floor near each machines as per his need handle all these bobbins at once from one location
and after successful consumption, operator needs to other with ease with the help of its wheeled base.
to go to inventory and procure these cones and It also acts as a Material Holding Adjustable Stand
make 3-4 back and forth rotations to take all 18-20 which can hold 30 cones of different specifications
cones to his work station manually. They don’t have comfortably near the looms occupying very small
any equipment to transport those bobbins at once. floor area as compare to the previous process. At the
They packed required bobbins in a bag randomly start of the day operator takes the stand in Inventory
which is placed aside the machine. This process store for procuring required cones& handle all the
causes lot of problem, for on the stack of cones near 18-20 cones at once till the workstations saving
machine causes disturbance to the operator working multiple back and forth rotations.

3
Results and Saving:
Newly developed Material Handling & Storing
Adjustable Trolley has been proven successful on
many fronts. It reduced the non-productive, non-
value adding material handling time by 75% and
eliminated unnecessary travel of the operator after
each cycle of operation by reducing the in general 4
iterations to inventory to 1. It reduced the occupied
floor space near loom to one forth and improved
the operator movements. It also eliminated major
possibility of damage to the cones by lifting them
up from the ground and more ergonomically user-
friendly handling

Feedback from MSME:

Adjustable Trolley Fabrication Mr. Rafeeq Khan, Director, Vatan Textiles.

Implementation: “Project Team has given us a very practical and

The design of the Material handling & Storing effective low cost solution for our bobbing handling
Adjustable Trolley were done in multiple stages and storing problem. We are planning to replicate
taking inputs from the industry at each stage. the system on our other looms as well. The project
The initial design was modified to inculcate all the team was sincere and prompt in their work. We are
possible differences of size & weight of bobbins glad to have collaborated with GIZ and JNEC”
available in the industry. The setup was fabricated
by the project team in Industry premises only which Learnings:
made it more customized product as per industry
This project was a very good learning experience for
requirement. The first model is installed on the floor
the project team, they learned all the steps involved
and Industry is planning to fabricate & replicate the
in developing a solution to address industrial
same design for all 10 looms on their shop floor.
problems. The thoroughly studied the problem,
conducted detailed interactions with the involved
parties, conceptualize the solution made CAD
prototypes and fabricated the actual mechanism on
their own. This practical exposure will boost their
confidence and make them industry ready during
their undergraduate studies only. This will not only
help them with their employability skills, but it will also
help them to grow as a good responsible engineer.

Developed Adjustable trolley being used

in Vatan textiles

4
Manufacturing

Design and manufacturing of a grinding

machine setup to estimate the material
removal rate of abrasive wheel for quality check
MSME : Sun abrasives pvt ltd| Chikalthana, Aurangabad
Project Category : Process Improvement
Academic Mentor : Prof. R. B. Patil
Student Team : Prasannakumar Dhanedhar, Swaraj Chede, Rohit Kakde, Saurabh Muley

Background and Objective: design solutions presented to the company. Again,

Sun Abrasives Pvt. Ltd. Is a well-known name in the setup was made to be capable of holding three
abrasive industry for its innovation, reliability and different grinders having different sizes and weight.
technical competence. It is a leading name in the Which made it a little difficult to avoid the usage of
production of grinding wheels and flap wheels. They excess material. The Team’s focus was to come
manufacture a wide range of abrasive wheel products. up with a low-cost mechanism which fulfil all the
They have started their work with a few clients requirements. Another important challenge in front of
and today they have large cliental which includes the team was to assure the safety of people working
automobile industries, wooden handcraft exporters, around.
forging industries, Stainless steel industries and
Allied industries who use their products regularly.
In this project, team’s prime objective was design
and manufacturing of semi-automatic mechanism
to determine the material removal rate so as to
reduce human efforts. This setup helps us to check
the efficiency of flap wheel without excessive human
interventions.

Challenge: Old method of grinding

The company produces three sizes of flap
wheels with two different materials and required a
Idea:
customised setup for the batch testing of these flap
In order to achieve the desired results by developing a
wheels by actual grinding test on sample workpiece.
semi-automatic mechanism for grinding purpose, the
The results of weight changes of the flap wheel
team tried to find out different possible mechanisms
and the test workpiece are noted for the efficiency
for this grinding process. After a lot of discussions
calculation. Previously this task was done manually
with the industry experts and with the consent of
with a worker using a hand grinder for taking test
the company, the team finalised an optimised and
runs and noting the readings of abrasive wear.
simplified design. Considering the high rpm rotation
The main challenge was to reduce unnecessary
of grinder, a high factor of safety was considered.
manpower being used for repetitive work and to
The updated design made it possible to grind eight
increase productivity of plant by increasing the rate
workpieces simultaneously on the setup with any of
of work and reducing the time for checking efficiency
the three required grinders.
of flap wheel. This was overcome by the exclusive

5
Implementation:
Project team designed and fabricated the mechanism
with the close collaboration of industry coordinators.
The project team implemented this setup in Sun
abrasives and After that took trials on this setup
which were successful, and the project is completed
in low cost. The Fabrication and testing of the setup
were completed in the company premises itself

3D model of Entire Setup

Newly developed setup at Sun Abrasives

Results and Saving:

With the semi-automatic, compact mechanism using eight test samples simultaneously in the octagonal
structure, the process time is reduced by 1/8. Due to no human interference during the grinding process, a
constant grinding pressure can be maintained throughout the testing cycle.
Feedback from MSME:
Mr. Rajesh Hundekar, Managing Director of Sun Abrasives appreciated the efforts and creativity of students.
“Exposure to real life industry problems is one of the key elements while learning problem solving skill.
students have successfully applied their theoretical knowledge and engineering skill to come up with the
innovative design and the Project was completed within the expected time. We appreciate the initiative taken
by GIZ and look future for similar opportunities to work together”
Learnings:
From this project, we got a chance to interact with industry culture and experience the sense of responsibility as an
engineer. Along with the implementation of our theoretical knowledge and practical skills, we got to learn several
new skills like project management, presentation skill, time management, cost reduction and communication skills.

6
Manufacturing

Design and Manufacturing of

Food vending machine
MSME : Lesokart Industries pvt ltd | Waluj, Aurangabad
Project Category : Process Development
Academic Mentor : Dr. M. S. Kadam
Student Team : Sonone Ajay, Korlahalli Aditi, Patil Mahesh, Jivrag Pallavi

Background and Objective: lakhs, not enough secure to be used on local basis
Lesokart Industires Pvt. Ltd. is a private industry and space not available for storage and hence
incorporated on 8th September 2017.It provides cannot be used in India. The students had to design
Laser Cutting, Panelling, Industrial heavy Duty and manufacture such a machine which solves the
Racks, Architectural Design and Tables in Stainless above problems.
Steel. It is the first Indian industry to manufacture Idea:
Food vending machine. A food vending machine is To overcome the problem of safety while loading
an automatic machine that sells different types of the products, the students decided to design two
food such as snacks and cold drinks when cash separate units for the machine i.e. Product unit and
is inserted. The main objective of this project is System unit. This idea of separating the units into
to launch food vending machine on local basis in two also solves the problem of storage. There is
India. The aim is to construct an automatic vending space for storage of extra products in the system
machine prototype model, which can be installed in unit. To reduce the costing of machine Raspberry-
schools, colleges, hospitals and other public places pi is used instead of Arduino Uno and sheets of
to dispense food items during needs with appropriate 0.5mm thickness are used instead of 0.8mm which
mechanical designs for items collection. To dispense reduces the weight of the machine hence reducing
different products is an automated process, without the machine cost.
man power, easy to save precious time of human
Implementation:
normally seen in fast moving cities.
The machine developed can be used in schools,
colleges, hospitals and other public places in India.
Challenge: As the machine has two different units – product
In India, till today there are no vending machines unit and system unit, it is very safe to load the
which are used on a local basis. The only machines products by just unlocking the product unit and not
used in corporate offices are also imported from the system unit. Also due to the separation of units,
other countries like Japan. Industry wants to launch there is space available for storage in system unit.
Food Vending Machines which can be suitable to Due to reduced weight of the machine and use of
be used on local basis in India such as schools, Raspberry pi instead of Arduino uno, the overall
colleges, hospitals and other public places to cost of the machine is reduced. The project team
dispense food items during needs with appropriate submitted the design & the industry was satisfied
mechanical designs for items collection. Imported with the design. Industry developed the machine
Vending machines used in corporate offices have along with the students & will be launching soon in
different problems like- the machines cost upto 2 India on local basis.

7
Feedback from MSME:
Mr. Pratik Patil, managing director of Leokart
Industries Pvt. Ltd. Appreciated the efforts and
creativity of the students of J.N.E.C.

Mr. Pratik Patil (Managing director,

Leokart Industries) with project team
Project Team with Newly Developed Food vending machine

“The students completed the project of food vending

Results and Saving: machine very impressively and appreciably. They
The vending machine developed is user friendly as completed our work before the given period. I
it displays proper instructions for the customer. It appreciate their work because the whole job done
accepts different modes of payment like cash, UPI, by them is 100% accurate and before the given
debit card and credit card. It is a one-time investment time slot. They developed a cost-effective Vending
for shopkeepers as it does not require continuous machine by reducing the weight of machine and the
attention. Also, the machine is secure enough to be machine developed by them performs smoothly”
used at public places.

Learnings:
The project helped the students to implement their
technical knowledge in practical and enhance their
designing skills. They learned about the detailed
working of refrigeration system and designing
different components in 3D-softwares like Creo and
Solidworks. Apart from the technical knowledge,
soft skills like teamwork, leadership skills, time
management and industrial interactions were
procured by the students which will help them in
their future.

Newly Developed Food vending machine at Corporate office

8
Auto Component Manufacturing

Optimization of plant layout in

Abhijay Autoparts
MSME : Abhijay Autoparts pvt ltd| Waluj, Aurangabad
Project Category : Layout Optimization
Academic Mentor : Prof. M. N. Bargir
Student Team : Janhvi Patil, Pranita Shah, Komal Sonwane, Pratiksha Chavan

Background and Objective: Idea:

Abhijay Autoparts currently manufactures precision In order to achieve the desired results team studied
machined components, gear blanks and shafts, various research papers and write-ups on systematic
compressor block, crank shafts, pressed parts& its layout planning (SLP) and plant layouts. The project
assemblies of all types of material including MS, SS, team collected all the possible dimensions of the
plant which would help them in developing the new
CI, Al ,Cu etc. These are extensively demanded in
layout. The process chart and flow diagram depicting
Automobile industries, Electrical industries, Electrical
the various activities was to be studied. A layout is to
motors and pumps manufacturing industries. To
be prepared clearly depicting the current positioning
minimize material handling, time, cost, optimize the
of men and materials and the process flow. Top
production rate and efficiency of the process the 10 components which contributed 50-70% of total
company decided to implement a new optimized production were selected. A new layout had to be
layout. drafted according to the flow processes, calculating
the space analysis.
Challenge:
Improving the inadequate material flow and long travel
distances was one of the most important challenges
for the project team. Also, there were bottleneck
problems and a proper streamline of material was
required. So, the project team had to create more
working space, streamline the material flow in plant,
reduce travel distance, achieve good work flow and
avoid accumulation of work.
New layout

Implementation:
After analysing all the possible layouts, the project
team and the company supervisors finalised a
suitable layout that helped in reducing the travel
distance, releasing floor space and overall savings
and implemented the layout on the floor. It was a
cumbersome task as many heavy machineries
needed to be moved and relocated but the results
Old layout
were very successful.

9
Shop Floor after new layout

Results and Saving: “The project team was quite dedicated, and the
The optimized layout reduced the travel distance company is happy with the work done by students as
thus freeing up area that can be effectively used it helped in enhancing the productivity, reducing the
for future expansion, stocking of raw material long travel distance and releasing space which lead
and finished products. The new layout eliminated to decrease in overall time required for production”
nonvalue adding travel of man & material and
improved efficiency of the overall operations. Learnings:
The project team learned lean manufacturing
Feedback from MSME: techniques such as Layout Improvements,
Mr Praduman shah & Mr Pruthivraj shah material handling and transport, continuous
flow, manufacturing flexibility, etc. The team got
acquainted with industry culture which will help them
in their future career.

10
Textile

Design & development of rolling and

unrolling setup for textile industries
MSME : Vatan Textiles pvt ltd| Beed by-pass, Aurangabad
Project Category : Process Improvement
Academic Mentor : Prof. Sarfraz Ali Quadri
Student Team : Rohan Koshor Dawkar, Kiran Suresh Dalal

Background and Objective: machine in wounded form and then it is unwounded

Vatan Textiles Ltd. is one of the oldest Textile for material inspection purpose manually. During
Industry in the Marathwada region they manufacture inspection process the material suffers from lot of
various jacquard fabrics for Shirting, Suiting, Dress stresses; which causes damage to material. After
Material, Home & Upholstery. Vatan Textiles is built testing labour has to wound the material manually;
on the foundations based on a legacy of skilled which result in more human efforts and kills a lot of
craftsmanship that how it caters to many National & time and effects on production of material.
International Clothing Brands.
The process of Textile manufacturing is very
meticulous in nature and it moves of multiple
stations from start to finish. After cloth has been
made it is rolled up to a bobbin and taken for the
testing purpose. During this process of testing, cloth
is rolled & unrolled multiple times manually during
inspection which affects the finishing of finished
cloth adversely. This cloth is again rolled up on a
machine roller. This is a time-consuming procedure
and extra efforts are needed for this. Vatan Textiles
Ltd. decided to bring the low cost semi-automation
mechanism in rolling and unrolling of cloth. Pic: Manual cloth inspection process in
vatan textiles pvt ltd.

Challenge: Idea:
Improving the cycle time of rolling and unrolling In order to achieve the desired results by developing
process of cloth was one of the main challenges for an mechanism of rolling and unrolling setup, students
the project team. There were many ready-made high team understood the manual process very carefully
cost solutions available to automize this process, and designed a low-cost mechanism which involves
therefore they decided to give this challenge to Rolling and Unrolling setup working on principal of
students of MGM’S JNEC, to develop a low cost chain and gear mechanism. This setup works on
semi-automated mechanism to improve cycle time of chain power transmission mechanism, operator has
this process. Rolling and Unrolling setup is used for to paddle by legs. This generated rotating power is
wounding the material on the bobbin. Initially material transmitted to first shaft which is connected to two
from machine is wounded first for testing of material pulleys. This power is again transmitted to next two
purpose. In testing section material is brought from pulleys on which two shafts are connected. On these

11
shafts rolling and unrolling takes place. Both the
shafts are running simultaneously with same speed
in same direction.

Implementation:
Project team designed the proposed mechanism
with close collaboration of industry co- Ordinator and
developed a setup at low cost automatic fixture which
consist of Two different pulleys, Two Belts, One
Chair, Chain Power transmission mechanism, Glass
dome, Sprocket. According to their suggestions we
had made some changes they needed in it at the
time of implementation.
The solution has been fabricated and the
implementation will be done in the Vatan Textiles plant. New Rolling and unrolling mechanism in Vatan textiles

Results and Saving:

Newly developed Semi-Automatic Rolling & Unrolling setup can is very robust and effective. The operator
efficiency increases as the ease of operation reduces the human operator efforts. It saves significant amount
of resources like manpower, excess of time and repetitive operations of rolling & unrolling. Project team
specially designed a sitting arrangement in the setup considering the ergonomics for better working while in
old setup worker is working in standing position time.

Project Team presenting solution to Mr. Rafeeq Ahmed Khan, Director, Vatan textiles pvt. Ltd

12
Manufacturing

Design of fixture for spot welding machine

MSME : Abhijay Auto Parts pvt ltd| Waluj, Aurangabad
Project Category : Process Automation
Academic Mentor : Prof. P. S. Shinde
Student Team : Abhishek sahuji, Lavesh Pingale, Sachin Harne

Background and Objective:

Abhijay Auto Parts Pvt. Ltd. ISO 9001:2008 Certified is
in the field of manufacturing of machined components,
press parts and assemblies. Abhijay currently
manufactures precision machined components,
gear blanks and shafts, compressor block, crank
shafts, pressed parts & its assemblies of all types
of material including MS, SS, CI, Al ,Cu etc. These
are extensively demanded in Automobile industries,
Electrical industries, White good industries, Electrical Existing fixture
motors and pumps manufacturing industries. RC-
Sector is one of such part which is being supplied Idea:
to Bajaj Auto Parts in Aurangabad. For making the
In order to achieve the desired results, the team
RC-Sector it consists of many operations blanking,
analysed the whole procedure and came up with
drilling, spot welding, Arc welding, etc. For all other the idea of some modifications in the existing fixture.
processes there are automatic or semiautomatic After some brainstorming sessions with industrial
machines except for spot welding. This process was mentor and project guide, team proposed the
carried out by 2 dedicated operators, both of which modified design which were leading towards safety of
perform the operation simultaneously one by one. The the operator, effortless loading and unloading action
main disadvantage of this process is operator fatigue and in addition of reduction in cycle time. So further
and the training time to one operator is about 4 to 6 we worked on table mechanism due to which there
Months. Industry wants to reduce the trained operator. was ease to the operator for doing the spot-welding
operation. As the proposed manual mechanism will
become safer and easier and the trained operators
Challenge: are eliminated as well as female operator can also
The spot-welding machine operates at high carry out the operation.
temperature and high pressure. As the operator
must perform the welding by keeping the fixture
in hands, creates a danger of burn accident to
operator and to absorb heavy jerk on hand thus
resulting in fatigue and impact on accuracy of the
job. Therefore, to overcome this company wanted a
low-cost automation or semi-automatic mechanism.
They decided to give this challenge to students of
Jawaharlal Nehru Engineering College
Proposed design for fixture

13
was implementation of table arrangement / manual
mechanism, the team has proposed the design and
got approved by the institutional guide and industrial
mentor. This will be implemented by the industry in
there welding department.

Results and Saving:

The newly developed mechanism reduced the cycle
time thus also increased the production rate and
saved the cost on training the operator. The low
rejection rate also increased the production rate and
saved the cost on training the operator. The rejection
rate of previous fixture was 1.59 % and now with new
fixture the rejection rate got reduced up to less than
1 %. Now considering on cycle time, a pair of two
jobs makes one cycle which take 26 seconds (old
Design for table arrangement or previous method) but with our proposed manual
mechanics the cycle time will be reduced by 5 to 7
Implementation: seconds.

This implementation step was been carried out in

two stages, firstly the fixture was manufactured as Feedback from MSME:
per the modifications proposed by the team. The Mr. Pruthiviraj Shah appreciated the efforts and
fixture was manufactured in industry itself on CNC creativity of Jawaharlal Nehru Engineering College
machine and trials were taken on it. After getting students,
up to desired outcomes by the proposed deign
the fixture was finalized by industry. Second stage

Mr. Pruthiviraj Shah

Abhijay Auto Parts Pvt. Ltd
Newly Developed Fixture

14
Sheet Metal

Design and development of auto-collector

mechanism for press machine
MSME : Trimurti Enterprises | Chikalthana, Aurangabad
Project Category : Process Automation
Academic Mentor : Dr. N. G. Phafat
Student Team : Kulkarni Nikhil, Gothwal Ruturaj, Shelke Anmol, Waghchoure Saurabh

Background and Objective:

Trimurti Enterprises is one of the leading manufacturers
of all types of automobile and engineering gaskets in
the metallic and non-metallic domain. The gaskets
are manufactured in this industry using press
machines with the help of compound dies (blanking
and punching operations). The process of sheet
metal feeding to these machines is done with the help
of a pneumatic auto feeder, and the process of gasket
collection is done manually by the operator. During
each individual cycle of press machine, the operator
must collect the gaskets getting knocked out from die
using a cardboard paper. To ensure the safety of the
worker and optimize the production rate and efficiency
of the process the students decided to automate the
process of gasket collection.

Challenge: Operator collecting gaskets on press machine.

The operating pressures of these press machines
are around 16 tonnes. The operator who collects Idea:
these gaskets with the cardboard sheet has his To overcome the problem of safety of the worker while
hands very close to these dies while operation. Thus, working on press machine, the students decided to
a mechanism or machine to replace this action of design a mechanism that will substitute the worker
manual collection was very important to avoid any himself performing the job of gasket collection. To
accidents, or in any situation compromising the keep up with the speed and load capacity of the
worker’s safety. Therefore, designing an economical operation that the mechanism would perform, the
solution that being compact enough to fit in available students decided to go with the pneumatic set up
spaces, flexible enough to work with dies of varying for the main circuit construction of the mechanism.
dimensions, and most importantly one that would The components like Actuators, DCVs and different
operate in sync with the press movement cycle valves were used by them to construct the circuit.
was the challenge given to the students of J.N.E.C The mechanisms support structure was designed
College by the Trimurti Enterprises. such that its height, progression, tray angle, and tray
size could be varied easily to sync in with the different
press machine beds and its dies dimensions.

15
Feedback from MSME:
The industry had been extremely supportive during
the process of data collection, employee interaction,
and query resolution. They were happy with solution
provided by the students to them.

Graphical prototype of the Solution

Implementation:
The implementation of the developed mechanism
can be done on any conventional press machine
in the industry that uses a compound die for the
manufacturing of gaskets or washers. Due to its Mr. Ravi Aher (Business Development Head,
adjustable height and angle feature the machine Trimurti Enterprises, Aurangabad)
is suitable for various bed heights of the press and
dies. The trays of the machine can be changed for “Students have worked nicely keeping an optimistic
smaller size and clearances of the dies. And due and creative approach throughout their work, they
to adjustable timings of the actuators the machine have submitted a very good design. In the future, will
can work for flexible press cycle timings. The be supportive to promote such innovative student
project team submitted the design & industry was ideas”
satisfied with the design. Industry will be fabricating
the mechanism along with the students & will be
implementing on their press machine.
Learnings:
The project proved to be a source of conceptual as
well as practical based exposure of the subjects to
Results and Saving:
the students. They learned about various pneumatic
The implementation of the mechanism will assure a components their classification and working,
safer and reliable atmosphere for the worker working the construction a pneumatic circuit using these
on the press machine thus, avoiding any kind of components and make operational mechanisms.
serious injuries or accidents. Reduction in production Apart from the technical knowledge, soft skills like
downtime, caused due to human labour fatigue and leadership skills, stress management, industrial
inexperience can be seen with the implementation interaction, and rapport building were procured by
of this mechanism. The increase in the production the students which will help them to work and groom
rate up to 16 % in 8 hours shifts with the automation in the industrial environment in their future them.
of the feeding and collection process can be seen in
the industry.

16
Manufacturing

Design and manufacturing a fixture for

wedm of relieve tool and steady rest for
thread mill operation
MSME : Swift Tools and Machines pvt ltd| Waluj, Aurangabad
Project Category : Process Improvement
Academic Mentor : Prof. D. S. Khedekar
Student Team : Lamture Namdev, Jaju Shubham, Choudhari Chaitali, Zaheer Qureshi

Background and Objective: Machines.t enough to fit in available spaces, flexible

Swift Tools and Machines is a manufacturing of enough to work with tools of various sizes and most
several types of milling cutters and jobs. Their important in minimum cost was the challenge given
product is widely used in several industries such to the students of J.N.E.C College by the Swift Tools
as automotive gear, elevator, spline shafts, screw
pumps and much more. The manufacturing of milling
cutters and hobs goes through various processes
such as turning, thread milling, gash milling, relieving,
hardening, grinding etc. At the relieving stage there
is an error arising in the job profile which is due to
the profile error of relieve tool which is manufactured
by WEDM process thereby causing idle time. The
error in relieve tool is in the form of clearance angle
of the tool which is not meeting the requirements.
Also, at the thread milling process error in job profile A thread milling operation on a workpiece
arising as well as machining time is exceeding the without use of steady rest.
limits. So this project is to provide an accurate angle
for relieve tool as well as some means for improving
Idea:
productivity and reducing scrap for thread milling.
For problem no. 1 : In order to achieve the desired
results, relieve tool should be positioned and held
Challenge: accurately during the wire cut machining. For this
Project team have chosen 2 challenges from purpose, team designed a locating and holding fixture
industry. Problem no. 1: To provide the accurate for relieve tool which will meet the requirements.
relief angle to the reliving tool to reducing the For problem no. 2 : Team have designed a steady rest
rubbing between tool and workpiece also achieving which will support the workpiece which is being cut
the longer tool life span with minimum job rejection. throughout the operation at the opposite end of that
Problem no. 2: To reduce the vibrations and forces of the cutter. So it will reduce all the forces which are
acting on workpiece while thread milling operation going to bend the workpiece as well deteriorate the
along with reducing the machining time with required whole profile and as the forces are less the machine
dimensional accuracy of the workpiece. Therefore, speed can be raised to some extent thereby raising
designing an economical solution that being compact the productivity.
enough to fit in available spaces, flexible enough to
work with tools of various sizes and most important
in minimum cost was the challenge given to the
students of J.N.E.C College by the Swift Tools and

17
A Steady Rest for thread mill operation designed in CATIA software

Implementation: Feedback from MSME:

For problem no. 1 : After approval of design by the Mr. Ankush Lamture, Managing Director of Swift
industry of the Locating and Holding Fixture for Tools and Machines appreciated our efforts and
reliving tool, it is manufactured and installed on creativity for this project.
WEDM machine successfully to achieve the desire
result.
For problem no. 2 : The design for the Steady Rest
is approved by the industry.

Results and Saving:

For problem no. 1 : The implementation of the
solution reduced the job rejection with almost 50%
which is from 30 parts per month to near about 15
parts per month. Increase in tool life span resulted
into reduced reworking and re-sharpening cost of
tool near about 80% and also reduced labour efforts.
For problem no. 2 : As the manufacturing of
fixture is in-process, the expected outcomes after
implementation of fixture is, reduced vibrations and
reduced cycle time from 11 min per workpiece to
Mr. Ankush Lamture, Managing Director of Swift
nearly 8 mins per workpiece along with dimensional
Tools and Machines with Project Team
accuracy.

18
Auto Component Manufacturing

Semi-Automatic Deburring Machine

MSME : Swamini Industries | Waluj, Aurangabad
Project Category : Process Improvement
Academic Mentor : Prof. D. S. Khedekar
Student Team : Suradkar Mahesh, Tagare Praveen, Wayal Ajay, Zagare Ramdas

Background and Objective:

Swamini Industries is one of the leading
manufacturers of wide ranges of automobile parts.
The main part is manufactured is main shaft.
Various processes are carried out on this part like
facing, turning, milling, deburring etc. The main shaft
undergoes many operations, but they found problem
in the deburring process. The burr formation is one
of the most common and undesirable phenomena
occurring in machining operations, which reduces
assembly and machined part quality. which is
currently done manually by filling on workpiece
which is the time-consuming process and effects the
accuracy.
Deburring process manually done by operator.
Challenge:
The burr formation is one of the most common and Idea:
undesirable phenomena occurring in machining To overcome the problem of manual deburring
operations, which reduces assembly and machined process which is time consuming students decided
part quality. To remove the burrs, a costly and to design semi-automatic machine which reduce
non-value-added process known as de-burring is the workers efforts and reduces time. To keep up
required for post processing and edge finishing. with this problems project team has been designed
so, in the industry this process was done manually the semi-automatic machine. The manufacturing of
and during this process there was chances to harm this machine is such way that only feeding of the
workers. Therefore, designing an semi-automatic job required, the designs in such way that it satisfy
deburring machine that being compact enough to any condition, less weight and fits in any space. In
fit in available spaces, flexible enough to work and the design of this machine we used the indexing
most importantly one that would operate less time mechanism for deburring action in every 90 degree
cycle was the challenge given to the students of of rotation.
J.N.E.C College by the swamini Industries.

19
Graphical model of the Solution

Implementation: Results and Saving:

The solution has been designed by the students The implementation of the mechanism will assure a
with industry inputs and it was presented to industry. safer and reliable atmosphere for the worker. Time
Industry has accepted the design & will be Fabricating required for process by manual deburring was 2
the machine in their plant. Project team have given minutes per component and calculated time required
all the details information about machine parts, for process by semi-automated deburring machine
materials and geometrical specifications necessary is 1:30 min so the difference between manual time
for the fabrication of machine. and machine time is 30 seconds per component.
That’s how this machine reduces the time required
and product quality will improve with the automatic
deburring.

20
Digitalization

Online Human Resource Management

System
MSME: Tool Tech Toolings | Waluj, Aurangabad
Project Category: Digitalization
Academic Mentor : Prof. A. V. Dusane
Student Team : Bhojraj Bharambe, Ashwin Kasture, Prajwal Padal

Background and Objective: Idea:

Tool Tech Toolings was established with an objective To address all the challenges faced by the industry
to serve the industry in the field of Special purpose the project team initiated round of rigorous
machines & process automation. It is one of the brainstorming sessions with the concerned
pioneers in Marathwada region for its services. The supervisors which resulted in a detailed concrete
database for proceeding to the final solution.
company generally used some standalone Human
Resource Management tools and techniques. They Based on that, project team decided to develop a
put forth the problem to student team to design a simple HR module with biometric entries so that
employees can punch their attendance without
robust, reliable and time efficient HR system with
wasting a lot of time. The basic suggestion was
Biometric attendance management. Which should
that the module must be hosted on a local server
fetch real time attendance data from biometric
so that the information will be safe and can be
module and save in online server database that easily accessed over the internet. The module also
databases can be managed from the web app. incorporated calculations of Salary & Incentives
with the help of a pre-set algorithm. The internet
Challenge: based module will also allow the workers to apply for
leaves & get the approval notification on their mobile/
Industry was tackling following difficulties in their
personal computers. The modules admin portal will
existing system that is They have manual attendance
be available online as well as offline so that the
registry and monitoring system which is a tedious task human resource manager can track the necessary
for the human resource manager, Leave applications information easily even without internet. The module
in the industry are still paper based which makes it also makes way for future expansions if company
very difficult to keep a track and results in tiresome decides to make the Android App of the same.
operations of calculating salaries and incentives
after each month.
Because of these Industry requires an Online
Human Resource Management Tool for all its HR
related operations. It needs Independent login for
all employees and staff with their current attendance
status. Features for online leave application and
approval of leave application by manager (admin
user). Better attendance tracking of employees.
Web portal so that each employee can check their
performance. Additional features like salary/bonus
calculation, online leave application and digital
notice board. Sample Dashboard of Employee attendance

21
Implementation:
JNEC students’ team has developed the proposed Digitalization software and presented the same to Industry
authorities. It has been overviewed and approved by the concerned authorities and it will be implemented in
industry as per industry requirements after it goes through testing with actual industry data.

Project Demo to Mr. Sunil Kirdak, Managing Director of Tool Tech Toolings

Results and Saving:

The developed Human Resource Management Module has a very well-designed User-friendly web
application for all possibilities of employee management like attendance, leave, salary & incentive on a
single dashboard. It is very affordable & cost effective for the industry to implement. By implementing this the
overall operation time for the Human resource management will reduce and the efficiency of the operation
will increase many folds.

Feedback from MSME:

The Industry found the HR module very effective and time saving. Industry will implement the module after
its successful trial with the Live Data. Project team were sincere in their efforts.

Learnings:
This project helped Students to learn many new things, students got an opportunity to work on a live project
giving them a first-hand experience of the corporate world. They understood the industry demand and
worked as per standards expected by the industry. This project provided Students a healthy environment to
work as team and in sculpt their skills.

22
Digitalization

Online Process Management System

MSME : Tool Tech Tooling | Waluj, Aurangabad
Project Category : Digitalization
Academic Mentor : Prof. C. M. Mane
Student Team : Anay Joshi, Purnendu Gokhale, Pranav Wadkar, Shabbir Hussain

Background and Objective:

Tool Tech Tooling was established with an objective
to serve the industry in the field of Special purpose
machines & process automation. The provide
special purpose machines & custom solutions
that are efficient, reliable & cost effective to the
customer industries who needs it. With focused
approach towards customer requirements, they
have developed a wide range of Special Purpose
Machines & solutions that have helped customers
maintain their competitive edge. Manual entry of current state of ongoing
An experienced and enthusiastic team of designers component at Tool Tech
equipped with latest tools in involved in providing
customers reliable, efficient, and cost-effective Idea:
solutions. State of the art infrastructure and skilled
In order to achieve the desired results by developing
manufacturing hands transform the designs into
Online Process Monitoring system, students team
reality to provide reliable products. To provide a
understood the manual process very carefully and
product as described above, there should be a robust,
designed a low-cost online system which can be
reliable and time efficient process management
installed at every end of the process line where the
system to keep a proper track of ongoing operations.
details like the in-time and out-time of the product
in process, quantity, current working status can
Challenge: be updated thus eliminating the previous time
Project planning and management is done on consuming process.
paper and manually which is very cumbersome and
time-consuming method. Also, it is very difficult to
track live status of project. To bring Digitalisation in
process, a team of Computer Science Engineering
students formed a project team and developed an
Online Process Monitoring system.

Online Process Monitoring system developed by

students’ team

23
Implementation:
JNEC students team developed the proposed Digitalization software. It has been overviewed and approved
by the industry representatives.
The prototype is ready, and it will be installed once the actual Deployment of the application for beta testing
is done on the production line under the supervision of developers.

Demo of the software in Tool Tech

Results and Saving: “Students have developed a nice prototype for the
The newly developed Process Management System prescribed problem statement. However, it can be
will help to keep a proper track of each component deployed after testing in real-time scenario. This
along with complete details i.e. its state, current system has the potential to be scaled up for large
operation it is undergoing, the status of batch. scale industry applications. Also, it can be updated
This system eliminates the issues of missing parts completely to IOT based in near future”
occurring due to delay in uploading the status,
improper records, manual entries which are currently Learnings:
faced by the company. This system will greatly This project helped students’ team to learn many
accelerate their production efficiency by maintaining new things, students got an opportunity to work on
a proper report of the production status which can a live project giving them a first-hand experience
be further studied to improve the manufacturing of the corporate world. Students enhanced their
process. technical and practical knowledge which they had
learned by directly implementing it side by side
Feedback from MSME: by working on live project. This project provided
Tool Tech Tooling appreciated the efforts and students a healthy environment to work as team
creativity of JNEC college students. and in sculpt their skills.

24
Manufacturing

Vibration monitoring of plastic

injection moulding machine
MSME : Sanjay Technoplast pvt ltd| Waluj, Aurangabad
Project Category : Process Monitoring
Academic Mentor : Prof. V. V. Ukarande
Student Team : Shubham Adgaokar, Harivijay Chormage, Sayali Dane

Background and Objective: Challenge:

Sanjay technoplast pvt limited manufacture the This project relates to an automated vibration
plastic parts required for automobiles etc.The monitoring system for a Plastic Injection moulding
machines used for manufacturing the products are machine. The aim of this research was to come
Plastic Injection Moulding Machines. This study up with a vibration monitoring system for a plastic
was motivated by the fact that machine production injection moulding machine, which included
time was wasted during planned maintenance incorporating an electronic circuit in the system, use
when, most times, the machines did not require any of IP address and then on a PC for improved user
maintenance at all. Also, the periodic intervals used interface and use of vibration sensors to determine
did not depict the correct ageing of the machine the vibration level of the machine.
components which resulted in unexpected failure of
the machine. Planned maintenance schedules are
done with the assumption that the machine is going
to breakdown after a certain period of time.
Experimental research design was used to determine
the acceptable ranges of vibration amplitudes in
order to classify the amplitude into 4 groups namely:
extremely rough, rough, acceptable and smooth.
The designed system produced consistent vibration
amplitudes for both machining and non-machining
operation. The system used different indicators Plastic injection moulding machine.
linked to the main processor of the circuit which
monitors the machine real-time performance. It
Idea:
was capable of alerting the user when the vibration
The project team developed a vibration monitoring
amplitude was out of range and also to switch off
system with the help of less space and power
the machine when the vibration threshold was
consuming electronic components with the help of
exceeded. The vibration monitoring system helps in
Arduino uno,vibration sensor. The analog output of
damage control and enables preventive measures
the vibration sensor is converted into digital readings
to be taken before damage occurs.
of vibration in (mm/sec) which can be fed to the data
base over an IP address so that we can obtain a time
instant trend chart.

25
System Architecture Module testing with the team.
Results and Saving:
The vibration monitoring system enables users
of the machine to operate the machine under
recommended conditions as it switches off when the
conditions are violated. The lights helps in signaling
to the user that he/she is still operating under set
conditions or if he/she gets carried away, a colleague
will be able to alert the user if the amber light is on as
the lights will be strategically positioned. Monitoring
the condition of the machine using the condition
monitoring system helps in carrying out maintenance
when necessary and avoid component failure or
secondary damage to the machine. This results in
Prototype Testing on a vibrating massage machine. reduction of down time and unproductive time when
planned maintenance or breakdown maintenance
Implementation: techniques are employed. This makes the machine
more reliable and it also increases its availability that
Project Team made the required connections of the
means increasing its productivity.
sensor and the Arduino board and with the help of
Ethernet module and Ethernet cable readings can
be transferred to the data base and further we can Learnings:
generate a trend chart. We can program as per MSME understood the importance of collaboration
requirement and can put 4 levels of vibration such with Academic Institutions and shown interest to
as (less, mild, strong & threshold). engage more students in coming year. Students
enhanced their technical and practical knowledge
while working on live project which will be helpful to
get the good employment opportunity for them

26
Sheet Metal

Development and automation of

sheet metal cutting machine
MSME : Power Heaters pvt ltd| Waluj, Aurangabad
Project Category : Process Automation
Academic Mentor : Prof. P. G. Dhoble
Student Team : Mahadev kundgar, Pratik Reddy, Rohit Kulthe, Ashwini Khonde, Pratiksha Gunale

Background and Objective:

Power Heaters, a trusted name in a HEATER
industry established in the year 1991, formed by
Shri. Anil Teli, with a vision to provide quality heating
elements to industries in India. Today, Power Heater
has grown to become a leading manufacturer
providing total heating and sensing solution to the
various industries such as Auto Mobile, Plastic
and Metal industries, Oil and Gas industries,
Thermocouple Cables, all types of Lugs, All types of
Asbestos Material, Bakelite Sheets etc. The sheets
which are required for the manufacturing of heaters
are cut by using the sheet metal cutting machine.
The process of sheet metal cutting is done manually
by the operator. During each individual cycle, the
operator must mark the require dimensions on the
Sheet metal cutting machine.
sheets and there is also the risk of cutting of fingers.
To ensure the safety of the worker and optimize the
production rate and efficiency of the process the Idea:
students decided to development and automation of To overcome the problem of safety of the worker
sheet cutting machine. while working on sheet metal cutting machine,
the students decided to design a mechanism that
Challenge: will measure the sheet automatically while worker
performing the job of cutting. To keep up with the
Operating the sheet metal cutting machine is very
speed and load capacity of the operation that the
tedious job for the worker. The operator who measures
mechanism would perform, the students decided to
the dimensions while working on the machine has his
go with the lead screw set up attached to the stepper
hands very close to the blades. Thus, a mechanism
motor for the main construction of the mechanism.
to replace the action of manual measuring was very
The components like microcontroller, pair of
important to avoid any accidents, or in any situation
smooth rod and linear bushes were used by us for
compromising the worker’s safety. Designing an
development and automation of the sheet metal
economical solution that being compact enough
cutting machine. The mechanism. was designed
to fit in available space as well as easy to operate
such that stopper is mounted on lead screw and two
were the challenge given to the students of J.N.E.C
rods, input will be seen on HMI display attach to the
College by the Power Heaters Pvt. Ltd.

27
microcontroller which give signal to the motor and it Results and Saving:
respond accordingly to input, then stopper moves to The implementation of the mechanism will assure a
the require length and stops the sheet at that point. safer and reliable atmosphere for the worker working
on the sheet metal cutting machine thus, avoiding
Implementation: any kind of serious injuries or accidents. Reduction
The project team submitted the design & industry was in production downtime, caused due to human labour
satisfied with the design. Students have done the fatigue. An unskilled worker can also operate the
fabrication of the mechanism with the close collaboration machine with ease. The increase in the production
of industry co-ordinator in college workshop & will be rate up to 300% in 8 hours shifts with the automation
implementing the full set-up on sheet metal cutting of the measuring can be seen in the industry.
machine in Power heaters waluj plant.

Graphical prototype & physical setup of the Solution

Results and Saving:

The implementation of the mechanism will assure a safer and reliable atmosphere for the worker working on the
sheet metal cutting machine thus, avoiding any kind of serious injuries or accidents. Reduction in production
downtime, caused due to human labour fatigue. An unskilled worker can also operate the machine with ease.
The increase in the production rate up to 300% in 8 hours shifts with the automation of the measuring can be
seen in the industry

28
Auto Component Manufacturing

Facing and Centring of Special Purpose

Machine
MSME : Abhijay Autoparts pvt ltd| Waluj, Aurangabad
Project Category : Process Improvement
Academic Mentor : Prof. K. R. Jagtap
Student Team : Aniruddha Shinde, Dapke Rushikesh, Vaibhav Chaudhary, Dhiraj Gadiya

Background and Objective: result as a waste of time, money and manpower.

Abhijay Auto Parts Private Limited is a Manufacturer, So as to overcome these difficulties designing of
Supplier & Exporter Of Gears, Shafts, Assembly flexibly economical solution being suitable to fit for
Parts, Bushes, Press Part, Steel Alloy Casting. The available floor area of workspace sync with two
company has evolved as a mark of quality and its special purpose machines was the challenge for the
products find warm acceptance in domestic as well students of Jawaharlal Nehru Engineering College.
as International market, and in varying industrial
projects. Abhijay currently manufactures precision
machined components, gear blanks and shafts,
compressor block, crank shafts, pressed parts & its
assemblies of all types of material including MS, SS,
CI, Al, Cu etc.
The company has come up with supplying Accelerator
lever for the Bajaj Auto. The manufacturing of this
product is done with help of semi-automatic Special
purpose machine. During each individual cycle of
SPM, worker must calibrate the work piece on the V
block and the job is fastened. Worker starts the cycle,
simultaneously worker perfumes same function Limited and compact work space with facing and
on second machine. The SPM performs complex centering attachment
operation on both ends of job, as the workspace is
limited the worker has to be precarious about the Idea:
safety and accuracy of work piece
To overcome the problem of the safety and accuracy
To ensure safety of worker and to optimize the while working simultaneously on two different special
efficiency the students decided to automate the purpose machines, students decided to design an
process operation of special purpose machine. self-automated attachment to the special purpose
machine, which will reduce the human involvement
Challenge: in between the operation and which will work on both
As the worker working on two different machines the special purpose machines more promisingly,
simultaneously, it would be difficult to obtain using robotic arm, Actuators, guide ways and motors
maximum efficiency, as the worker must take care Using program. The equipment’s efficiency will be
of couple of things on two different machines. Like increased by almost 20 %, by implementation of this
making the job fastening precise and accurate and automated attachment.
working in compact limited workspace. Fails to
do this will impact the inaccurate product, this will

29
Front and Top view of design of Attachment in between two SPM

Implementation: Results and Saving:

In order to achieve the desired quality results the The implementation of mechanism will assure safer,
implementation of the self-automated programmed faster and accurate production, on the special
attachment would make significant difference in purpose machine, thus avoiding any kind of accidents
the efficiency of the industry. Due to flexibility of the or injuries. Reduction in production downtime and
attachment it can be programmed to work on both inaccuracy caused by labour involvement and in
machines simultaneously. The movements of arm experience can be seen by the implementation of
and tray can be adjusted. The machine performs this mechanism. The increase in production rate
same operation cycle again and again so it will not by reducing production time of about 76 minutes (1
be hectic to change the settings all the time. It will hour 16 minutes) can be seen in the industry.
need a calibration once as a maintenance part. The
project team submitted the design and industry was
satisfied with design.

30
Auto Component Manufacturing

Design and development of welding fixture

for shock absorber bracket
MSME: Sky Industries pvt ltd| Waluj, Aurangabad
Project category: Process Automation
Academic Mentor : Prof. K. A. Jahagirdar
Student Team : Aniruddha Chourasia, Siddesh Dagwal, Ajinkya Gaikwad, Virendra Suryawanshi

Background and Objective:

Sky Industries is a manufacturing industry which
manufactures shock absorber brackets. With Metal
Man Pvt. Ltd. as its client, the produced products
are being used in Bajaj Boxer and Bajaj Discover.
Located in MIDC Waluj, the industry has a variety
of machinery including press machine and special
purpose machine (SPM). Sky Industries is always
looking to optimize its production processes and
innovation and is committed towards manufacturing
with maximum efficiency. For the safety of its workers
and increasing the production rate, the industry
has an objective to design a fixture so that both
Boxer shock absorber bracket and Discover shock
absorber bracket can be welded at the same special
propose machine (SPM) station.

Challenge:
Operator Changing Fixture for Next Operation
The production of Bajaj Boxer’s shock absorber
bracket is around 2600 pairs (LH and RH) per day
and that of Bajaj Discover’s shock absorber bracket Idea:
is around 700-800 pairs (LH and RH) per day. Due To arrive at the solution, we first identified the
to separate rotary welding SPMs the operating similarities between the components and their
time of Boxer SPM is around 15-16 Hours and that corresponding fixtures. Our team found that the
of Discover SPM is around 10-11 hours, thus the hole (where stud is to be welded) and stud have the
Discover SPM is idle for 5 hours. same diameters and both brackets were flat on their
Hence, designing a full proof fixture which will allow sides (top and bottom). Based on fixture similarities
interchangeability in order to utilize the idle hours we concluded that RH of Boxer bracket and LH of
is a challenge which has been undertaken by the Discover bracket and vice versa, facilitated easy
students of J.N.E.C given by Sky Industries. interchangeable welding with the existing linear
pneumatic clamp. The dissimilarities were the
curvature and height of the studs. So to compensate
for this we provided with a height adjustment bush
and guide pins for proper resting. Hence the need of
interchangeability was fulfilled.

31
Fixture with Boxer (RH) and Discover (LH)

Implementation: Results and Saving:

Our team first worked on raw idea to meet the industry Based on our quantitative analysis we could
requirement and suggested them to use pneumatic conclude that the though the cycle time is the same
swing clamp. As their client i.e. Metal Man did not want the production time was reduced significantly. Before
a swing clamp, team then designed a fixture using when one machine had to work approximately 16
linear pneumatic clamp which is already available hours (2600 pairs of Boxer bracket and 800 pairs
with the industry. To leverage existing fixture and of Discover bracket) to get the task done on both
component similarities, we suggested them to weld SPM, with our interchangeable fixture they will be
an LH bracket of Boxer and RH bracket of Discover able to get the same task done within approximately
at the same table and vice versa on another table 12 hours on both SPM, that is 4 hours less wear and
with our design, they encouraged that idea and then tear for the machine and 4 hours less operator fatigue
later our design was approved by them. Now they which will also increase the life of the machine.
will see to the fabrication of the fixture on their end.

32
Auto Component Manufacturing

Improvement in effectiveness of
VMC machine (OEE)
MSME : Tool Tech Toolings pvt ltd| Waluj, Aurangabad
Project Category : Process Improvement
Academic Mentor : Dr. A. B. Kulkarni
Student Team : Aniket Prem Jadhav, Mangesh Dhepe, Krishna Hiwale, Nilkhant Dhole

Background and Objective:

Tooltech Toolings Pvt Ltd manufacture special
purpose machines and process automation. Various
SPM are supplied to badve engineering and Bajaj
and their clients are Endress Hauser Siemens.
Tooltech Toolings Company having four VMC, one
HMC, one DMC, one CNC machine. All machines
are operated by operators. Job loading, selecting
tool, setting tool, job setting, feeding program, job
unloading are the main operations carried out on the
VMC machines. In order to do this deburring, and
tapping operations are carried on the job manually. Various machines at Tooltech toolings Pvt Ltd.
Tool tech toolings need to improve in effectiveness
of VMC machine and operator performance also Idea:
needs to decrease the down time.
In order to achieve the desired result, students
took an overview of the company. Students study
Challenge: various Quality topics like OEE (Overall Equipment
Machines was the main challenge identified by the Effectiveness) and TPM (Total Productive
company. Operator performance and efficiency Maintenance) and started implementing it in the
of operator is also assigned to students. Tool tech company. Student identified losses and finding
tooling company Pvt Ltd manufactures Special solutions on it. Students discussed with operators
Purpose machines and process automation. Task about vmc machines operations and their problems
was assigned to mechanical engineering Students they are facing during operation. Students collected
of MGM’s Jawaharlal Nehru engineering college to the information on the shop floor. In order to achieve
look for various reasons leading to the problem and the desired result Students observed vmc machine
neutralize them. operations carefully and operator performance and
motions of the operator. Students had taken all the
important data and observation data for doing further
analysis.

33
Various sheets for data collection
Collecting important data of machines

Implementation: Results and Saving:

The OEE tool can be used in different manufacturing
On collecting all the important data students
environments, with the suitable accurate
found out various factors which are responsible
measurement system. The OEE figure obtained
for decrease in the effectiveness of machine and
shows the real effectiveness of the process or line.
operator performance. So, to overcome these
With the help of OEE, several downs which lesser
problems students done study on OEE in which
the production rate are figured out.
students focuses on availability and performance. By
increasing availability and decreasing the downtime After giving several suggestions the efficiency of VMC
the slight improvement in effectiveness in production machine is slightly improved (final measurement are
rate. In addition, students created various data remaining) without doing any external investment. A
collection sheets which are daily job card, weekly habit of collecting the production data on operator
maintenance sheet for preventive maintenance, basis has been adapted by the MSME.
colour coding system for operator performance
and calculating efficiency of operator. These data
Learnings:
collection sheets are submitted to company and
students discussed with company people about Thanks to GIZ, for providing the industrial projects
implementing these various data collection sheets to students which opens the door for students to
and suggested to make it mandatory. acquire practical knowledge directly into industry.
By doing these projects, we learn the cross function
working of industry ahead of academics. This project
helps us to enhance our technical and practical skills
required for the industry. Project makes us quite
familiar with industry which is useful for our future
in technical areas. We also learn lots of things like
teamwork, consistent improvement, dedication,
creativity, punctuality.

Sample of Developed Data Sheet

34
Manufacturing

Design and development of automatic

packaging machine
MSME : Trimurti Enterprises | Chikalthana, Aurangabad
Project category : Process Automation
Academic Mentor : Dr. D. R. Dolas
Student Team : Sandeep Rathod, Sonawane Gopal, Sangharsh Raut, Aniket Potdar

Background and Objective: Idea:

Trimurti Enterprises is one of the leading To overcome the problem of manual Packaging
manufacturers of all types of automobile and project team designed a mechanism that will help
engineering gaskets in the metallic and non-metallic to package the washers automatically and increases
domain. This project introduces an automatic the rate of packaging in turn reducing labour
packaging machine in industry. The main aim of this cost. The design consist of a hopper, DC motors,
project is to design and fabricate a small and simple Pneumatic cylinders, Controllers (PIC), Sealing
packaging system. Packing technology have been machines & rollers.
increasing rapidly and proving its role in automation
beneficially. In many small-scale industries this type
of setups are required for copper washer packaging.
The purpose of this project is to develop a low-cost
automation solution.

Challenge:
The industry produces copper washers on a large
scale. The produced copper washers are packaged
manually by the labours. Due to which there is time
consumption is huge which increases the labour cost
for the packaging. So the industry put forth a challenge
to reduce time consumption and labour cost during
packaging. So project team decided to develop a low
cost automatic packaging machine which will reduce
time consumption and save excess labour cost.

3D model of the Auto-packaging Machine

Manual Packaging of Washers

35
Implementation:
The rate of packaging will also increase by this low-
cost automation solution & By using different rollers
and size of the bags various washers can be packed
on the same setup. A Single operator will be needed
to operate the machine for handling the bags when
filled and packed by the machine. The project team
submitted the design and industry was very much
satisfied with the solution provided by the project
team. The fabrication and implementation of the
proposed mechanism will be done in industry, which
will help reduce the time & cost consumption with
freedom of customization. Project Team at Trimurti Enterprises

Results and Saving: Learnings:

The implementation of the mechanism will assure The project allowed the student team to work on the
the savings on many fronts. The Manual Packaging live industrial problem which was a very wonderful
required at least 4 operators on the packaging table opportunity like no other. Students learned many new
which now can be operated by 1 operator and excess things and got the hands-on experience working on
labour will be utilised for different operation. The rate the real-life problems of industry which boosted their
of packaging will approximately double from 120 moral. They learned about various components like
bags per minute to approx. 200 bags per minute. The Controllers, hoppers, pneumatic cylinder, DC motors.
same will be reflected on the cost of the operation Also building a circuit, designing the automation was
and non-value-added cost can be reduced.“. very good learning experience which will help them
in their future working life as engineers.

Feedback from MSME:

“Project team has sincerely worked throughout their
project, submitted solution is a design as per our
expectation and requirement and we believe this
will reduce our problems. We are positive about this
initiative from start and will be working with Academia
to encourage such innovative ideas”

36
Auto Component Manufacturing

Design and development of

staircase lift
MSME : Abhijay Autoparts pvt ltd| Waluj, Aurangabad
Project Category : Product Development
Academic Mentor : Prof. S. L. Thengade
Student Team : Ashish Rathi, Imaad Quadri, Shubham Jadhav, Yogesh sangle

Background and Objective: the circle of guide sleeves, extending from the drive
Abhijay Auto Parts is one of the Pioneer of Innovative housing and cooperating with the bolts.
Products and Process in Marathwada. They always
look for better cost effective and outstanding Challenge:
solutions, they are in process of developing a cost Many different models of Staircase lift is available in
effective and compact Staircase Lift, so they included the market but the cost of the same are very high and
the project team in their research and development unaffordable to the like of Marathwada region. The
process. The National Center for Health Statistics challenge is to design a compact , robust and cost
2006, Maisel et al. also note that in the US, 11.5 effective Staircase life with some Mechanisms like
million people aged 65 and older reported difficulty four bar mechanism, single slider crank mechanism,
climbing 10 steps without resting. With estimates of double slider crank mechanism, etc.,
home wanting to age in place.
Generally a mechanism is designed for the desired
Traditional solutions to addressing home performance output of the machine and these
inaccessibility have typically involved either moving mechanisms are being used in case of climbing
to alternate housing or modifying the home to remove wheels. This project focuses on presenting the
accessibility barriers. The complex challenges development of a staircase lift wheelchair. This wheel
associated with a move and the failure of many chair is adaptable to climbing and descending stair
to adequately modify their homes have serious and slopes. Operation on level ground is similar to
implications for people with mobility limitations. the operation of a conventional wheel chair. All above
Inaccessible housing has been associated with this thing we have need to be manufactured lift.
premature institutionalization, increased care costs.
A staircase lift includes upper and lower support
girders fixedly disposed along stairs, vertical rods
Idea:
disposed between the support girders, inclined The complex challenges associated with a move
support rods fixed on the vertical rods, a load receiver and the failure of many to adequately modify their
in the form of a platform or a seat with a back panel, homes have serious implications for people with
the load receiver being movably supporting on the mobility limitations. Inaccessible housing has been
upper and lower support girders, a flat drive housing associated with premature institutionalization,
disposed on the back panel of the load receiver, and increased care costs. A staircase lift includes upper
a motor-driven drive disposed in the drive housing, and lower support girders fixedly disposed along
the drive including bolts having ends supported stairs, vertical rods disposed between the support
in endless grooves formed in the drive housing, a girders, inclined support rods fixed on the vertical
closed endless circle of guide sleeves supported on rods, a load receiver in the form of a platform or
the bolts, a pair of gear wheels driving the bolts, and a seat with a back panel, the load receiver being
a plurality of support rollers equidistantly disposed in movably supporting on the upper and lower support
girders,

37
a flat drive housing disposed on the back panel of the load receiver, and a motor-driven drive disposed in
the drive housing, the drive including bolts having ends supported in endless grooves formed in the drive
housing, a closed endless circle of guide sleeves supported on the bolts, a pair of gear wheels driving the
bolts, and a plurality of support rollers equidistantly disposed in the circle of guide sleeves, extending from
the drive housing and cooperating with the bolts.mechanism.

Graphical design of staircase lift.

Implementation: RESULT:
The invention is a lift which can be produced The implementation of the mechanism will assure
economically with simple means and still be a safer and reliable atmosphere for the worker
satisfactorily functional. A lift for inclined or vertical working on the press machine thus, avoiding any
operation has a pair of guiderails that run parallel kind of serious injuries or accidents. Reduction in
to one other, on which guide rollers run that are production downtime, caused due to human labour
mounted on swivel plates so that they can swivel
fatigue and inexperience can be seen with the
and contact the rails from opposite sides. At least
implementation of this mechanism. The increase in
one guide roller on each swivel plate is designed
the production rate up to 16 % in 8 hours shifts with
as a drive roller. The periphery of the drive roller is
pressed against a respective engagement area of the automation of the feeding and collection process
the rail by a spring force in such a way that the drive can be seen in the industry.
force of the drive roller is primarily transferred to
the rail by friction. The lift according to the invention
has the advantage that there is a secure guiding of
the frame in any desired direction and directional
change.

38
Auto Component Manufacturing

Welding defect detection in silencer

MSME : Yeshwant Industries pvt ltd| Waluj, Aurangabad
Project Category : Process Improvement
Academic Mentor : Prof. S. B. Pawar
Student Team : Joshi Rushikesh, Kale Akshay, Shaikh Shahejad, Thorat Harshanand

Background and Objective:

Yeshwant Industries is specialized in Tube Notching
Machine, Welding Machine, Panel Bending & Rolling
SPM, Progressive Press Tool, Transfer Line Press
Tool, Conventional Press Tool, and Robotic Welding
Fixtures. It is engaged in tool room activities like
press tools, fixtures, relation gauges and jigs etc.
Also are equipped with full range of latest as well
as conventional measuring instruments to check the
quality of products manufactured in the industry. In
the project the main object is to find out how much
excessive penetration takes place inside the silencer
which causes back pressure problem in engine that
reduces the torque at crankshaft. A radiograph inspection of the fusion weld.

Challenge: Idea:
A three-wheeler automobile exhaust pipe of an The silencer pipe is made up of 3 different sections
automobile company has encountered a problem which are joined with the help of MIG welding.
with the robotic MIG welding. A lot of sold products But during the welding process the weld material
have been called back due to consumer complaints penetrate excessively into the pipe and protrude
about deficient pickup. The diagnosis found that from its inner surface reducing its effective inside
while welding, the weld has penetrated excessively diameter. This protruded material creates obstacle
inside the pipe, reducing its internal diameter, which and disturbs the overall flow characteristics such
is causing the exhaust gases to create back pressure as flow rate, flow velocity, pressure, etc. of fluid
in the engine, resulting in poor pickup by the vehicle. flowing inside the pipe. So, by measuring these
The pipe had complex bend geometry and consisted flow characteristics we can easily get the idea of
of a catalytic converter and a muffler joined. The welding defect present in the pipe. In this method
expectation of the solution is that it should provide a digital flow meter is used to measure the flow
an easy diagnosis instantly, to be implementable in characteristics of fluid (air) flowing through the pipe.
a mass production. The flow meter is attached across the silencer and
air is passed through the pipe at prescribed pressure
and temperature and readings are taken. The same
experiment is carried out with different specimen

39
pipes with the aid of a fixture designed particularly. After taking trials and experiments the flow characteristics
are calibrated. And in such a way the measurements of these characteristics could be used to determine,
whether the defect is present in the silencer or not.

The fixture used to hold silencer stable against highly compressed air.
(Silencer is held at three positions at middle and at outer end.)

Implementation:
The project will be implemented at manufacturing plant where the freshly manufactured silencers will be
directly tested for welding defect. The project solution has been finalized after discussion with industry
coordinator and they are planning the fabrication at their end.

Results and Saving:

This method is very effective to determine whether extra penetration of welding take place inside silencer
or not. This method of solution provides accurate reading and reduces time required for inspection, so it is
helpful in mass production.

40
Our Team of Mentors

Dr. M. S. Kadam Dr. A. B. Kulkarni Dr. N. G. Phafat Dr. D. R. Dolas

Pros. D. S. Khedekar Prof. R. B. Patil Prof. S. B. Salvi Prof. K. R. Jagtap

Pros. P. S. Shinde Prof. K. A. Jahagirdar Prof. S. L. Thengade Prof. V. U. Ukarande

Pros. A. V. Dusane Prof. C. M. Mane Prof. P. G. Dhoble Prof. M. N. Bargir

Prof. S. B. Pawar Prof. S. N. Quadri

GLIMPSES OF INDUSTRY INTERACTION DURING ACADEMIC YEAR 2019-2020

Contact Details
Sarfraz Ali Quadri
College Co-ordinator, MSME Students Innovation Projects
Member, Industry Institute Interaction Cell,
Jawaharlal Nehru Engineering College,
E-mail: [email protected] | Website: www.jnec.org/iiic

@IIIJNEC JNEC III CELL jnec_iii_cell JNEC III CELL