neha - factory visit

Comments on Factory Visit

We visited 4 units on the April 21, 2005, primarily recycled aluminium sheets manufacturing unit, machine making unit, wood processing unit and water pump manufacturer. All the four visits have given us a fair idea about certain manufacturing processes and sufficient background information to explore these processes further.

On our first visit to the aluminium sheet manufacturer, Mr. Rajendra Singh, showed us how scrap metal is collected, from where it was collected, how it is melted in an air blasted oil fired furnace at 650 degree Celsius. The technicalities involved during the melting process were also explained like the use of chlorine and flux. He even showed us where the air was blasted in from and the furnace oil that was used. He even demonstrated how the hot molten metal would be poured from the furnace into the moulds. We were shown book moulds and how other kinds of moulds could be used according to requirement. This was followed by the hot rolling and cold rolling of sheets, where the metal gains compactness. The required thickness of the sheets was determined during the rolling process and can be varied changing the amount of pressure applied. Then the sheets are cut into circular sheets or square sheets. The final process was the annihilation process, where there is strength release and it is done at 400 degrees Celsius.

We then visited another unit belonging to the same people where they manufactured machines, based on the principle of continuous casting of material. This was particularly interesting though difficult to understand. We saw a worker make groves of a big roller that would be used to manufacturer sheets used to make the bus body.

Post lunch, we visited a technically sound wood processing unit. Here, we meet Mr Samir Weaton who was a furniture designer. He gave us a brief but a very comprehensive description on how wood is processed. We were shown how logs of wood were first cut into planks and then seasoned for around 15 days. Seasoning of wood involves putting it in a air tight room with a heater, which heats the wood sufficiently to remove all the excess water. We were then taken around the unit and shown the hi-tech machines like multiple boring machine, 4 sided planar, spindle, router etc. What amazed us the most was the efficiency and precision with which the machines worked. We were also given a glimpse into the room where they tested the shelf life of products, their design studio and the tool shop. We were also explained how they dispose their waste. What was more interesting was the process followed for designing for international buyers and the factors taken into consideration then.

Our last visit was to a water pump manufacturer, who also manufactured the small plastic parts used in the pump. We saw how plastic granules are put into a mould at a particular temperature. This unit was a very small unit where most things were done manually.

On the whole, the trip was very informative.