Summer Internship
Bajaj Auto Limited
I was selected for the 2-month flagship internship program: Octane 2024 of Bajaj Auto Ltd. I was assigned to the Forging & Machining division of the Materials Department. The internship experience was both enriching and insightful.
Study of Tooling & Cutting tools - Transmission Gears & Shafts
01.
Visit to assembly plant to see different parts of bikes
02.
Visit to vendors to observe different manufacturing processses
03.
Guidelines for FTG selection for different part families of Bajaj parts
04.
Latest materials available for gear cutting and contacting their suppliers
05.
Inventory reduction through hob commonization
01
New Material Proposal for Gear Cutting Section
Proposed latest materials that can be used for hobbing, shaping and broaching for obtaining better tool life. Contacted the suppliers of the same for the quotation of the materials as well.
02
Guidelines for Fixture-Tool-Gauge (FTG) selection
Visited vendors and explored the best industry standards for selecting the optimal fixtures, tools, and gauges for various processes to be applied to different part families of transmission shafts and gears
03
Tool Inventory Reduction
I selected a particular vendor and collected data for all hobs, including those on the shop floor, sent for resharpening, and in backup. I then gathered gear data for high-volume models to obtain the Module, Pressure Angle, Outer Diameter, Inner Diameter, and Tooth Depth. I performed hob commonisation for different combinations, excluding those with semi-topping and full-topping. This resulted in a great reduction in hob inventory, leading to significant cost avoidance.
*Data and reports cannot be presented as per company policies.
