TRAINING REPORT ON

WHEELS INDIA PUBLIC LIMITED

Submitted in partial fulfillment of the award of

Diploma in Mechanical Engineering

Offered by the State Board of Technical Education & Training, Andhra Pradesh
Submitted by

MD. Tanveer
(22008-M-031)
Under esteemed guidance of
[Link] Rao , ME
FIE

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC
SRIKAKULAM
2022-2025

MECHANICAL ENGINEERING PROGRAM OF THIS INSITUTE GOT ACCERDITED

BY NATONAL BOARD OF ACCERDITATION (NBA), NEW DELHI FOR THE
ACADEMIC YEARS 2023-2026
 A Training report
on
Wheels India ltd.

Submitted in partial fulfillment of the requirements

For the award of the degree of

DIPLOMA IN MECHANICAL ENGINEERING
BY
[Link]

22008-M-031

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC SRIKAKULAM, ANDHRA PRADESH

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 ACKNOWLEDGEMENT

I MD Tanveer, student of Government polytechnic Srikakulam, Department of

mechanical engineering, would like to extend my sincere & heart full obligation to Wheels
India Ltd to provide me an opportunity to work as a trainee in their esteemed organization.

My appreciation extend to my mentor Mr. [Link] & [Link] under

whose supervision I complete my training. Under his sincere guidance & support I was able
to complete my industrial training successfully. I am thankful to them for their able guidance
& support that carried along with me all through internship. I would also like to thank
[Link] & all the departments' heads & employees of wheels India Thervoy Kandigai.

I am equally great full to Dr. B. Janaki Ramayya, Phd , our Principal of government
polytechnic Srikakulam, for extending his support & his valuable suggestion always help me
during my project.

A special gratitude I bestowed to Mr. [Link] rao, ME Head of Mechanical

Engineering section , government polytechnic Srikakulam for his help & support.

I would love to take this opportunity to thank my beloved faculty, family, friends and
all those who's effort and help have made this internship a success. Above all, I thank god
almighty for giving me strength to work and successfully complete this project.

I wish to express my heartful gratitude and sincere thanks in abundance to my faculty

for their continuous guidance for the completion of the training

Signature of the Head of the Department Signature of the Guide

S MUTTHU KUMAR P THAMIL SELVEN

Mechanical Engineering Mechanical Engineering

Govt. Polytechnic Govt. Polytechnic

Srikakulam Srikakulam

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 INDEX

[Link] CONCEPT PAGE NO.

1 Certificate 5
2 Abstract 6
3 Introduction 7
4 Process flow chart 4
5 My role 9
6 Utility devices 12
7 Conclusion 22

DEPARTMENT OF MECHANICAL ENGINEERING GOVERNMENT

POLYTECHNIC SRIKAKULAM

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 CERTIFICATE

This is to certify that the report on industrial training in “wheels India Ltd. ” , is an authentic
record of our own work carried out during the period from 18/11/2024 to 19/05/2025 of Mr.
[Link] bearing pin 22008-M-031 of final year DME submitted in partial fulfillment for
the award of “DIPLOMA IN MECHANICAL ENGINEERING” by the State Board of
Technical Education & Training, A.P. during the academic session 2022-2025.

Signature of the Training Guide Signature of HMES

Signature of Principal

ABSTRACT

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 This industrial training report presents a comprehensive overview of the training
undertaken at Wheels India Limited, one of India’s leading manufacturers of wheels for
commercial vehicles, agricultural tractors, and construction equipment. The objective of the
training was to gain practical exposure to real-time manufacturing processes, quality control
systems, and industrial operations.

During the training period, various departments such as Production, Quality

Assurance, Maintenance, and Research & Development were explored. Emphasis was placed
on understanding the wheel manufacturing process, which includes processes such as
forging, machining, welding, painting, and final inspection. The training also offered insights
into the application of Lean Manufacturing and Kaizen techniques implemented at Wheels
India to improve operational efficiency.

This report summarizes the key learnings, observations, and technical knowledge
gained during the internship. It also includes an analysis of the production workflow, safety
protocols, and the use of advanced machinery and automation. The hands-on exposure and
professional environment at Wheels India significantly contributed to bridging the gap
between theoretical knowledge and practical application.

This report documents the internship at Wheels India Limited, focusing on the
integration of engineering principles with industrial operations. The training emphasized
innovation in design, efficiency in production, and adherence to quality standards. Areas of
study included CAD/CAM integration, hydraulic systems in suspension products, and realtime
quality monitoring systems. Exposure to the company’s continuous improvement strategies,
including Six Sigma and TPM (Total Productive Maintenance), highlighted the importance of
innovation in maintaining competitiveness. The experience bridged academic knowledge
with industry practices, providing valuable insights into the dynamic field of mechanical and
industrial engineering.

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 INTRODUCTION

Wheels India Limited, established in 1960 and headquartered in Chennai, Tamil

Nadu, is a leading manufacturer of steel, aluminum, and wire wheels. A part of the TVS
Group, one of India's largest automotive conglomerates, the company has evolved into a
global player in the auto components industry.

Product Portfolio
Wheels India offers a diverse range of products, including:

Steel, cast aluminum, and forged aluminum wheels for passenger vehicles, commercial
trucks, and tractors Wheels ,Wire wheels for motorcycles and specialized applications Air
suspension systems for heavy vehicles Chassis components and hydraulic cylinders Precision
components for wind turbines and other heavy engineering application

The company operates multiple state-of-the-art manufacturing plants across India,

including:

1. Padi, Tamilnadu. (Established in year 1962)

2. Rampur, Uttar Pradesh. (Established in year 1986)

3. Ranjangaon MIDC, Pune, Maharastra. (Established in year 1997)

4. Bawal, Haryana. (Established in year 2005)

5. Sriperumbudur, Tamilnadu. (Established in year 2007)

6. Pantanagar, Uttarakhand. (Established in year 2009)

7. Wardha, Maharastra. (Established in year 2009)
8. Irrungattukottai, Tamilnadu. (Established in year 2010)

9. Thirumudivakkam. Tamilnadu. (Established in year 2012)

Certifications and Awards

Wheels India has achieved several industry certifications and awards, including:

ISO 9001, ISO/TS 16949, ISO 14001, ISO 45001 certifications Wheels
Ford Q1/Global Excellence Award (2005)
Toyota Supplier Award for Quality & Cost (2009)
CAT SQEP Silver Certification (2009)

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Research and Innovation

The company invests heavily in research and development, holding over 84

international patents. Its R&D facilities focus on developing innovative solutions to meet the
evolving needs of the automotive industry. Wheels Global Presence

Wheels India exports over 15% of its products, particularly in the construction and
earth-moving equipment segment, establishing a strong global footprint.

Recent Developments
In recent years, the company has expanded its product offerings and manufacturing
capabilities, including the inauguration of a cast aluminum wheel plant in Thervoy Kandigai,
Tamil Nadu, in 2020.

Governance & Compliance Policies

Code of Conduct for Directors and Senior Management: Mandates integrity,

fairness, confidentiality, and compliance with laws.

Related Party Transactions Policy: Outlines procedures for identifying and managing
transactions with related parties to ensure transparency and fairness.

Material Subsidiary Policy: Defines criteria for determining material subsidiaries and
outlines governance practices for such entities.

Code of Conduct for Prevention of Insider Trading : Establishes guidelines to prevent

insider trading and ensure compliance with securities laws.

Vigil Mechanism / Whistle Blower Policy: Provides a channel for directors and
employees to report genuine concerns about unethical behavior or violations of company
policies.

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 Process flow chart
A process flow chart is a graphical representation used to illustrate the sequence of steps in a
process. It helps to break down a task or workflow into manageable parts, using standardized
symbols such as ovals, rectangles, diamonds, and arrows. These symbols guide viewers
through the flow of activities, making it easier to understand how a process begins,
progresses, and ends.

Flow charts are commonly used in various fields such as business, manufacturing, engineering,
and software development. They are particularly helpful for identifying bottlenecks,
redundancies, or areas for improvement within a process. By laying out each step visually,
teams can analyse the efficiency of current workflows and make informed decisions to
enhance productivity.

Moreover, process flow charts serve as effective communication tools. They help different
stakeholders—whether managers, employees, or clients—grasp how a system operates
without needing deep technical knowledge. When used in training, documentation, or quality
management, they ensure everyone is aligned with the process and can follow it consistently.

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 MY ROLE

During my industrial training at Wheels India Ltd., I was assigned to the Rework Department,
specifically focusing on paint defects in wheels. This department plays a crucial role in
maintaining the final quality of wheels by ensuring that any surface or coating imperfections
are identified and corrected before final dispatch.

Intro
The rework of paint defect wheels is a critical operation in wheel manufacturing.
It ensures that only high-quality wheels, both functionally and aesthetically, are
delivered to the customer. During the manufacturing process, wheels undergo
several painting steps, and any imperfection at this stage can lead to rejection or
dissatisfaction. The rework department identifies, rectifies, and restores such
defects to meet strict quality standards.
This report outlines the types of defects observed, rework processes followed,
tools used, safety protocols, and my personal experiences working in this
department during my industrial training at Wheels India Ltd.

Importance of Paint Quality in Wheels

Paint is more than just a decorative finish in automotive wheels. It protects the
wheels from corrosion, weathering, chemicals, and physical damage. Paint
defects, even minor ones, can lead to long-term issues such as:

 Rust or corrosion due to exposed metal

 Poor visual appeal affecting customer satisfaction
 Non-compliance with OEM (Original Equipment Manufacturer) standards

Thus, ensuring uniform paint coverage and finish is essential. Reworking paint
defects saves material, prevents waste, and maintains the company’s brand
image.

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Common Types of Paint Defects
Some of the most frequently encountered paint defects in wheel production
include:

 Runs and Sags – Caused by excess paint or incorrect viscosity.

 Orange Peel – A textured surface resembling an orange peel, due to poor
spray technique.
 Fish Eyes – Small craters formed by oil, silicone, or other contaminants.
 Pinholes – Tiny holes caused by air entrapment or surface contamination.
 Blistering – Bubbles under the surface caused by trapped moisture or
solvents.
 Color Mismatch – Inconsistent shades due to poor paint mixing or
spraying conditions.
 Dust/Dirt Inclusions – Particles embedded in the wet paint film.
 Overspray – Paint particles settling outside the intended area.
 Cracking or Peeling – Due to poor surface prep or incompatible paint
layers.

Each defect has specific causes and requires a targeted rework procedure.

Causes and Prevention of Paint Defects

Major causes of paint defects:

 Improper surface cleaning or preparation

 Incorrect mixing ratios of paint or hardener
 Spraying under unsuitable environmental conditions (humidity,
temperature)
 Equipment issues like clogged nozzles or air pressure inconsistency
 Human error due to lack of training or negligence

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 Preventive strategies:

 Strict adherence to paint process SOPs

 Regular equipment calibration and maintenance
 Clean and controlled painting environment
 Training staff on best painting practices
 Periodic audits of paint quality and parameters

Standard Wheel Painting Process

At Wheels India Ltd., the paint process for aluminum wheels typically involves
the following steps:

 Pre-treatment: Cleaning with chemicals and deionized water to remove

dust, grease, and oxides.
 Powder Coating: Application of electrostatic powder, which is then baked.
 Diamond Cutting (optional): CNC machining for a dual-tone look.
 Clear Coat Application: Spray application of a clear protective layer.
 Oven Curing: Heat treatment to ensure durability and adhesion.
 Inspection: Visual and instrumental checks to ensure paint quality.

If any of these steps fail, the wheel is routed to the Rework Department

Rework Process for Paint Defects

Rework begins with identifying and classifying the defect. A standard rework flow
is:

Visual Inspection: Initial assessment by trained inspectors.

Defect Marking: Using markers or tapes to indicate defective areas.
Surface Preparation: Sanding or stripping defective paint using machines or
manually.
Cleaning: Removal of residue using air jets, alcohol, or solvents.

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Masking: If needed, to protect undamaged areas.
Repainting: Application of fresh paint using manual spray or touch-up
techniques.
Curing: Reheating in curing ovens to solidify the paint.

Final Inspection: Ensuring the defect is corrected before the wheel proceeds to
packaging.

Tools and Equipment Used in Rework

To perform rework effectively, the following tools and devices are used:

Sanding Tools – Electric sanders, abrasive pads

Air Spray Guns – Manual spray painting tools, it is a high-precision spray gun is
essential for applying paint evenly during the rework process

Infrared Lamps – For local curing

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Thickness Gauges – Measure paint coating thickness

Gloss Meters – Verify finish quality

UV Test Lamps – Check clear coat coverage

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Compressed Air Units – For dust removal

Paint Booths – Controlled environment for rework painting

All equipment is handled by trained technicians to ensure defect-free results.

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Quality Control and Documentation
Every reworked wheel is documented with key information:

 Wheel batch number and part number

 Nature of defect
 Date and time of rework
 Materials used
 Operator ID and remarks
 Final inspection results

This documentation is entered into the quality management system and

analyzed for continuous improvement. Regular internal audits are conducted to
ensure rework effectiveness and reduce recurrence.

Paint Application Process in Detail

The paint process for wheels typically includes multiple layers to ensure both
aesthetic appeal and durability. It begins with pre-treatment, where wheels are
cleaned and treated to enhance paint adhesion. Next, a powder coat is applied
followed by baking. In premium models, a diamond cut process is performed to
give the wheel a dual-tone look, and finally, a clear coat is added to protect the
finish.
Every step must be monitored for temperature, humidity, and paint composition.
Any deviation can result in defects like poor adhesion, discoloration, or uneven
finishes. Hence, automated paint booths and real-time quality monitoring
systems are used.

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Types of Paints Used

1. Powder Coatings – Durable and environmentally friendly, used for base

coats.

2. Liquid Paints – Used in the clear coat or decorative finishes.

3. UV Coatings – High-gloss finishes for premium applications.

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Each paint type requires different curing times and conditions to achieve optimal
results.

Safety Protocols Followed

Safety is a top priority in the rework department. Personnel are equipped with
PPE such as:
 Respirators
 Protective Goggles
 Anti-static Clothing
Workstations have proper ventilation, and emergency protocols are in place to
handle spills or accidents. Fire extinguishers and safety showers are strategically
placed.

Advanced Troubleshooting Techniques in Paint Rework

Troubleshooting in the Rework Department requires technical skills and a deep

understanding of paint chemistry, process timing, and equipment behavior.
When a defect recurs or the root cause is not immediately visible, advanced
steps are taken:

 Microscopic Analysis: A sample of the defect is analyzed under a

microscope to understand surface anomalies.
 Cross-section Testing: Layers of paint are tested to check adhesion
between coats.

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  Environmental Log Review: Temperature and humidity logs from the paint
booth are reviewed.
 Paint Batch Traceability: Paint lot numbers are traced to check for off-spec
formulations.
 Spray Gun Testing: Nozzles and settings are checked for pressure
consistency.

Through these techniques, deep-rooted issues like contamination, faulty material
supply, or machine calibration errors can be identified and resolved.

Environmental and Health Considerations

The paint rework area must follow strict environmental and safety standards, as
the materials used (solvents, paints, clear coats) can be hazardous.

Key practices include:

 Ventilation Systems: Paint booths and curing areas are equipped with
exhaust fans and air purifiers.

 PPE: Operators must wear gloves, respirators, goggles, and anti-static

clothing.

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 Material Safety Data Sheets (MSDS): All chemicals used are accompanied
by MSDS for reference during handling.

 Spill Kits and Fire Extinguishers: Readily available in rework zones.

 Waste Disposal: Used paint containers and rags are disposed of as per
hazardous waste rules.

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  Noise Control: Machines like compressors and sanders are acoustically
enclosed to reduce noise pollution.

All employees are trained on first-aid and emergency evacuation procedures.

Lean Manufacturing in Rework Operations

Though rework typically implies a corrective action, Lean Manufacturing
principles are actively applied to minimize it. The goal is not just to fix defects but
to prevent them through process improvement.

Key lean concepts used:

 Kaizen: Small, continuous improvements in painting processes.

 5S System: Organizing the workplace – Sort, Set in order, Shine,
Standardize, Sustain.

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  Root Cause Analysis (5 Whys, Fishbone Diagram): Identifying the origin of
recurring defects.
 Visual Management: Color-coded charts and boards show rework
performance metrics.
 Poka-Yoke: Mistake-proofing tools such as interlocks and auto-cleaning
nozzles.
 Standard Work Instructions (SWI): Step-by-step paint rework procedures
to maintain consistency.

These principles improve quality and reduce waste across departments.

Statistical Data and Rework Metrics

Every quality-focused organization tracks KPIs (Key Performance Indicators) to
evaluate the effectiveness of the rework process.

Some common metrics:

Rework Rate (%) = (No. of wheels reworked / Total wheels produced) × 100

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  Defect Frequency by Type – Which defects occur most often (e.g., 30%
orange peel, 20% dust inclusion)
 Cycle Time for Rework – Average time taken to reprocess a wheel
 Rework Cost per Unit – Cost associated with materials, labor, and time
 Operator Performance – Based on defect detection and rework success
rates

These metrics are reviewed weekly/monthly by the quality and operations teams
to identify trends and implement preventive actions.

Recommendations for Improvement

Based on observations and interactions during my training, I propose the

following improvements:

Introduce Automated Defect Detection: Vision systems with AI can assist human
inspectors in catching micro-defects.
Humidity Control Units: Ensuring consistent environmental conditions will
reduce fish eyes and blisters.
Standardized Paint Viscosity Checks: Every batch of paint should be checked
before use.
Rotational Operator Training: Cross-training staff increases flexibility and
reduces dependency on few skilled individuals.
Defect Simulation Training: Trainees should be exposed to simulated defects and
taught how to fix them.
Feedback Loop to Production: A system where rework trends are regularly
shared with upstream departments to fix root causes.

Implementing these can reduce the rework burden, improve efficiency, and
enhance employee

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 CONCLUSION

The industrial training at Wheels India Ltd. has been an enriching and
insightful experience, bridging the gap between academic knowledge
and practical application. Throughout the training period, I gained
valuable exposure to various manufacturing processes, quality control
measures, and lean production practices followed in the automotive
industry.

Working alongside experienced professionals enabled me to understand

the importance of precision, efficiency, and teamwork in a high-
performance industrial environment. I also learned how theoretical
engineering principles are implemented to solve real-world challenges in
production and operations.

This training has not only enhanced my technical skills but also
developed my understanding of industry expectations, safety standards,
and corporate discipline. It has motivated me to further improve my
competencies and pursue a career in the manufacturing sector with
greater confidence.

Overall, my time at Wheels India has been a significant milestone in my

professional development.

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