GALA PRECISION | SPRING ANALYSIS & OPTIMIZATION

Gala Precision is one of India's leading spring manufacturers, producing everything from tiny precision springs for electronics to massive suspension springs for trucks. Walking through the factory floor on my first day, I was struck by the scale — rows of coiling machines, heat treatment ovens, and quality inspection stations stretching as far as I could see.

My main technical project was settling a design debate: should a particular spring design use open or closed coils at the ends? I set up FEA models in Ansys to simulate both configurations under compression. The results were clear — closed coils reduced stress concentrations by 20% and improved load distribution. My analysis gave the client confidence to proceed with the closed-coil design.

The most satisfying part of my internship wasn't the FEA work — it was a simple Kaizen improvement. I noticed that springs were rolling off the conveyor during the stress-relieving process, creating scrap and requiring manual rework. I designed a set of angled brackets that kept springs centered on the conveyor. The result: 90% reduction in spillage and 15 minutes saved per day. Sometimes engineering is about the small fixes.