TRAINING REPORT

SUBMITTED IN REQUIREMENT FOR SIX WEEK INDUSTRIAL TRAINING

AT

MAHINDRA & MAHINDRA SWARAJ DIVISION

Mohali
(From 9 JUN to 20 JUL)

SUBMITTED BY

NISHANT VERMA Mechanical Engg Univ Roll No (0900117067)

Department of Mechanical Engineering GOVERNMENT POLYTECHNIC

AMBALA

CONTENTS
S.No
1 2 3 4 5 6 7 8

Text
Certificate from company Preface Acknowledgement Objective of training Company profile Swaraj Division Product Manufacture Introduction to various Shops & departments Light Machine Shop Heavy Machine Shop Assembly Shop Heat Treatment Shop Paint Shop Material Testing Lab.

Page No
3 4 5 6

27 28 33 36 44 53 57 58 59 61 63 65 68 70

Tool Room Manufacturing Engg. Deptt. R & D Deptt PPC Deptt. Quality Deptt. Maintainence Deptt. Management Deptt.

Certificate from company

PREFACE
Working in manufacturing industry like PTL (Punjab Tractor Limited) is a wonderful learning experience for me during my academic career I got an opportunity to undergo this training in esteemed organization like PTL, SWARAJ TRACTOR DIVISION The Project assigned to me was to Control the Rejection of Bull Pinion Shaft (BPS) both right and left .And Input and Intermediate shaft used in Swaraj tractor for power transmission .Bull Pinion Shaft (Lt & Rt) are the shafts on which bull and pinion gears are mounted to transmit the power to left and right wheels of tractor. During my working in LMS, it provided me a good exposure of working with automatic CNC machines and realized the speed and accuracy with which it works .Here I studied its various physical and operating features like its layout, operation performed, its control, working etc. Entering in the industry is like steeping into the world ever concept which is taught in the class room is practical in different dimension in the industry and the study on the subject practice in the organization gives a deep insight into the practical side of technique and industry itself. The objective of this training is to gain an inside into functioning of technical departments with respect to an organization. The practical orientation of technical student is must to quality as potential engineer. In my training period a new theory was introduced by the management of the company which is known as TPM (Total Productive Maintenance). Initially it was introduced on some selected areas of the company like machine no 496.01 in LMS, which also proved as good learning experience for me.

ACKNOWLEDGEMENT

Training is systematic way to gain new knowledge. It is possible only in the light of guidance, advice and help from a number of sources without which a learner is a soldier in the vast uncharted sea without radar. I would like to express my sincere thanks to Principal Mrs. Sadhna Jain , With whose guidance I am able to join Punjab tractors Ltd. Mohali, for six months training. I am also thankful to Mr. J.SINGH for allowing me to undergo training at their organization. The help rendered by Mr. H.S Baweja, Supervisor and Manager Machine Shop (LMS) Finally, I am indebted to all whosoever have contributed in this report work and friendly stay at PTL.

OBJECTIVES OF TRAINING
1 .To study the various process which are done on various part of tractor 2 .To study about production planning. 3. To study the function of different department. 4. To study process flow chart 5 .To study about management. 6. To study about human resource management and their behaviour about employees. An easy training but a tuff job T R A To be remain on your seat Remain attentive all time

- Active participation

I N

- Interact to clarify Note points difficult to memorize

I N G

Improve listening habits Never neglect programme

- Gain as much you can

INTRODUCTION
India being a predominantly agricultural country where agriculture is the life and blood of the economy has been a traditional manufacturer of different types of farm machinery and implements. However the use of advanced agricultural techniques in India started only in early sixties. Modernization and tractorization in Indian agriculture is only post independence phenomenon. One of the achievements of green revolution has been that the farmers increasingly realized the advantage of tractorization for obtaining the timelines of operations. This would happen only because of awareness of new farm technology among the farmers, rise in the level of their income and education. , Tractors were

introduced to Indian agriculture in early twenties. Jogindera Singh was the first farmer to use a tractor called a steam plough then on the 12000 acres estate he had inherited in the remote Kheri district of Uttar Pradesh. But the demand of tractors rose sharply in last two decades. However the rate of adaptation of tractors is different in different parts of the country. Punjab occupies number one rank in this regard. Punjab possesses only 1.5% of the geographical area of the country; the density of the tractors in Punjab is the highest (85 tractors per hectare) as compared to national average of 10.5 tractors per hectare. India is primarily an agrarian nation, with more than 50 per cent of our GDP being contributed directly or indirectly by agriculture. No wonder, India is considered the largest tractor market in the world. If that sounds great, let us face hard facts. In terms of total tractors in use in the country, we are ranked a distant eighth. In terms of penetration, India has a tractor density of 10.5 tractors per thousand hectares of Gross Cropped Area (GCA) as compared to the international average of close to 30 tractors per thousand GCA. Figuratively speaking, Indias large gross cropped area (GCA) is next only to the big two USA and Russia. That and the highly fragmented land holdings in India have helped our country to become the largest tractor market in the world. Thus the Indian tractor market, per se, has to be viewed only after considering its position in the world (see Box 1). Description Units World India Indias Total/Avg. rank Arable land Million hectare 1,444 170 2 Irrigated area Million hectare 249.6 45.8 2 Tractors in Tractor/000 28 10.5 8 use hectare Despite a phenomenal increase in tractor population in the country, the tractor density is very low at about 10.5 tractors per thousand hectares of GCA in comparison to the international average of about 28 tractors. Also, the small size of land holding in India, have led to low average power of tractors at 35 horse power (HP), which is far lower than the global average of above 80 HP.

Easy availability of bank finance coupled with declining interest rates has propelled the demand for tractors. Furthermore, a good monsoon, a strong growth in agricultural production and an increase in the irrigated area are expected to lead to a secured long-term growth of 7-8 per cent in the next century. There has been a boom in the tractor industry since 1997. The sales of tractors are not evenly distributed. They are mainly concentrated in the North and Northwest where Punjab, Haryana and UP account for nearly 50 percent of the entire tractor sales. Punjab alone accounts for 26 per cent. The main reason is comparatively larger land holdings and the affluence of farmers in these states. New markets like Madhya Pradesh, Tamil Nadir, Andhra Pradesh, Maharastra and Gujarat are also growing at a faster pace. Punjab Tractors (PTL) leads in the North, while Tractors and Farm Equipment (TAFE) dominate in the South. High transportation cost is one of the main factors preventing brands from going national.

Historical precedents
Indian lives in villages, and villages depend upon agriculture. Agriculture provides livelihood to about 64% of labor force and contributes nearly 27.1% of GDP. Indian agriculture till independence followed obsolete methods. Continuous increase in population has been on stressing the demand of more output from agriculture and to meet this demand we need 225 million tones of food grains by 2000 AD. In the first five-year plan agriculture was accorded top priority. Furthermore, since irrigation was recognized as key to agriculture, irrigation was accorded great importance in the planned development, which started in 1950. Major initiatives were also taken in agricultural education and research.
All these developments made mechanization mandatory for agriculture and import of tractor began. Acceptance of mechanization was however slow and by 1960, population of tractors in the country barely exceeded 10,000.

The Beginning

The decade of 60s India saw green revolution resulting in increase in both production and productivity. With the parallel emphasis on industrialization, the birth of Indian Tractor Industry took place in 1959-60 when the imports were restricted and 5 tractor manufacturing units set up in the private sector,. Date of commencement of commercial production and collaboration are given in table (attached). Total indigenous production of tractors by 1965 was just 6000.With the successful introduction and acceptance of the high yielding seeds, however, there was a sudden upsurge in the demand for tractors after 1967 and demand started multiplying at an annual rate of nearly 50% (1967: 18,000, 1970: 33,000). A natural consequent of this sharp upsurge and consequent shortage was heavy price premium on tractors. Recognizing the situation, import of tractors into the country was liberalized and over and above the domestic production of 20,000 in 1970, 13,000 tractors were imported. SR. NO. 1. 2. 3. 4. Manufacture Eicher Tractors Collaborator Year of commencemen t of production 1959 1963 1963 1964

5.

Gebr, Eicher Tractorenfabric, West Germany Tractors and Builders Motokov-poraha, Ltd/ Hindustan Czechoslovakia Tractors Ltd. Tractors And Farm Massey Fergusion UK Equipment Ltd Escorts Ltd. Motoimport warazawa Zaklady Mechaniczne Ursus, Poland International Tractor International Harvester Co. of India Ltd. Company USA Mahindra & Mahindra Ltd.

1965

The Second Phase

Since the pace of indigenization of the five tractor-manufacturing units already set up was far below expectation, the government decided to diligence the Tractor Industry in 1968 and invited new entrepreneurs. Seeing the sharply growing demand, Tractor Industry became the most sought after industry in the country and as many as 18 fresh entrants approached the Government for setting up manufacturing units. The interest of a large majority, however, lay in quick profits through sales of imported tractors. Nevertheless six new manufacturers did enter the Tractor Industry; four in private sector and two in the government. Combined output of 11 units had risen to 32000 by 1975. The Governments decision to freely invite new entrepreneurs to tractor manufacture in 1968 and sudden upsurge in demand, with the green revolution, led to a scramble, of new entrepreneurs for new collaborators 6 units, eventually, established the actual manufacturing facilities. They were as follows: S.No. Name of the Unit Collaborators Year of commencement of local production 1971 1971 1974 1975 1974 1974

1. 2. 3. 4. 5. 6.

Escorts Tractors FORD UK Ltd. HMT Ltd. Central Motokov praha, Govt. Czechosolovakia Kirloskar Ltd. Tractors Klochner Humboldt Deutz, West Germany

Harsha Tractors Motoimport USSR Ltd. Punjab Tractors CMERI India Ltd. Pittie Tractors Ltd. Own know how

The Maturing Years

With the entry of new units in 1970 and increasing Government pressure towards indigenization picked up substantially after 1970 and by 1978 almost all the tractors manufactured were nearly indigenous. A fillip to indigenisation was also given by the overall industrialization of the country, when a large number of ancillary manufactures had also established themselves and were in a position to supply a wide variety of components to the tractor industry. The sharp liberalization of imports in 1970 had given the nascent Indian Tractor Industry a substantial setback in 1970-73, when low cost import particularly from East European countries had become far more attractive. Recognizing that such was not the intention, the government decided to ban imports in 1973. Banning of imports and increased competition not only led to growth of local production but also spread pace of indigenisation. While domestic demand was growing sharply from 1975 onwards (compound growth rate of 18%), tractor industry suffered another major setback in 1982 when due to severe credit restrictions by the Government, bank credit for retail purchase of tractors by farmers was drastically curtailed and demand fell sharply. But after 1987, the situation again changed and the demand of tractors picked pace because of the priority given by Government to agriculture side. The buoyancy, in the tractor market, experienced in the late seventies, led to the setting up, of two more units, for the manufacture of tractors, one in the public sector, in collaboration with a UK firm and the other, a private sector unit, with indigenous know how. These units are: S. No. 1. 2. Name of the unit Collaborators Year of commencemen t of local production Leyland 1981

Auto Tractors Ltd. (a UP British Govt. enterprise) (UK) Partap Steel Rolling Mills Ownknow how 1983 Ltd.

Punjab Tractors Ltd. (PTL) is the second largest (after the 1st quarter of FY 1999-2000) player in the industry with a market share of 18.45. Unlike M & M, 90% of PTLs turnover comes from its tractors business. During the year 1998-99, the company had a sale of 48336 tractors as against 40,425 tractors last year. Over the last five years PTL has grown at a rate of 17%. During the last year PTL had a growth rate of 22.4%. It was during this period that PTL managed to improve all this because of its strong dealer network, low cost structure and high employee productivity turnover.

. On the financial front the companys performance has been satisfactory. Punjab Tractors has undertaken an expansion programme to enhance its installed capacity from its hitherto capacity of 36,000 tractors to 60,000 tractors per annum

Range of Tractors available in India

In India, the variety in land conditions makes it necessary to diversify the availability of tractors. Today tractors with HP ranging from 12 to 75 are available in India. At present 44 models tractors are available in India. 25 H.P. CATEGORY
SINGLE CYLINDER

303H.P.CATEGORY

SWARAJ-722 EICHER-241 EICHER-242 EICHER-243

MULTI CYLINDER

SWARAJ-733FE ESCORTS-335 ESCORTS-435 ESCORTS-430 HMT-3022 M & M-265DI M & M-365DI TAFE-30DI GUJRAT-G312 51 H.P. & ABOVE SWARAJ-855 HMT-5911 MF-375 ET GUJ-G614 GUJ-G804 41-50H.P.CATEGORY ESCORTS-355 FARMTRAC-50 FARMTRAC-55 FARMTRAC-60 HMT-4511 M & M-475DI M & M-575DI

SWARAJ-724 EICHER-312 ESCORTS-325 HMT-2522 M & M-225DI TAFE-25

36-40 H.P. CATEGORY SWARAJ-735FE EICHER-364 EICHER-369 ESCORTS-340 HMT-3522 M & M-B275 M & M-B275DI

SWARAJ: BIRTH OF AN INDIA A GROWING ENTERPRISE ORGANISATION:

In Hindi word SWARAJ means freedom from bondage and was first used by Bal gangadhar tilak during the time of freedom. Since PTL was the first largest tractor project in India, moreover fully based upon Indian technology. So, SWARAJ was appropriately chosen as its brand name. SWARAJ GROUP sells its product under this brand name. SWARAJ tractor was established in 1965 by a team dedicated engineers and scientists working at Central Mechanical Engineering Institute at Durgapur.. The name SWARAJ was chosen because it meant freedom, Freedom from bondage and freedom from foreign collaboration as well. The first tractor was made over a period of five years. Indias first large-scale project based on totally indigenous design, knows how and technology was promoted by the Punjab State Industrial Development Corporation (PSIDC) with the support of Government of India and public financial institutions.

Punjab Tractors limited (PTL)\

PTL is the second largest (after the 1st of FY 1999-2000) player in the industry with a market share of 18.45 unlike M & M, 90% of PTLs turnover comes from its tractor business. During the year 1998-99, the company had a sale of 48336 tractors as against 40,425 tractors last year. Over the last five years PTL has grown at a rate of 17%. During the last year PTL had a growth rate of 22.4%. It was during this period that PTL managed to improve all this because of its strong dealer network, low cost structure and high employee productivity turnover Besides agricultural tractors, the companys product line also includes harvesters, combines and forklifts. Punjab Tractors has undertaken an expansion program to enhance its installed capacity from its hitherto capacity of 36,000 tractors per annum. Despite the slowdown the tractor industry, the demand for thecompanys Swaraj Tractors has stayed well ahead of production. Overall, thus, the companys prospects seem encouraging.

GROWTH:
The project for the manufacturing of 5000 tractors per year was set up at Mohali, Punjab. It was set up during November 1972-March 1974 at an estimated cost of 3.7 crores. Despite all hurdles and constraints, the project was completed with in the estimated cost and well ahead of the schedule time of 24 months. The engines for the SWARAJ tractors were produced from M/S Kirloskar Ltd. PTL went into commercial production with the introduction of its first model SWARAJ 724 in April 1974. The construction work for this division stated in March 1972 and this first batch of tractors rolled out on 14 November 1973. Commercial production stated on April 1974 with SWARAJ 724, a 26.5 BHP (SAE) tractor as its first model\

THE FIRST GROWTH (1978-82)

By now PTL was on the growth path and was thinking, planning and executing the expansion program. Capacity was increased to 12,000 tractors per year at a capital outlay of 9.2 crores. During this time PTL added one more division into its stable, the Swaraj Foundry Division (SFD). This division was set up for manufacturing Grey iron castings at a rate of 5000 Mt/year at a capital outlay of 1.80 crores. This division stated supplying castings to PTL in 1980. In 1983 PTL introduced another model of tractors the SWARAJ 855 and became the first manufacture in the tractor industry with widest range of products. With a view to board its product line, PTL was granted a letter of intent for the manufacture of the industrial fork lifter and tied up with Komatsu of Japan

SECOND GROWTH (1987 ONWARDS)

In contrast to the depressed situation that prevailing during 198286, tractor market showed encouraging growth trend. The buoyancy in the tractor industry emerged as a result of the high priority accorded by the Central Government to agriculture. The growing reorganization of the important role that farm equipment plated in increasing food output and the spread of mechanization to hitherto dormant market of Madhya Pradesh and Bihar led to rapid expansion markets in states like Uttar Pradesh. In wake of the strong market coupled with various customer-oriented initiatives that PTL took during 1982-86, PTLs own market performance has shown encouraging growth. The demand for SWARAJ tractors for the past couple of years has become so strong that customer prefer to wait for period upto six weeks to buy SWARAJ tractor rather than pick up some other brand easily available. By keeping such demand in the market, the growth of SWARAJ has increased to a higher limit. And today it is a multi-division manufacturing company manufacturing Tractors, Harvester Combines, Forklift Trucks, Agricultural Implements and Automotive Castings.

POSITION OF SWARAJ PRODUCTS IN MARKET

With more than 2 lacks of tractors & harvester combines operating in Indian farms, SWARAJ are now a well-established brand name in country. SWARAJ is now an internationally recognized name in the developing world. The products of SWARAJ are not only restricted to Indian market but they had entered in international market. SWARAJ tractors find an important place in developing countries like Ghana, Tanzania, Zambia, Kenya, Sudan , Uganda, Indonesia & Malaysia ,etc. they are also sending their combines to south Korea having first A.C. cabin combine in India. Long way back , they had also transported the machined rims to Japan, a project millions of dollar

WELCOME TO SWARAJ DIVISION

SWARAJ welcomes its esteemed customers and feels proud on your joining the SWARAJ family. Today the SWARAJ family has grown to a size where it has more than 3.5 Lac satisfied customers. The companys philosophy of serving its customers with total commitment has earned a tremendous goodwill among discerning farming community. We once again reaffirm our commitment to provide a high quality product to farming community.

Punjab Tractor Limited consist of three divisions:

Swaraj Tractor Division (STD) Mohali Swaraj Combine Division (SCD) Chapparcheri Swaraj Foundry Division (SFD) Mazri Swaraj Automotive Ltd. Swaraj Engine Division (SED) Mohali

Swaraj Tractor Division (STD)

This plant in SAS Nagar was established in 1970 and was the first to be set among all other divisions. The first batch of tractor was rolled out on November 14,1973. Commercial production started in 1974. This was Indias first large-scale project on totally indigenous design and technology. It manufactures different models of tractors. Presently, around 80 tractors are produced in a day in two shifts. At present, its product range includes:

Tractors
a) Swaraj 724, a 26.5 bhp tractor introduced in 1974. b) Swaraj 735, a 39 bhp tractor introduced in 1975. c) Swaraj 720, a 19.5 bhp tractor introduced in 1978. d) Swaraj 855, a 55 bhp tractor introduced in 1983. e) Swaraj 744, a 45 bhp tractor introduced in 1999. f)Swaraj 744, a 24.5 bhp tractor. g) Swaraj 733, a 33 bhp tractor introduced in 2000.

Agricultural implements

Disc plough Cultivator Disc Harrow Planter(Seed sum-fertilizer) Shurbmaster

As this is the oldest unit of PTL, most of the higher management decision are taken here such as as budgeting, finance, modernization, marketing et

SWARAJ -735 FE
Model S-735 FE Displace-ment (CC) 2592 Engine Type RV-30 TR Rated Engine Speed 2000 BorexStroke(mm ) 100x110 Width(mm) 1675 H.P(SAE) 39 Idling Speed (rpm) 650-+50 Type 4 Stroke Water cooled Length (mm) 3440 Tyre Size (Front) 6X16 Height(mm) 2275 No.of cyl.) 3 Gear Box Sliding mesh type Power(kw) 29.1 Wheel Base 1955

Tyre Size (Rear)

12.4x28 Ground clearance(mm) 390

SWARAJ-855
Model S-855 (FE) Displacement (CC) 3308 Engine Type RB-33 TR Rated Engine Speed 2000 BorexStroke(mm ) 110x116

SWARAJ- 855FE
H.P.(SAE) 55 Idling Speed (rpm) 650-+50 No.of cyl. 3 Power(kw) 41 Wheel Base Gear Box Sliding mesh type 1955

Type 4 Stroke Water cooled Length (mm) 3420

Tyre Size (Front) 6X16(6.50X24)

Tyre Size (Rear)

13.6x28(16.9X28) Ground clearance(mm) 400

Width(mm) 1730 Height(mm) 2275

Swaraj Combine Division (SCD)

It was set up in 1980 near village Chappercheri, tehsil Kharar, District Ropar at a capital outlay of Rs. 26 million to manufacture self propelled harvester combine SWARAJ 8100. Gradually the division has increased its product range. In 1985, it bought out diesel Fork Lifter FD20 and FD25 with lifting capacity of 2 and 2.5 tonnes respectively. A product totally based on its own design and technology. Later in this year the company also entered into technical collaboration with Komatsu Forklift Company of Japan for manufacturing both diesel and electric forklifts upto 10-tone capacity. In keeping with the diversification, manufacturing of tractor-trailer and shelters for ONGC has also been undertaken at Swaraj Combine Division.

Swaraj Foundry Division

Punjab Tractors Limited set up a captive foundry unit with an investment of Rs. 150 million in the year 1980. The division is located at village Majri in Ropar District 22 kms from Chandigarh. This division supplies automotive castings to all other units of PTL, SML & SEL. The current production capacity is about 8000 tonnes of Grey iron castings per annum on single shift basis.

SWARAJ AUTOMOTIVE LIMITED

Swaraj automotive Limited situated at Nabha, district PATIALA of Punjab state. It was a sick unit before the Swaraj Group over took it, with constant efforts of the new management, now it is again on the path to success. It supplies tractor seats, mudguards, and bonnets etc. to the tractor divisions and seats to Maruti

SWARAJ ENGINES LIMITED

Swaraj Engines Ltd., situated at phase 9, industrial area, Mohali was established in technical and financial collaboration with Kirloskar oil engines Ltd. For manufacturing diesel engines for Swaraj Tractor Division. The Governor of Punjab Mr. S.S.Ray paid the foundation stone of the factory on 29th Dec. 1987. It started production from 28th Dec. 1988. In the first year of production only RV-2 engines were produced. In the second year RV3 engines were also introduced. In the third year two more models R-11 and RV-33 were introduced. Recently in 1999 a new RBB engines has also been introduced. During the few years of its existence, it has not only increased its product range but also increased its production from 345 in the first year more than 18000 engines now.

SWARAJ RESEARCH AND DEVELOPMENT UNIT

The Research and Development unit of Swaraj is situated at Industrial Area, Phase-II in S.A.S Nagar. In this unit the research of new models of tractors is being done and the modification in old models is being done.

EXPORT PERFORMANCE
After having established Swaraj in the Indian market, PTL made a determined start in 1978 to establish it in the international market. Over the year a large number of Swaraj Tractors and implements are operating in many countries in Africa (Zambia, Tanzania, Ghana, Kenya and Nigeria), the Middle East and South Asia. For the last few years PTL is the Indias largest exported of tractor and implements.

LISTS OF PRODUCTS MANUFACTURED

Swaraj group of industries manufactures a wide range of products. Following is the list of products:

1. TRACTOR:
The range of tractors manufactured is Besides the above models special types of tractors manufactured by SWARAJ GROUP such as: a) b) c) d) e) f) g) Swaraj 724, a 26.5 bhp tractors introduced in 1974. Swaraj 735, a 39bhp tractors introduced in 1975. Swaraj 720, a19.5 bhp tractors introduced in 1978. Swaraj 855, a 55 bhp tractors introduced in 1983. Swaraj 744, a 45 bhp tractors introduced in 1999. Swaraj 744, a 24.5 bhp tractors Swaraj 733, a 33 bhp tractors introduced in 2000

2. HARVESTER COMBINE:
It was Indias first indigenously built HC called H-8100. ASHOKA LEYLAND supplies its engine. It is six-cylinder engine developing a power of 105 BHP.

3. FORK LIFTER

These are also called lift trucks. They are used for loading and unloading of heavy equipm ent and articles in an industry. It has very short turning radius so that it can move easily in limited space. The heart of fork lifter (FD) is a 48 BHP engine by KIRLOSKAR OILS LIMITED. The fork lifter is manufactured by SWARAJ in collaboration with a Japanese firm KOMATSU. These fork lifters have power steering system and have partial automatic drive. These can be either battery operated or diesel operated. Following is the list of fork lifters manufactured: FD-20 FD-25 FD-30 FB-20 FB-25 FB-30

4. ENGINE:

The engine required for several models of tractors are supplied from SWARAJ ENGINE LIMITED.

5. CASTINGS:
Castings of various parts of tractor/combine as different housing, gear box, rear cover etc. are manufactured by SWARAJ FOUNDRY DIVISION.

INTRODUCTION TO VARIOUS SHOPS AND DEPARTMENTS MANUFACTURING SYSTEM STD operates through a series of departments, which can be broadly classified into: 1. Production
Light machine shop (LMS) Heavy machine shop (HMS) Assembly shop Heat treatment shop Paint shop Material Testing Lab.

2. Product services
Tool room Tool control cell (TCC) MANUFACTURING ENGG. DEPARTMENT Research & Development Production planning & control (PPC) Material Management & Control (stores) Quality Engineering

Maintenance Construction

3. Support services
Management system Finances Purchase

1. Production LIGHT MACHINE SHOP INTRODUCTION

LMS is the largest section in the factory. All transmission components viz. shafts and gears used in Tractors are manufactured here. It has 117 machines. Facilities of this shop include Equipment for blank operation, boring drilling etc. Except the bevel gear generator & gear shaver, which have been imported from WMW & Churchill of West Germany respectively, all other machines are from HMT Ltd. The rupees thirty one million plant and machinery of this shop installed in area of 33,000n sq. ft. and casting/forging and high standard of quality. This shop is manned by 160 highly experienced Operators & inspectors

FUNCTION OF THE DEPARTMENT

Gear manufacture and grinding, machining of bull gears, bevel gears cutting of all rounds on power hacksaws, facing and centering, all type of grinding inner and outer gears, hobbing and broaching machine .Gear shaving, Gear deburring machine, drilling of all gears reporting system, number of workmen shifts operations.

DIFFERENT MACHINES USED IN LIGHT MACHINE SHOP

DEBURRING MACHINE Gear Hobbing Machine Gear Tooth Rounding Machine Gear Shaving Machine Gear Shaper Vertical Milling Machine Internal Grinding Machine External Grinding Machine Drilling Center Bevel Gear Generator Cylindrical Grinding Machine Angular Head Grinder Deburring Machine Multi purpose CNC Machine Tuning Center Vertical Pull Broaching Machine Special Purpose Drilling Machine Power Hacksaw Horizontal Milling Machine Boring Machine C N C Twin Chuck Machine C N C lathe C N C Grinding Machine

Multi Job Holder Hobbing Machine Center Facing Machine Vertical Turning Center Slant Bed Turning Center Tool And Cutter Grinder

ACCESSORIES USED IN LMS

o Turning Accessories: Tool holders, chucks (power, mechanical), Tapping attachment and drilling attachment. o Milling Accessories: Vices (bench vice, machine vice), arbors. o Broaching Accessories: Broach holders. o Drilling Accessories : Quick change chucks & sleeves o Grinding Accessories: Grinding wheel flanges, chucks. o Hobbing Accessories: Hobbing fixtures, Centers, Arbors o Shaving Accessories: Cutting Arbor, Work holding fixtures.

MACHINE SPECIFICATIONS
Identification number, type, make, broader specification viz. Machine no., make, type, overall dimensions, no. of speed, speed range, no. of feed m feed range and other special information.

Documents/slips used in LMS

11.1 Daily Production and quantity certification statement 11.2 Idle activity slip 11.3 Tool issue slip 11.4 Daily material movement slip 11.5 Daily Machine load chart

VARIOUS COMPONENTS MADE IN LMS

S.NO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

COMPONENTS
BULL PINION SHAFT LT BULL PINION SHAFT RT BULL PINION BEVEL WHEEL LT BEVEL WHEEL RT BULL GEAR (735-SS) CAGE ASSY C.M GEAR CONNECTING SHAFT CROSS DRIVE SHAFT GEAR Z-18 GEAR Z-24 GEAR Z-25 GEAR Z-26 GEAR Z-28 GEAR Z-29 GEAR Z-30 GEAR Z-30 GEAR Z-31 GEAR Z-34 GEAR Z-35 GEAR Z-36 GEAR Z-42 GEAR Z-49 GPTO FIXED GEAR (744/855) GPTO SLIDING GEAR GEAR COUNTER(4WD)

S.NO
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

COMPONENTS
IDLER CLUSTER INPUT SHAFT INTERNAL GEAR KPS ASSY LAY SHAFT LT CAGE PLANET CARRIER(744/855) INTERMEDIATE GEAR RT CAGE GEAR MAIN DRIVE (4WD) GEAR TIMING GR IDLE ASSY BUSH GEAR IDLE GEAR CAM SHAFT GR FIP G OIL PUMP DR GEAR CRANK ASSY GEAR REV GR MAIN DRIVE GR COUNTER SHT PINION DIFF FLANGE COMPANION CASE DIFF GR LT BRG HSG CASE DIFF ASSY SHAFT MAIN GEAR OUTPUT(4WD)

MANUFACTURING OPERATIONS IN LMS

Facing: It is the operation of finishing the ends of the work, to make the ends flat and smooth & to make the piece of required length. Under Cutting: It is similar to grooving operation but is performed inside a hole Chamfering: It is the operation of beveling the extreme end of the work piece. Chamfer is provided for better look/ to rough turning: in this operation max. metal is removed & very little dimensions are left for further machining. Finish Turning: Here min. metal is removed & very fine finish is obtained on the work surface Grooving: It is the operation of turning the groove or neck in order to terminate a thread of to provide adequate clearance enable nut to pass freely on threaded work piece, to remove burs Knurling: It is a process of embossing a diamond shaped regular pattern on the surface of the work piece using a special knurling tool. Broaching: It is a method of metal removal by a tool that has successively higher cutting edges in a fixed path Drilling: It is a process of making hole in an object by forcing a rotating tool called drill. Boring: It is a process of enlarging a hole that has already been drilled. Grinding: To grind means to abrade to wear away by friction or to sharpen. In grinding, the material is removed by a means of a rotating abrasive wheel Hobbing: It is the process of cutting teeth or gear & shafts & is performed by a rotating tool called hob on the hobbing machining. Shaping: The process of cutting gears on the shaper is known as shaping for teeth cutting is multi-point cutting tool

INTER RELATIONS WITH OTHER DEPARTMENTS

Tool room: jigs, fixtures and cutting tools, maintenance: attending breakdowns and carrying out preventive maintenance of machine tools etc, Industrial engineering: provision of process charts for machining operations, Assembly: ensuring proper fitment of components on a day to day basis. Quality control and inspection, storage and inspection R&D. Heat treatment: Shot blasting operations, lab testing, inspection etc

HEAVY MACHINE SHOP INTRODUCTION

All heavy castings of tractors are machined in this shop with the help of variety of special machines (SPM). These machines are tailor made by HMT to suit component requirements. In addition, facilities of this shop include general-purpose turning, drilling and milling machines. About 20 SPM and 30 GPM are installed in a covered area of 47,000 sq. ft. at a cost of 20 million, 2600 tones of castings are machined every year on a two shift basis. In addition to the machining of castings for the tractor, some jobs are also performed for Swaraj Mazda Limited.

FUNCTIONS OF THE DEPARTMENT

Machining of heavy castings like differential housing, gear box housing, rear cover, trumpet housing, steering housing of tractors, machining of tractor parts, machining of some components for Mazda.

INTER-RELATION WITH OTHER DEPARTMENTS

Tool room- Requirement of jigs, fixtures and cutting tools. Maintenance-Attending breakdown and carrying out preventive maintenance of machine tools Industrial engineering Provide process charts for machining operations. Assembly Ensuring proper fitment of components, production planning and control, micro loading of components on day-to-day basis. Quality control & inspection Storage and inspection.

INSTRUMENTS FOR HEAVY M/C SHOP

S.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Instruments Vernier calliper Vernier calliper Vernier calliper Micrometer Micrometer Micrometer Micrometer Micrometer Micrometer Micrometer Depth vernier Bore gauge Bore gauge Bore gauge

Size 0-100 0-400 0-600 0-25 25-50 50-75 75-100 100-125 125-150 150-175 0-200 10-18 18-35 35-60

Components Diff. hsg., assembly Gearbox hsg. Trumpet hsg. Gearbox hsg. Cage assembly Diff. hsg. Gearbox hsg. Diff. hsg., Gearbox hsg. Gearbox hsg., Trumpet hsg. Trumpet hsg, differential hsg. Diff. hsg. Trumpet hsg. Cage assembly Trumpet hsg. Gearbox hsg. Cage assy. Diff. hsg. Gearbox hsg. Rear cover trumpet hsg., Cage

COMPONENTS MACHINED IN THE SHOP

o Gearbox housing (Material R-33, Casting, 180-230 BHN. 76-kg wt.) o Differential Housing o Rear Cover o Trumpet Housing

TYPES OF MACHINES

o Radial drilling machine o Vertical milling o Horizontal milling o Simplex milling o Duplex milling o Lathe o Double end o T/W boring o Automatic lathe o SPM (Special Purpose Machine) o

MACHINING OPERATION
Drilling: It is a process of making hole in an object by forcing a rotating tool called drill. Boring: It is a process of enlarging a hole that has already been drilled. Facing: It is the operation of finishing the ends of the work, to make the ends flat and smooth & to make the piece of required length. Chamfering: It is the operation of beveling the extreme end of the work piece. Chamfer is provided for better look/ to rough turning: in this operation max. Metal is removed & very little dimensions are left for further machining. Milling: It is a process of material removal to make flat surface. It can be vertical or horizontal

Turning: It is a process of material removal from the cylindrical periphery of a shaft Taping: It is the process of making threads on the inner or outer periphery of a hole

ASSEMBLY SHOP INTRODUCTION

SWARAJ TRACTOR DIVISION deals in the assembly of tractors SWARAJ 722, SWARAJ 724, SWARAJ 735, SWARAJ 733 and SWARAJ 834.The assembly process is carried out on a main line that has the various subassemblies along its length The major work this shop undertakes is the over all assembly of the tractor. Various components from the other shop are transported to this for their assembly. It consists of 100 highly skilled workmen. Their main work area includes

SECTIONS IN ASSEMBLY
o Cage Assembly o PTO shaft assembly o BPS L/R assembly o Diff assembly and testing o Trumpet housing and assembly o Diff assembly and Trumpet housing assembly o Gear box assembly and Testing o Steering assembly o Brake housing assembly o Coupling Gear box assembly with Diff housing assembly o Front axle beam assembly o King pin assembly o Engine assembly o Assembly other main link items like Leveling Rod ,Trailor rod, Front and Rear frame, Battery Mtg, Frame, Stay bars, Brake pedal, Clutch Pedal assembly. o Greasing all points o Invasion into painting chamber o Mounting of front and rear tyre. o Fender assembly with lights other electrical filaments o Radiator assembly

o Dashboard assembly with seat assembly o Fuel tank assembly o Side panel, Bonnet, Front shield, Rear shield, Front grill etc assembly o Air cleaner and Exhaust assembly o Battery fitment o Oil filing and battery filling o Testing

The Assembly shop is the production shop where assembly and subassembly of all the parts take place. The final processed parts from the various parts of production shop such as HMS, LMS, and AND HEAT TREATMENT reach the assembly shop. The assembly shop can be divided into various groups depending on subparts being assembled. These groups are: 1) Differential assembly and sub assembly 2) Differential Cover assembly 3) Gear box assembly and sub assembly 4) Steering gear box assembly +Gear shifting mechanism assembly +brake assembly. 5) Assembly of various links, foot board and other accessories. 6) Assembly of engine with clutch mechanism.

7) Assembly of 5th and 6th assemblies. 8)

DIFFERENTIAL ASSEMBLY
Before the various differential parts such as BP shaft, differential cage etc. are assembled, the various sub-assy. of parts listed above are performed in the sub units. In the first unit, both the BP shafts are fitted with various components such as circlips, needle bearings etc. to be able to be assembled to the diff. Cage. The second unit assembles the various diff. Cage parts. This constitute the assy. of Cross Bar, Planetary Gear, Planetary Gear Cover, Crown Wheel etc. The various bolts required to make the assy. of above parts and integral one are nutted using an pneumatic bolter gun. After this, the diff. cage is collected from the conveyor firstly fitted with the necessary bearing races. Then the diff. Cage unit and the BP shaft is assembled, making up a complete one unit. The Trumpet Hsg. and the Axles are assembled in a different assy. shop and there on the whole unit along with the Bull Gears is assembled to the differential Cage. The Assy. of Diff. Hsg. is complete with the assy. of lay shaft extension, the oil filter and the brake mechanism.

Following are main parts of differential housing: (A) Crown wheel. (D) P.T.O. shaft. (F) B.P. shaft right. (H) Bevel gears. (J) Bearing cones. and etc). (B) Tail pinion. (E) B.P. shaft left. (G) Bull gears. (I) Bearings. (K) Brakes housing assembly (with disc

(C) Cage assembly. (With sun, planet gears and cross)

(L) Oil seals, gaskets and fasteners etc.

PICTURES OF ASSEMBLED DIFFERENTIAL

REAR COVER ASSEMBLY

The second stage of Assy. shop is the rear cover assy. shop which incorporates the gear pump assy. and the direction control valve. The rear cover is collected from the conveyor and the various attachments such as Power Cylinder, Piston Assy., Response Valve etc. is made, and the cover is tested for its efficiency on the testing jig. After which it is sent to the first stage where the whole unit is assembled to the rear cover assembly and sent for further assembly.

DIFFERENT VIEWS OF ASSEMBLED REAR COVER

Testing

TESTING MACHINE FOR HYDRAULIC

TESTING OF REAR COVER

GEAR BOX ASSEMBLY

The Gear Box Assy. is the third stage of the assy. unit in which the gear box is assembled. Firstly, the gear box housing is collected from the conveyor roller and successively parts such as the counter shafts, clutch shafts, main shaft along with the ball bearings are assembled to the unit. There is separate sub unit assembling the planetary cage and gears which is then attached to the Gear Box output shaft to obtain the duplex speed ratios of the tractor.

Following are the main components of gearbox

(a) Input shaft assembly. (c) Lay shaft assembly. (e) Actuator shaft ass. (g) Gear box housing. (i) Shifter forks. (k) Fastness, gaskets and spacers. (l) Planet gear and carrier ass. with internal gear. (b) Output shaft assembly. (d) Intermediate shaft assembly. (f) Gears. (h) Shifter rods. (j) Bearings.

LAY AND INTERMEDIATE SHAFTS WITH REQUIRED GEARS

DIFFERENT VIEWS OF ASSEMBLED GEAR BOX

Steering Gear Box, Gear Shifting , Brake Assembly

This unit consists the 4th stage of the assy. unit. In this unit the sub assy. of the steering gear box, gear shift mechanism on gear cover and the brake mechanism is assembled of these mentions sub assemblies, the brake assembly is sent to the 1st stage of assy. and the steering gear box and gear box cover assy. is sent to the 3rd stage of assy. Apart from these sub assembly unit also produces the KPS assy. i.e. The King Pin Shaft Assy. which is assembled to front lay beam to hold the front wheel.

Assembly of Gear Box, Differential Hsg. and other accessories

In the 5th stage of assy. the Gear Box is mantled to the diff. Apart from this, various other accessories such as Foot Board, Battery Clamp and other links such as Accelerator Pedal Link, Clutch link, Brake Link etc are mantled in this section.

Assembly of Engine and Clutch Mechanism

This unit is separate 6th stage of assy in which the engines are received from the stores and fitted with the clutch mechanism and lay beam along with the counter weights.

Assembly of Engine with the rest of transmission section

The assy. of the engine and rest of the transmission is done within the 7 th stage. In this stage the whole of the chassis is formed as an integral unit. The various links and mechanism between the engine and the gear box or diff is fastened together and the whole integral unit is checked for its complete accessories etc. After the assy. of this stage is complete, the assembled integrated unit is ready to pass through the paint shop.

In all the above stages of assy. the skilled workers are used to accomplish all the stages of assy. But they are also held by the pneumatic bolt guns and the over head automatic conveyors and the alarm conveyor etc to make their job easy. Also the whole of the assy. is done on the assy. jigs or stands which is kept moving at a speed of about 7cm/min. Also it is to be made in mind that any spill of the sub parts such as bolts, nuts etc. by mistake is not going to spoil the working space as all these spills gets underneath the working space and as a result the working space remains clean and tidy.

Final assembly line

After paint the assembly is unloaded from conveyer and final assembly. In this division following parts are attached to it: Front tyres Rear tyres Fuel tank: its capacity is 60 lts (depending on the model) Radiator: its function is to cool the engine by means of water.it cools the water and again supplies it to the gallery for cooling. Fan Battery:12 v batteryis used . its function is that it helps in starting the engine. Wiring Dashboard : indicators are their for observing the performance. Fender Steering wheel Air cleaner : it is situated at the front . its function is that it supplies the clean air to the engine. Sheet metal Bonnet Seat Side seats Filling up oil : 6 lts.

 Stickers

Procedure of roller testing:

In this section tractor is mounted on the roller and is started. The tyres moves on to the roller and following checks are performed there: Check the water level in the radiator. Check the level of oil. Differential filled in b\w max. and min. marks on dipstick. Air cleaner Steering gearbox fully filled. Fip fully filled. Clutch paddle free play 0.75-1 inches adjusment Brake paddle free play 1.75-2 inches Check working of all gauges (temp. oil pressure, rpm) Check all electric systems Hydraulic testing Leakage from all possible points. Check for proper gear engagement. Check for any abnormal noise. Engine: Oil pressure: at 725-750rpm 0.5kg\cm2 At 2150-2200 rpm >0.5<4.5 kg\cm2 Temperature of water in working condition : 70-80 degC. Check the vibrations of clutch at 725-750 rpm. Check the abnormal noise of spider kit. Check for p.t.o working.

HEAT TREATMENT
INTRODUCTION
The heat treatment shop lays a very important role in the automobile Industry. Various parts such as axles, gears, shafts etc. if not heat- treated will not work for a longer time. Heat treatment shop at STD is adjoining the LMS. Most of the parts of tractors and Mazda manufactured in LMS are heat treated here. The shop is equipped with several heating furnaces and testing machines. The shop is manned by skilled staff and workers.

All Transmission components after undergoing machining operation are subjected to heat treatment. Heat treatment is done so as to improve hardness and strength of these components viz gears and shafts.

TYPES OF FURNACES
o Pit Type-Carburizing is done to increase carbon content o Sealed Quenched Type- Certain reactions are allowed to take place resulting in formation of carbon by products. The reagents used are mainly N2, LPG and methanol. All other gears and shafts manufactured in L.M.S. are heat-treated.

TYPES OF FURNACES AND MACHINES

MACHINE NAME
1. Gas Carburizing Furnace 2. Induction Hardening Machine 3. Quenching Tank 4. Shot Blasting Machine 5. Tempering Machine 6. Lapping Machine 7. Hydraulic Press 8. Cutting Machine 9. Hardness Testing Machine 10. sealed Quenched Furnace

NO OF MACHINES
8 1 2 2 3 2 2 1 3 6

In the heat treatment section the various processes like carburizing quenching, tempering, normalizing, annealing and washing of the different components is done purpose of Case hardening is to form Unlike carbon rich steels which can be hardened by heating, mild steels do not contain enough carbon to perform this operation. Instead carbon is forced into the skin of the metal to produce a piece of mild steel which has an outer casing containing more carbon than its core. This process is known as case hardening.. This will produce a carbon rich skin or case of about 1mm thic

The sequence of operations done on a particular component

As follows:Punching on the components. Fixture preparation. Washing of components. Carburizing. Quenching. Washing of the components. Tempering. Shot blasting.

LIST OF COMPONENTS GIVEN HEAT TREATMENT ARE :1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Gear z-28. Intermediate shaft Dog gear z-36 Dog gear z-32 Dog gear z-32 Input gear z-50, 52,53 Sleeve big. Input shaft. Lever. Ring gear. Drive shaft. PTO fix. Sleeve52/16. 19 20 21 22 23 24 25 26 27 28 29 30 Gear z-35 Bull pinion shaft Input shaft without gear. Input shaft gear z-21, 23,24. Hi/low intermediate shaft Sleeve small. Bull gear. PTO slide PTO internal gear Bull gear PTO slide. Output shaft.

13. 14. 15. 16.

Lay shaft. Idler cluster internal gear. PTO gear z-37 17 HOB (for intermediate shaft 18 Gear z-28,25 loader special 19 Idler rev gear z-24

31 .32 33 34 35 36

Sleeve-68 Gear PTO z-56 Sleeve-37Bp shaft. PTO rear shaft PTO gear z-33 Drive shaft z-18

. Process for normalizing (8620). Process for normalizing (EN28/EN9). Process for stress relieving. Bush spool valve. CM gear z-43, 46. In the heat treatment plant there are various furnaces and tanks used for different purpose. Carburising is carried out in gas carbursing furnace (GCF). The process of tempering is carried out in tempering furnace. Quenching and washing are carried out in quenching tank (QT) and washing tank respectively STEPS IN WHICH THE COMPONENTS OPERATED IN THE HEAT TREATMENT PLANT ARE:(1). PUNCHING OF THE COMPONENTS:Machine name:- punching machine. Operation:- Punching. Tool used:- Number punch. About operation:All the components are given codes or numbers first. The punching machine is hydraulically operated. The jobs are held in the fixture and then with help of a punch different codes are punched on the jobs.

(2). FIXTURE PREPARATION:After punching fixture preparations is done. In this operation the fixture prepared according to the size, shape and quantity of the components. The fixtures are very large in size and can carry numbers of gears, shafts and other small components. (3). WASHING OF THE COMPONENTS:This is done in the washing tank to remove the oil from the component, which is on them because of machining. For washing of the component water and caustic soda is used. Caustic soda is used because oil cannot be removed by water alone caustic soda is useful in removal of oil from the surface of the components. In washing tank there are number of nozzles through which water and caustic

soda mixture stikes over the surface of the component at high pressure, this high pressure helps in removal of oil and other impurities. (4). CARBURISING: This is the phenomenon by which carbon penetrate the steel. Iron at temperature above its critical temperature has affinity for carbon. The carbon is absorbed into the metal to convert outer surface into high carbon steel. The depth of case depends upon the time and temperature of treatment. The atomic size of iron (fe) is less than that of atomic size of carbon (c) so, the Penetration of carbon cannot be done easily, that is why heating of metal is done. The metals heated above critical temperature, at this state the atomic size of iron increases and hence peneyration of carbon can be done easily

The temperature inside the furnace is set according to the requirement. In GCF there is a drip feed panel through which the quantity of isopropanol is controlled. In carburising isoprpanolis used for making carbon at high potential. The percentage of isopropanol is controlled with the help of drip feed panel. When the liquid from the drip feed panel enters the furnace it atonce burst into a gas having carbon at very high potential. Since carbon has property to flow from high potential towards the low potential therefore it is helpful for the penetration of carbon into steel. When the temperature inside the furnace reaches about 930 c, the penetration of carbon in the steel started. This penetration of carbon into steel at temperature 930 c is called active carburising. After active carburising the drip feed amount stops i.e. there is no drip feed given but the temperature remains the same, now the penetration of carbon gradually decreases and also the percentage of carbon decreases this is called diffusion carburising. The active and diffusion carburising are done alternatively because if they are not done alternatively the percentage of carbon in the component suddenly increases which will damage the grain structure of the components and also some extra carbon get attached to the surface of the job and its removal is very difficult. After active carburising and diffusion carburising reduction carburising is done. In reduction carburising the drip feed amount decreases and the temperature inside the furnace decreases from 930-810 c. If the temperature and the drip feed does not decreases this will effect the grain size and shape of the job, therefore when the temp. Decrease the job acquires its original grain

size. Heat treatment is the operation of heating and cooling a metal in its solid state to change its physical properties. Acc. to the procedure used, steel can be hardened to resist cutting action and abrasion, or it can be removed grain size reduced, toughness increased, or a hard surface produced on a ducible interior. (5). QUENCHING: --

Quenching or rapid cooling from above the critical temp. by immersion in cold water or other cooling medium, is a hardening treatment . It increases the strength of the metal and increases the wear resistance, but makes the metal brittle and has low ductility.

Testing parameters and indicative limits for quenching oil are:-

S.NO. PARAMETERS TEST TEST SPECIAL LIMITS INDICATION LIMITS TESTED EQUIPMENT METHOD FOR FRESH OIL FOR OIL USED 1. Kinematic Viscometer viscosity temperature at 40 c contolled both soap and water Specific gravity @30 c Hydrometer 500ml cylinder ASIMD 445 20-25 19.32

2.

ASIMD 1298

0.84-0.87

0.83 minimum

3.

Flash point Flash point apparatus

ASIMD 92

178 C

178 C

4.

Specific value All Of mgkOH Condenser Gm

ASIMD 94

Less than 1.0

5.

Acidic Value Sludge

Karl fisher Titrator

ASIMD 1744

0.2 maximum

Less than 1.0 Centrifuge Apparatus ASIMD 91

(6). WASHING: After quenching the washing of the component is done. The washing us done to remove oil dust and small chips from the surface of the components. The mixture of water and caustic soda is used for washing. It is carried out in the washing tank where number of nozzles throws the mixture of water and caustic soda at a very high pressure on the surface of components. (7). TEMPERING: Tempering consist of reheating below the critical temperature. The quenched metal to restore some of the ductility and to reduce the brittleness. Increased toughness is obtained at the expense of high strength. The table representing the tempering of an intermediate shaft is shown below:

S.NO 1.

PROCESS Loading

DETAIL OF PROCESS TEMP. Loading of charge in GCF at 920-930 c 920-930 c

D.F.A Nil

2.

Heating cycle

After loading temp. Fall to At temp. At temp At temp.

600-650 c 750-770 c 850-870 c 910-930 c

Nil 0.1-0.4 LPH 0.8-1.0 LPH

3.

Carburising

Carburising temp. 910-930 c Carburising cycle contd. Up to C.P goes to 0.8-1.0% Checked by carbon Apparatus or by oxy Probe. (a) Feed to stop when 910-930 c 0.8-1.0%C.P received (b) When C.Preduced to 910-930 0.6-0.7%(C.P to be Checked by carbon Determination method or By ox probe) (c) Repeat (a) &(b) until Case depth 0.6-0.7 mm Achieved

LPH 1.0-1.2LPH 0.4-1.2 LPH

4.

Diffusion

LPH

Nil 0.4-1.2 LPH

5.

(Note)

Take out at least two Pin on regular interval Of time from the start Of different cycle for Checking of case depth Until depth is achieved. Switch of GCF2 shut Down temperature (a) Ensure oil 910-930 c Temperature between To 60-80 c 800-830 c (b) Quenching the charge Q.T Ensure the C.P of GCF 0.7-0.9% at the time of Quenching. Temper the charge at 180-220 c 180-220 c in tempering furnace the I-5hrs. (tempering time is depending upon surface hardness achieved after and thickness of the component). 0.2-0.4 LPH

6.

Cooling cycle

7.

Tempering

(8). SHOT BLASTING:Machine name: - shot blasting machine Operation: -cleaning of carbon from the surface of components Shots material: - High carbon steel balls. Speed of shots: -80m/sec. In this machine the different components are placed on the two big size plates, which are attached to the two big gates. At one time one gate is kept closed and one is kept open. When one gate is closed the machine gets started and then the high carbon steel balls strikes at a speed of 80m/sec on the surface of the components to clean carbon stick to their surface. Shot blasting is done in a machine called shot blast. In the process of carburising some extra carbon get attached to the surface of the components that can easily removed with the help of shot blasting. For the removal of carbon from the surface of gears it takes 2-3hrs of operation in shot blasting machine. When the process starts the table starts rotating and the shots from the top of the container falls on the components. The shots come down with the help of the motor of 20HP. For cleaning of carbon different size

of shots are used. The process is carried out in 12min for bull gears, 19min for small gears. This time variation is given according to the hardness of the gear or shaft e.g. if the hardness of the simple gear is from 30-35 we will give 3-4 min for its shot blasting. If the hardness varies from 60-70 we will give 10-20 min for its shot blasting no matter what is the size of gear. .

PAINT SHOP
Operations performed in paint shop are: o Surface preparation(Pre Treatment Cell) carried out for sheets and rims o Painting o Inspection o Rejection(Reprocessing)of sheets and rims

PRE TREATMENT CELL

1. Degreasing-1 3. Water rinse-1 5. Water rinse-2 7. Activation 9. Water rinse-4 11 Passivation. After components is rejected and repainted through the previous procedure. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) Sanding improper. Cleaning not OK. Primer paint fault. Water splash/oil in air. Dust after paint. Pin hole. (Due to incorrect temperature). Paint cloat. Orange peal. Shade not matching. Denting on surface. 2. 4. 6. 8. 10. Degreasing-2 De rusting Water rinse-3 Phosphating Water rinse-5

PAINTING
Chassis paint line: Washing: Here chassis is first washed with a chemical cleaner, concentration of which is 5% and auto sprayed in a chamber Drying: The chassis is then dried by hot air whose temperature is up to 60 to70C. Primer Painting: A thin layer of primer paint is sprayed in the chassis so that the final paint is strongly fixed on. Flash off: This is the distance given so as to allow paint to dry. Final painting Flash off Banking: Chassis is allowed to bake for around 30 minutes

QUALITY INSPECTION
If painting in both sheets and rims is satisfactorily the piece is selected otherwise rejected .Various parameters checked are Depth of penetration of paint Thickness of paint costing Smoothness Uniformity

REJECTION
If piece is rejected it is either again processed whereby is again send to PTC or discarded. Rejection can be due to following factors: Runs (flows): due to low viscosity of paint Thin coating Over and Under Baking Non-Uniformity and crow footing Vendor defect Presence of dust

METHODS OF SURFACE PREPERATION

o Rubbing surface with sand paper o By shot blasting o By buffing o By chemical process

PAINTING
This process (sheet and rim painting) includes o Full primer plus one coat of paint(30-40 microns) o Flash off (This is the distance given so as to allow paint to dry) o Baking(120-130 degree centigrade) o Rubbing o Cleaning with tag rag o Final painting

CHASSIS PAINTING
Washing Drying

Primer painting Flash off Final painting Flash off Baking

Various Parameters checked are

Depth of penetration of paint Thickness of paint coating Smoothness Uniformity

Reasons for rejection

Flow Less paint Crow footing shade variation Dust Vendor fault

MATERIAL TESTING LABORATORY Functions of Material Testing Laboratory

Checking of Castings and Forgings (Dimensional and Metallurgical Check) Paint Testing Rubber Testing Forging and Casting Forgings and Castings are pre-inspected before machining. Check Dimension as per drawing. Metallurgical Test:

Depending on the criticality and size of lot, certain numbers of castings and forgings are selected for testing. Thereafter a small piece is cut from each of these selected forgings and casting and each of these piece undergoes following testing. Chemical Composition Testing

done using Computerized Spectrometer Here Argon gas is used and spark is produced. Thus wavelength of spectrum produced is recorded in order to obtain chemical composition of the forgings. Chemical Composition is generally Carbon, Tin, Chromium, Iron, and Nickel. Microstructure Testing

done on Microstructure Testing Machine. This test gives the arrangement of grains in the chosen piece. Hardness Testing

done on Hardness tester Machine. Brinell hardness is checked prior to machining operation for each of these castings and forgings. Thereafter heat treatment, Rockwell hardness is checked. For extremely soft materials hardness testing is carried out on Microstructure Tester Machine.

2. Product services 1) TOOL ROOM

In industry various types of tools are used. The tool room caters to the needs for manufacturing of gigs, fixtures, gauges, dies, etc. During machining wear & tear of the tool takes place. The tool room is provided in order to re-sharpen these tools.

Functions of Tool Room

Re-sharpening of the tools- whose wear & tear has taken place. This ensures that there is no delay in production due to blunt tools. New Jigs & Fixtures- In order to improve the production rate & quality of the work & to decrease the job setting time, new jigs & fixtures are developed in the tool room. Maintenance of old jigs & fixtures- Old jigs & fixtures that lose their accuracy due to breakage or wear & tear are repaired in the tool room. New development work- Any modification & development work is carried out in tool room, for e.g. a new component is to be installed in a tractor, its die assembly is developed in the tool room. Manufacturing of measuring tools- Certain measuring tools used in the metrology lab for quality check are manufactured in the tool room.

Machines used in the tool room

Precision Grinding Machine Jig Boring Machines Dahlih Machine (Here die assembly is manufactured ) Lathe Machines (Re sharpening of tools takes place ) CNC Turning Machines (Here certain measuring manufactured)

tools

are

2) MANUFACTURING ENGG. DEPARTMENT

This department is commonly known as Industrial Engg. department. This department is backbone of the industrial unit. All shops come under this department. It deals with the activities related to industrial engg.

INTRODUCTION
The Manufacturing Engg. Department (M.E.) plays a vital role in efficient and smooth working of the manufacturing and developing programs of the company. Industrial Engineering is engineering approach to the detailed analysis of the use and the cost of the resources of an organization. The main resources are men, money, material, equipment and machinery. The Industrial Engineer carries out such analysis in order to achieve the objective and policies of an organization. It is not associated with meeting cost factors, but with organization structure, administration, technology and human problems etc. Earlier it was mainly employed to manufacturing industries for improving methods of production, to develop production work standards and to formulate production contract and wage policies. But with the advancement of technologies and industries, I.E also spread to non-manufacturing like construction, transportation etc. It is the most important and result oriented department in terms of production, planning, designing, optimization of methods etc. Some functions involve planning of layouts of all the shops to get maximum benefits of available space, setting workers time standards to perform a certain job by motion study and implementing standards laid. Other functions of this department also include selection of tooling, fixture etc. In PTL the M.E. department is further divided into three sections: Process planning Plant and machinery Work- study

Job responsibilities of M.E.: To set up production norms for all production departments i.e. to set up time standard for the entire job. To design/improve work place arrangement to improve productivity and to create good working conditions and environment for work place. To design/improve material handling system to make its use and optimize its cost.

To design material storage system for optimizing utilization and minimizing cost. To calculate efficiencies of shops and thereby incentives. To set up new machines and to make process plan. Design formats for management reports like rejection of manpower facilities, production target v/s production efficiency. Plant layouts: best optimum utilization of space can be achieved by optimum layout. Installation of new machines and conveying systems.

Functions of M.E. department:

Receiving components and drawings from R&D. Prepare and release of process sheet. Assessment of direct labour requirements. To make decisions for required equipments. To make decision for purchasing new machines. Installation of new machines at proper places. Releasing of jigs, tools and fixture drawings. Preparation of release of operating conditions of machines. To study the machining time. To make operation research. Miscellaneous and advisory functions.

Applications of M.E.:
Earlier it was mainly applied to manufacturing industries for improving methods of production, to develop work standards or to formulate production control and wage policies. Later on, the use of M.E. also spreaded to non-manufacturing activities such as construction and transportation, farm and air-line operations and maintenance, public utilities, government and military operations. But today it finds its major application in manufacturing plants and industries. In an industry besides the production, other departments utilization M.E. concept is marketing, finance, purchasing and industrial revolution etc.

3) SWARAJ RESEARCH AND DEVELOPMENT UNIT: ACTIVITIES

1. Design and development of new product based on market requirements. 2. Product improvement (Engine, Transmission, Sheet Metal, Hydraulics, and Steering) based on field performance reports. 3. Value Engineering 4. Product Reliability 5. Design, Development and commissioning of test reports. 6. Testing of components for performance and product reliability. 7. Assistance in vendor development. 8. Co-ordination, periodic testing and evaluation of tractor model at Central Farm Machinery Training and Testing Institute (CFMTTI), Budni.

RESEARCH & DEVELOPMENT

Expenditure on R&D during 2006-07: (Rs. in Crores) Capital Recurring Total Total R&D Expenditure as %age of Total Turnover 1.21 Major research and development activities have been: 1. Swaraj 724 FE Orchard Special tractor model commercially launched. 2. Swaraj 978 FE (72 HP) tractor model commercially introduced in domestic market. 3. New sheet metal with contemporary styling introduced on Swaraj 744 FE tractor model. 4. New sheet metal introduced on Swaraj 735 FE tractor model. 5. On-going product improvement for performance, reliability and value addition continued with vigour. 2.98 8.56 11.54

Testing Of Engine in R&D Section TESTING: Before starting the engine the lubricating oil is filled into the engine and then engine is mounted on the fixture. The flywheel is directly attached to turbine through connecting shaft and engine is started. The After minute run-ning the tappet clearance is checked. Tappet clearance is to be kept .25.005. The clearance is necessary otherwise the thermal expansion of valve will alter the opening of closing of valve angles. After that engine is run at 2400 r p.m. m. for 2.30 hours and then the engine is run at various r.p.m. and loads to calculate the power, b.h.p. and s.f.c. POWER OUTPUT: The engine shop is having latest technology and all the information is available digitally. The load can be increased or decreased r.p.m. or s.f.c. can be changed from within the electronic cabin. Power test is done. on 2200 r.p.m. (Maximum r.p.m. of engine is 2400) where torque is rated and is indicated on digital meter. The alteration in r.p.m. is made by varying the load and fuel supply is kept constant. The power is calculated as follows POWER = (R.P.MTORQUE)/(7023.746) H.P. If the power calculated from above formula comes lower than prescribed limit than usually fuel timing is altered. The fuel timing is altered with the help of F.I. pump. Usually the engine is tested on 18 Celsius advancement By revolving the pump away from engine the timing is reduced and by revolving F.I.P. toward the engine the time is advanced.

S.F.C.: It is one of the most important parameter for engine comparing. It is defined as the ratio of amount of kg of fuel used per hour by the engine to power produced by the engine. S.F.C. = = = (297000) / (POWERTIME) Gm/B.H.P/Hr. fuel gravity volume of oil (100 cc) time 0.825 100 3600 297000 Constant =

TORQUE BACKUP TEST: It is capacity of engine for maximum load that after the engine r.p.m. Will decreased to zero. TORQUE (backup) = {T (max) T (rated)} / {T (rated)} 100 T (rated) is displayed by meter on 2200 50 r.p.m. and T (max) is displayed by meter at 1500 + 100 r.p.m. T (max) is found by loss of r.p.m and increased of torque. The engine is loaded till torque is max and after which the loaded cause drop in torq

4) PRODUCTION PLANNING & CONTROL INTRODUCTION

Production can be defined as the transformation of raw material by manufacturing methods into useful and valuable things needed by society. PPC is the very basis of manufacturing. Production planning and control is the process of planning in an industry in advance of actual production it consists of the following activities: 1. Determining the practicability of a product design. 2. Analyzing the product for best method of production 3. Determining the economic lot size 4. Select the best equipment 5. To Determining the best sequence of operations to manufacture each individual item, part, assembly 6. Designing or supervising the design of tools, jigs, fixtures, or other devices to best assist the manufacturing equipment to function as planned. 7. Estimating expenditure for equipment and tools and help making cost estimates on new jobs. 8. Setting, starting and finishing dates for each important item assembly and the finished product scheduling. 9. Controlling the inventory of raw materials and in process parts. 10. Dispatching material, tooling and equipment to the plant locations. 11. Keeping track of progress of production. 12. Providing program evaluation review.

PRINCIPLES OF PPC
1. Investigation 2. Co-ordination 3. Evaluation

INVESTIGATION
It includes the following functions: 1. Organization and interpretation of information received from the selling, purchasing and engineering departments. 2. What production steps have to be performed as well as where and when to perform them. 3. Calculation of materials requirements Development of detailed production schedules

4.

CO-ORDINATION
This activity consists of initiating action, which brings the needed materials, tools etc to the proper machines and at the scheduled times.

EVALUATION
It consists of constantly reviving of production materials, methods, tooling, operating times etc., so that the planned manufacturing results are realized in terms of quantity, quality, time, and location.

OBJECTIVES OF PPC
From the above discussion it is clear that there are basically two major and important objectives of PPC: 1. Planning the activities of production Collect and organize the pertinent production information generated by the selling, purchasing and engineering departments. Translate the information collected above into production schedules, such that the over-all plant facilities are economically used and the production requirements of each department are satisfied. 2. Controlling the production activities Release the production orders in conjunction with the production schedules. Revive production progress and initiate remedial action. If it becomes necessary to revive production scheduling

5) MATERIAL HANDLING EQUIPMENTS

Trucks of different types Trolleys Cranes of different types Belt conveyors, overhead conveyors Roller conveyors-commonly used Chain conveyors Hoists Monorails

Work instructions for testing:

Mount the tractor on to the roller. Attach the weight of 1200 kg. Start the tractor and raise the lift. Run the tractor for 15 minutes. If any problem then shifted to rework. After this tractor is stopped and links are lowered. Deload the tractor from the roller.

6) QUALITY ASSURANCE DEPARTMENT ROLE OF QA:Audit compliance to Quality Systems for manufacturing and allied operations as apart of Management Information System on quality.

SCOPE OF AUDIT: Finished product quality Inplant components quality Output quality and compliance to quality systems at each stage/area of inplant manufacturing operations Outsource components quality Compliance to specified quality systems by the Venders in their manufacturing operations.

AUDIT CONCERN:Audit from periodic check on conformance to quality systems,audit concerns arise from feed back on Warranty Field failure Dealer pre delivery inspection In house pre delivery inspection Quality engineering reports on inplant and out sourced components

KEY AREAS:-

Tractors ready for dispatch to dealers after final quality certification by Quality Engineering (QE) department. 1. Tractors as dismounted from assy. Line before any rework is carrie3d out on them. this is in pursuit of the operations objective of Zero defect dismount and dispatch 2. Stage wise audit of assembly shop operations. 3. Paint shop operations. 4. Outsource components reaching the assembly line. 5. Machine shop operations. 6. Inplant components reaching the assembly line. 7. Audit at Vender premises to check on compliance to prescribed Quality System in their manufacturing operations.

AUDIT METHODOLOGY:Step-1: Refer to quality systems pertaining to the subject under audit in terms of -Drawing / Specifications for output quality -process sheets/job description for job contents,method , tools and measurement criteria. -Quality Engineering specipications like controls charts and check lists. Step-2: Prepare check lists specifying attributes to be audited and sample size. Step 3: Following the check list,record actual against specifications. Step4: Generate audit report on level of conformance highlighting.

7) MAINTANENCE DEPARTMENT INTRODUCTION

Many changes have taken place in the maintenance system and practice used in the industries with the progress made by technology. Along with production, maintenance plays vital role. In fact production and maintenance go side by side if a machine is under breakdown, it can not subjected to production process with the advent of new modern technology, the entire concept of maintenance has changed. Earlier maintenance practices were only confined to breakdown maintenance, but now different types of maintenance practices are followed like: 1. Scheduled maintenance 2. Break down maintenance 3. Preventive maintenance 4. predictive maintenance

The following are the main objectives of maintenance:

To achieve the minimum breakdown level and to achieve the production target at low cost. To keep the plant in proper working conditions. Machine and other facilities should be arranged so that they can be used to their max capacity The maintenance division of the factory ensures the availability of all the facilities necessary for the performance of functions at optimum return of investment.

IMPORTANCE OF MAINTANENCE
1. Equipment break down leads to inevitable loss of production time ,which is prevented by maintenance department 2. Plant maintenance plays an important role in the production management by preventing breakdowns which caves inevitable shortfall of target, needs sub contracting work, rescheduling of production, need of over time etc. 3. Routine check ups of facilities ensure safe and efficient operation of machinery 4. Maintains optimum production efficiency of machinery. 5. Helps in maintaining the operational accuracy and reduces the work content 6. Reduce breakdowns and concerned downtimes thus achieving the target of max production at min cost. 7. Ensure safety of life and limbs of workers and machine operators.

At present the maintenance dept of PTL have five subsections. 1. Electrical maintenance cell 2. Engineering machine maintenance cell 3. Material handling equipment maintenance cell 4. Spare part planning and control cell 5. Engineering utility maintenance

3. Support services MANAGEMENT INFORMATION MECHANISM:

Copes of report are marked to and discussed with: Head of the department in whose area the audit has ben conducted Head of the department responsible for correcting any non conformance or inadequacy of the quality system Executive director (manufacturing)

Key Area:-Audit of finished tractors. Activity list:1. Identification of category of tractors for audit 2. Identification of individual tractors/locations 3. Selecting/modifying suitable checklists. 4. Obtaining g the inspection equipment 5. Actual observation and recording on checklist. 6. Returning of utilized equipment. 7. Report writing 8. Getting reports signed by Auditee. 9. Discusion and finalization of reports with CM-QA. 10. Circilation to ED (Mfg) ,VP (W), DGM-QE. 11. Re-audit to check correction after the given date. 12. Consolidate reports weekly 13. Monitor monthly.

REPORTING SYSTEM:
1. To initiate prompt corrective action, non conformance to be reported at the earliest and latest by the end of the day or the day on which the audit has been completed. 2. Formal audit report to be circulated through CM-QA to DGM-QE and VP (W). 3. for non conformance areas,seek action taken report and date by which it wil be corrected from DGM-QE no weekly basis. 4. Compile the consolidated monthly audit report on No. of audits Areas of non-conformance. Action taken by audit 2. Report to be circulated to ED (Mfg),VP(W) & DGM-QE.

Target / Schedule: Five tractors by Friday of each week. Monitoring System: Consolidation report for the month 3. To initiate prompt corrective action, non conformance to be reported at the earliest and latest by the end of the day or the day on which the audit has been completed. 4. Formal audit report to be circulated through CM-QA to DGM-QE and VP (W). 5. for non conformance areas,seek action taken report and date by which it wil be corrected from DGM-QE no weekly basis. 6. Compile the consolidated monthly audit report on No. of audits Areas of non-conformance. Action taken by audit 7. Report to be circulated to ED (Mfg),VP(W) & DGM-QE. Target / Schedule: Five tractors by Friday of each week. Monitoring System: Consolidation report for the month.

BIBLOGRAPHY

BOOKS & MATERIAL CONSULTED 1. 2. 3. 4. 5. 6. SWARAJ HAND BOOKS SWARAJ PROCESS SHEETS ALL ABOUT GEARS(MONTHLY SERIES) DAILY DIARY Workshop Technology vol II Machine Tools by B.S. Raghuvanshi. Metrology and Instrumentation By K.P.S. Chauhan.

WEBSITES CONSULTED 1. 2. 3. 4. 5. 6. www.swarajenterprises.com www.bigmachines.com www.howstuffworks.com www.amazon.com/e-books www.google.com Wikipedia