Swaraj Tractor Division,Mahindra and Mahindra Limited, Mohali,Punjab
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SIX WEEK TRAINING REPORTON MECHANICAL RESEARCH
Submitted By:-
Gurtej SinghRoll no.100261195886
PREFACE
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If you know the laws of buoyancy it doesn’t mean that you know how toswim. It is only through jumping in the water that you get the feel of the depth.This is applicable to every aspect of life. Therefore practical training is of utmost importance.The object of undergoing this training was to get familiar with the weary waters of the industry and to learn how to put theory into practice. I have beengreatly privileged to have undergone training at PTL.This report contains the extract of things I learned during my training period.
ACKNOWLEDGEMENT
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Any endeavor cannot lead to success unless and until a proper platform is provided for the same. This is the reason I find myself very fortunate to haveundergone my industrial training of six weeks at PUNJAB TRACTORS LIMITED.The persons of my department and all other departments have extended a warmand helping hand.I am very fortunate to have had a chance to feel the gravity of what roleMechanical Engineering plays in the industry. It was a golden opportunity for meto get a chance to experience what it feels to be in a company where discipline,quality and hard work are the motto. This training helped me a lot in bridging thegap between the theoretical and the practical aspects of my knowledge.First of all I would like to thank Mr. K.K Sharma for his valuable guidance &encouragement as a teacher and a friend throughout my training period.I am also thankful to MR. J. SINGH for giving me an opportunity to undergotraining in such a renowned company.My heartily thanks to Mr. H.S.Baweja who was my project manager & my guide through the project works. They always went out of their way to help me at all times. Their experience & knowledge motivated me to bring out the best intimes.I am sure that the knowledge & information that I have gained during this period would be of immense value for my growth in the field of Mechanical Engineering.
CONTENTS
1)
INDIAN TRACTOR INDUSTRY.
2)
BEGINNING OF INDIAN TRACTOR INDUSTRY.
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3)
MATURING YEARS OF INDIAN TRACTOR INDUSTRY.
4)
INDUSTRY STRUCTURE.
5)
FUTURE POTENTIAL.
6)
COMPANY`S OUTLOOK.
7)
INTRODUCTION TO COMPANY
8)
SALES SCENARIO OF VARIOUS TRACTOR COMPANIES
9)
PRODUCTS MANUFACTURED
10)
UNITS OF SWARAJ GROUP
11)
MANUFACTURING SYSTEM
12)
QUALITY CONTROL INSPECTION
13)
MAINTENANCE DEPTT.
14)
BIBLIOGHRAPHY
INDIAN TRACTOR INDUSTRY
Introduction
:
–
India being a predominantly agricultural country, where agriculture is the life andblood of the economy, has been a traditional manufacturer of different types of farmmachinery and implements. However, the use of advanced agricultural techniques inIndia started only in early sixties. Modernization and tractor-ization in Indian
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agriculture is only post independence phenomenon. One of the achievements of green revolution has been that the farmers increasingly realized the advantage of tractor-ization for obtaining the timeliness of operations. This would happen onlybecause of awareness of new farm technology among the farmers, rise in the levelof their income and education.The biological source of energy especially bullocks, could not cope with therequirements of the changed situation. Therefore, introduction of tractors gotaccelerated in several agriculturally advanced states of country like Punjab,Haryana, Maharashtra, etc. Tractors were introduced to Indian agriculture in earlytwenties. Sh. Joginder Singh was the first farmer to
use
a tractor, called a steamplough then, on the 12000 acres estate he had
inherited in the remote Kheri districtof Uttar Pradesh. The demand of tractors rose sharply in last two decades.However, the rate of adaptation of tractors is different in different parts of thecountry. Punjab occupies number one rank in this regard. Punjab possesses only1.5% of the geographical area of the country; the density of 85 tractors per hectarein Punjab is the highest 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 beingcontributed directly or indirectly by agriculture. No wonder, India is considered thelargest tractor market in the world. If that sounds great, let us face hard facts. In termsof 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 GrossCropped Area (GCA) as compared to the international average of close to 30 tractorsper thousand GCA.Figuratively speaking, India’s 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
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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.Despite a phenomenal increase in tractor population in the country, the tractor density isvery low at about 10.5 tractors per thousand hectares of GCA in comparison to theinternational 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.
The Beginning of Indian Tractor Industry
The decade of 60’s India saw green revolution resulting in increase in both productionand productivity. With the parallel emphasis on industrialization, the birth of IndianTractor Industry took place in 1959-60 when the imports were restricted and 5 tractor manufacturing units set up in the private sector, all with foreign collaboration. Date of commencement of commercial production and collaboration are given in following table.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 the demand
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started multiplying at an annual rate of approximately 50% (1967:18,000; 1970: 33,000).A natural consequence of this sharp upsurge and consequent shortage was a heavypremium on the price of tractors. Recognizing the situation, import of tractors into thecountry was liberalized and over and above the domestic production of 20,000. In 1970,13,000 tractors were imported.The Government’s decision to freely invite new entrepreneurs to manufacture tractor in1968 and sudden upsurge in demand, with the green revolution, led to a scramble of new entrepreneurs for new collaborators. 6 units eventually, established the actualmanufacturing facilities. They were as follows:
The Maturing Years
–
With the entry of new units in 1970 and increasing Government pressure towardsindigenization picked up substantially after 1970 and by 1978 almost all the tractorsmanufactured were nearly indigenous. A fillip to indigenization was also given by theoverall industrialization of the country, when a large number of ancillary manufactures
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had also established them 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 Industrya substantial setback in 1970-73, when low cost import particularly from East Europeancountries had become far more attractive.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 present44 models tractors are available in India, listed category-wise as follows:
Range of Tractors available in India
—
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Industry Structure
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The tractor industry is segmented on the power / size of the tractor engine, expressed interms of horse power (HP). The HP-wise composition of tractor industry sales (asshown in the table 6 and the graph showing Indian HP Range Trends) reveals that 31-40 HP tractors still constitute the largest segment with 57% of the total tractor sales inFinancial Year (FY) 2002 - 2003. It can also be seen that demand for less than the 30HP segments, which used to be 35% in FY 1990—1991 has been pushed to the backseat by the 31 —40 HP segment.This shows an interesting shift in tractor demand from lower HP to higher HP tractors inrecent times. The shift could be categorized as two — fold. One, the drastic shift fromless than 30 HP to 31 — 40 HP levels and two, the meager shift from 41 — 50 HP to 50HP levels. The general change in the farmers’ preference for higher HP tractors issignificant in more ways than one. Firstly, it seems to belie the notion that as theaverage farm sizes dwindle, it would render the use of tractor uneconomical. Then,there is the running costs angle to it as well. While the higher HP tractors are morecostly in terms of maintenance and running costs, still the fact of the matter is that thesale of the higher HP tractors are increasing..
Future potential
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With a total of 140 million hectares and with the performance of around 2.18 lac tractorsin the year 2001 - 2002, India today stands as the largest manufacturer of tractors in theworld. With the average number of tractors in India per hectare well below the worldaverage, the Indian market is a market with a huge untapped potential.India is the largest market for the below 50 HP tractors in the world. In internationalmarkets, the average HP of tractors used is around 80 -100 HP. As per reports, exportsrose from around 160 tractors in 1990-91 to an estimated 7500 tractors in 1998-99. Theexport market, according to industry players, has been projected to grow at around 10%per annum over the next five years.At present the Indian tractor industry is among the select few in the world that isgrowing.
Company’s Outlook
It has been established that there is a close relationship between the growth rate in foodgrain production and intensity of tractor-ization. Increasing benefits of mechanizationhave resulted in an increase in the tractor demand and thereby tractor population over the years. The density of tractors varies from state to state with Punjab taking the leadat 65 tractors per 1000 hectares of irrigated land. With the total land currently under irrigation being a small fraction of the total irrigation potential of 1134 lac hectares, asteady demand for tractors in the near future can be anticipated.
P.T.L.’s Birth
Keeping in mind Punjab’s agrarian economy it was decided by the Punjab governmentto encourage the growth of industries, which complement Punjab’s agriculture growth.
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This task was entrusted to Punjab State Industrial Development Corporation (PSIDC),which has played a major role in bringing Punjab to the threshold of the industrialrevolution.With the dual objective of industrial and agriculture growth, PUNJABTRACTORS LIMITED was established on 27 June 1970.
Introduction to the Company
-Punjab Tractors Limited, a public limited company, is India’s first large- scale projectbased company with a totally indigenous design, know-how and technology. PunjabState Industrial Development Corporation (PSIDC), which was a major player, promptedit; the government of India and financial institutes like Punjab Financial Corporation(PFC) provided significant support. The public subscribed the remainder. TheShareholding Pattern chart displays the shareholders in Punjab Tractors Limited andtheir share proportions.The factory is located at the Sahibzada Ajit Singh Nagar, which is an important townshipof Punjab. A Board of Directors manages the company with the Secretary, industrialdepartment, Punjab being the ex-officio chairman. The Vice —Chairman and ManagingDirectors manage the day-to- day affairs.
Growth of PTL
Punjab Tractors Limited started with an annual capacity of 5000 tractors and with acapital of Rs. 3.7 crores. It went into commercial production in the year 1974; its firstproduction of 26.6 BHP tractors was given the name SWARAJ— 720. Ever since thenP.T.L. has not looked back. In the first twenty year of its existence its capacity has been
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increased to 24000 per annum, which is a considerable achievement by any standards.PTL is considered as a highly reputated and impressive company in India. Itmanufactures many products and is helping in to develop India and improving itsfarming techniques.
In all, SWARAJ provides with a host of varied products, which includes:-
• TRACTORS• HARVESTING COMBINE• FORK LIFTERS• AGRICULTURE IMPLEMENTS• AUTOMOTIVE CASTINGS• LIGHT COMMERCIAL VEHICLES• SHELTER• ENGINES• CASTINGS• ROUGH TERRAIN
“ Origin of the word “SWARAJ”
The word SWARAJ”, in Hindi, means “freedom from bondage”. Since, P.T.L. was thefirst 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.
Position of SWARAJ products in market
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With more than 2 Lac tractors and harvester combines operating in Indian farms,SWARAJ are now a well-established brand name in country. SWARAJ is also aninternationally recognized name in the developing world.The products of SWARAJ are not only restricted to Indian market but, they had enteredin international market. SAWRAJ tractors find an important place in developingcountries like Ghana, Tanzania, Zambia, Kenya, Sudan, Uganda, Indonesia, Malaysia,etc. They are also sending their Harvesting Combines to South Korea having first ACcabin Harvesting Combine in India. Earlier, they had also transported the machined rimsto Japan, a project worth millions of dollars.
SALES SCENARIO OF VARIOUS TRACTORCOMPANIES
Nowadays, the markets are flooded with tractors of various companies. Most of thecompanies provide a range (in terms of power) of tractors to capture the market. Thedata is collected for the year. Following is the detailed list of sales of leading tractor-producing companies:
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We see that three-four companies dominate total tractor production in India and around.SWARAJ occupies third position in the market in terms of sales of tractors.
LIST OF PRODUCTS MANUFACTURED
SWARAJ GROUP of industries manufactures a number of products.Following is the list of the components manufactured by them:• TRACTOR • HARVESTOR COMBINES• FORK LIFTRES• LIGHT COMMERCIAL VEHICLES• SHELTERS• ENGINES• CASTINGS
1. TRACTOR
Following is the list of models of tractors that have been manufactured by this company:1.SWARAJ 722: a 25 bhp tractor introduced in 20032. SWARAJ 724: a 26.5 bhp tractor introduced in 19743. SWARAJ 735: a 39 bhp tractor introduced in 19754. SWARAJ 720: a 19.5 bhp tractor introduced in 19785. SWARAJ 834: a 55 bhp tractor introduced in 2004
2. HARVESTER COMBINE
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It was India’s first indigenous built Harvester Combine called H 8100. Its engine issupplied by ASHOK LEYLAND LIMITED. It is a six-cylinder engine developing a power of 105 bhp. It was basically designed to harvest wheat and paddy.
3. FORK LIFT TRUCKS
These are also called fork lifters. They are used for loading and unloading of heavyequipment and various articles in an industry. It has very short turning radius so that itcan move easily in limited spaces. The heart of the FD is a 48 bhp engine supplied byKIRLOSKAR OILS INDIA LIMITED.The fork lifter is manufactured by SWARAJ in collaboration with a Japanese firmKOMATSU. These can be either battery operated or diesel operated.
Following is the list of fork lifters manufactured
a. FD—15 FB—15b. FD—20 FB—20c. FD—25 FB—25d. FD—30 FB—30
4. LIGHT COMMERCIAL VEHICLES:
SWARAJ MAZDA manufactures light vehicles, which are, used as loadingvehicles, mini buses, and special order vans.
5. SHELTER
SCD manufacturers shelters on order basis, which are made for defensepurposes. Some work of the shelter is done in PUNWIRE also.
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6. ENGINES
:The engines are required for various models of tractors are supplied bySWARAJ ENGINE LIMITED.
7. CASTINGS
Castings of differential, gearbox, rear cover; trumpet SWARAJ FOUNDARY DIVISIONproduces housing required for the production of tractors. Also, castings of variouspulleys, reduction gearbox and gearbox of Harvester Combine are also supplied byFoundry Division.
Units of SWARAJ Group -
Originally, SWARAJ had set up its plant for the production of tractors. But with thepassage of time, to fulfill the requirements of Indian market, it diversified into other fields, with the collaboration of foreign companies like Komatsu, Mazda etc. it opened itsnew Division near Chandigarh. Following are the five divisions of SWARAJ GROUP:•
SWARAJ COMBINE DIVISION • SWARAJ FOUNDARY DIVISION • SWARAJ ENGINE DIVISION • SWARAJ TRACTOR DIVISION
SWARAJ COMBINE DIVISION
It was set up in 1980 in village Chappercheri, on Landran road near Kharar in Distt.Ropar. It was started with a capital layout of Rs. 2.6 crores to manufacture self-propelled harvester combines modeled SWARAJ-8100. It was India’s first indigenouslyproduced self-propelled harvester combine.
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In 1985, indigenous diesel fork FD-20 and FD-25 with a lifting capacity of 2 tones, 2.5tones respectively was brought out. Later in the year, company also entered incollaboration with KOMATSU FORKLIFT CO. of Japan for manufacturing both dieseland electric fork lifters up to 10 tones capacity.In year 1990, the production of tractor was also started here. Presently this division ismanufacturing around 75 tractors (FE-855, FE-939).This year target has been set to 30000 tractors annually. Additionally, SCD ismanufacturing some components for SWARAJ MAZDA DIVISION.SWARAJ COMBINE DIVISION (SOD) is also producing FIBRE RE ENFORCEDPLASTIC (FRP) shelters for Indian army. Shelters are used for various purposes likehousing electronic data, handling systems, refrigerated vans, mobile radio stations andother similar defense applications.
SWARAJ FOUNDARY DIVISION
This plant is located in village Majri near Kurali in Ropar Distt. It is situated at a distanceof around 22 km from Chandigarh. This plant was set up in the year 1980 with an initialinvestment of Rs. 15 crores.This division supplies the casting to all other units of SWARAJ GROUP. It includessupply of input shafts, hub, gear main drive and many other components used in L.M.S.In H.M.S. shop it supply gearbox, differential rear cover, trumpet housing. The currentcapacity of this plant is 800 tones of gray iron casting per annum on single shift basis.
SWARAJ ENGINE DIVISION
This plant is located in Mohali. It was setup in technical and financial collaboration withKIRLOSKAR OIL ENGINE LIMITED. It was setup in the year 1987 for the manufactureof diesel engines. This plant manufactures engines for SWARAJ TRACTORS. It alsosupplies connecting rods to SWARAJ MAZDA DIVISION.
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The installed capacity of this plant was 1500 engines per annum. Engine production inthis company has reached level of 15921, a volume growth of 27% as compared toprevious year. Total revenue of this plant has reached up to Rs.72.6 crores. It usesabout 99.4% indigenous components.
SWARAJ TRACTORS DIVISION (MOHALI )
Introduction -
Swaraj Tractor Division is situated at phase-IV, S.A.S. Nagar, an important industrialtown, 5 Km from Chandigarh, in Ropar District, in Punjab. It was set up on May 27,1970 with the dual objective of industrial and agriculture growth. It was the firstSWARAJ DIVISION to be set up. This was India’s first large-scale project totally basedupon indigenous design and technology of India itself. It manufactures different modelsof tractors i.e., of different HPs. Presently around 90— 100 tractors are produced in aday in two shifts.Rated capacity : 40100 tractors per year.Employee strength : Around 3000Annual turnover : Rs. 1300 crores
Hierarchy of the Organization –
The Board of Directors with the Secretary Industries, Department, Govt. of Punjab as itsEx-officio Chairman, manages the company. The Vice-Chairman and the ManagingDirector manage the day-to-day operations.Level 1 : Chairman•Ex-officio (Secretary Industries, Govt of Punjab)
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Level 2 : Working Director •Vice-Chairman and Managing Director Level 3 : Executive Directors•Finance• Human Resource and Development• International Business Division• Manufacturing• Material Services• Swaraj Automotive Limited• Swaraj Motors Limited• Senior Vice President (MarketingLevel 4 : Vice President• (3-4 under each Executive Director in level 3)Level 5 : Assistant Vice PresidentLevel 6 : General Manager Level 7 : Chief Manager Level 8 : Senior Manager Level 9 : Manager Level 10 : Assistant Manager Level 11 : Senior Engineer Level 12 : Engineer Level 13 : Assistant Engineer Level 14 : Junior Engineer Level 15 : Operating Class
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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 shopHeat treatment shopPaint shop
2. Product services
• Tool room• Tool control cell (TOO)• Industrial engineering• Research & Development• Production planning & control (PPO)• Material Management & control (Stores)• Quality Engineering• Maintenance• Construction
3. Support Services
• Management systems
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• Finances• Purchase
LIGHT MACHINE SHOP (LMS)
INDRODUCTION
:
LMS is the largest section in the factory. All transmission components viz. shafts andgears used in Tractors are manufactured here. It has more than 120 machines;Facilities of this shop include Equipment for blank operation, boring, drilling etc. Exceptthe bevel gear generator & gear shaver, which have been imported from WIv1W &Churchill of West Germany respectively, all other machines are from HMT Ltd. Therupees thirty one million plant and machinery of this shop installed in an area of 33,000sq. ft. and casting, forging and high standard of quality.
TYPES OF MACHINES
Cylindrical grinder, internal grinder, copying lathe, gear hobber, Radial drilling machine,drum turret lathe, turret lathe, Honing machine, Centre lathe, Capstan lathe, Capstanlathe, Vertical pull broaching machine, Chuckmatic, Fay Auto, Centering & facingmachine, Vertical Milling machine, Horizontal Milling Machine. Deburring machine, D/Eboring machine Gear Shaver GTR machine, Bevel Gear Generator, Gear shaper, CNCmachine, Power Hacksaw Special purpose drilling machine, twin chucker, Centre Holegrinding machine.
Function of the department
Gear manufacture and grinding, machining of bull gears, bevel gear cutting of all roundson power hacksaws, facing and centering, all type of grinding inner and outer gears,hobbing and broaching machine. Gear shaving gear deburring machine, drilling of allgears reporting system, number of workmen shifts operations .
Inter relations with other departments
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•
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.•
Production planning and co-ordination
: Micro loading of components on a dailybasis• Quality control and inspection, storage and inspection R & D
• Heat treatment
- shot blasting operations lab testing, inspection etc
Different Manufacturing Operations In LMS
1.
Facing
: It is the operations of finishing the ends of the work, to make the ends flatand smooth& to make the piece of required length.
2.
Under Cutting
: It is similar to grooving operation but is performed inside a hole.
3.
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 operations max. Metalis removed &very little oversize dimensions is left for further machining.
4.
Finish Turning
: Here min. metal is removed &very fine finish is obtained on thework surface.
5.
Grooving:
It is the operation of turning the groove or neck in order to terminate athread or to provide adequate clearance enable nut to pass freely on threadedwork piece, to remove burs &to protect the work piece from being damaged.
6.
Knurling:
It is a proc of embossing a diamond shaped regular pattern on thesurface of the work piece using a special knurling tool.
7.
Broaching
: It is a method of metal removal by a tool that has successively higher cutting edges in a fixed path. Each tooth removes a fixed amount of material.
8.
Drilling
: It is a process of making hole in an object by forcing a rotating tool calleddrill.
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9.
Boring :
It is a process of enlarging a hole that has already been drilled.
10.
Grinding :
To grind means to ‘abrade’ to wear away by friction or to ‘sharpen’ .Ingrinding, the material is removed by a means of a rotating abrasive wheel. It isgenerally used for sharpening the cutting tool, for grinding threads, better surfacefinish etc.
11.
Hobbing
: It is the process of cutting teeth on gear &shafts & is performed by arotating tool called hob on the hobbing machine.
12.
Shaping
: The process of cutting gears on the shaper is known as shaping. Thetool used in shaping for teeth cutting is a multipoint cutting tool.
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. About 20SPM and 30 GPM are installed in a covered area of 47,000 sq. ft. at a cost of 20 million,2600 tonnes of castings are machined every year on a two-shift basis. In addition to themachining of castings for the tractor, some jobs are also performed for Swaraj MazdaLimited.
COMPONENTS MACHINED IN THE SHOP:
• Gearbox housing (Material—R-33, Casting, 180-230 BHN, 76-kg wt.)• Differential Housing• Rear Cover • Trumpet Housing
FUNCTIONS OF THE DEPARTMENT
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Machining of heavy castings like differential housing, gear box housing, rear cover,trumpet housing, steering housing of tractors, machining of tractors parts, machining of some components for Mazda.
ORGANISATION STRUCTURE
Hierarchy, reporting system, no. of workmen, shift operations.
INTER-RELATION WITH OTHER DEPARTMENTS
•
Tool room
- Requirement of jigs, fixtures and cutting tools.•
Maintenance
- Attending breakdown and carrying out preventivemaintenance of machine tools.•
Industrial engineering
- Provide process charts for machiningoperations.•
Assembly
- Ensuring proper fitment of components, productionplanning and control, micro loading of components on day-to-day basis.•
Quality control & inspection
— Storage and inspection.•
R&D
•
Paint shop
TYPES OF MACHINES
• Radial drilling machine• Vertical milling• Horizontal milling• Simplex milling• Duplex milling
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• Lathe• Double end• T/W boring• Automatic lathe• SPM (special purpose M/c)
ASSEMBLY SHOP
Function:
Assembly of all finished components and bought out components for Swaraj- 722, 724,733, 735, 744, 834
Sections in Assembly
1. Cage Assembly2. PTO Shaft Assembly3. BPS L/R Assembly.4. Differential Assembly and Testing5. Trumpet Hsg. and Assembly.6. Differential Hsg. and Trumpet Hsg. Assembly.7. Gear Box Assembly. and testing8. Rear Cover Assembly and testing9. Steering Assembly.10. Brake Hsg. Assembly.11. Coupling Gear Box Assembly with Differential Hsg. Assembly.12. Steering assembly. to be assembled with 1113. Brake Hsg. Assembly. to be assembled with 12
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14. Front Axle Beam Assembly.15. King Pin Assembly.16. Engine assembly.17. Coupling Engine Assembly with 1318. Assembly. 13, 14 with 1619. Tie Rod assembly. with 1720. Assembly other main link items like Leveling Rod, Trailer Hook, Front and Rear Frame, Battery Mtg. Frame, Stay Bars, Brake Pedal, Clutch Pedal, Assembly. FootBoard Assembly.21. Greasing all points22. Invasion into painting chamber 23. Mounting of front and rear tire24. Fender Assembly. with lights and other electrical fitments25. Radiator Assembly.26. Dash Board Assembly and Seat assembly.27. Fuel Tank Assembly.28. Side panel, Bonnet, Front Shield, Rear Shield, Front Grill etc Assembly.29. Air Cleaner and Exhaust Assembly.30. Battery fitment31. Oil Filling, Battery filling etc.32. TestingThe Assembly Shop is the production shop where assembly and sub-assembly of allthe parts take place.The final processed parts from the various parts of production shop such as HMS, LMSand Heat Treatment reach the assembly Shop. The various parts reach the assembly.shop only after being washed, cleansed and dried, which takes place when the different
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parts are on their way to assembly shop. The above washing process takes placeautomatically i.e. the machinist has to drop the final Part on the roller conveyor, and theparts reach the assembly shop after being automatically washed and dried.The assembly shop can be divided into various groups depending upon sub- partsbeing 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 5 and 6 assemblies.
Differential Assembly
:Before the various differential parts such as BP shaft, differential cage etc. areassembled, the various sub-assembly. of parts listed above are performed in the subunits. In the first unit, both the BP shafts are fitted with various components such ascircular clips, needle bearings etc. to be able to be assembled to the differential Cage.This constitutes the assembly of Cross Bar, Planetary Gear, Planetary Gear Cover, andCrown Wheel etc. The various bolts required making the assembly. of about parts andintegral one are bolted using a pneumatic bolter gun.After this, the differential cage is collected from the conveyor firstly fitted with thenecessary bearing races. Then the differential Cage unit and the BP shaft are
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assembled, making up a complete one unit. The Trumpet Hsg. and the Axles areassembled in a different assembly shop and there on the whole unit along with the BullGears is assembled to the differential Cage. The Assembly of Differential Hsg. iscomplete with the assembly of lay shaft ext., the oil filter and the brake mechanism
Differential Cover Assembly
The second stage of Assembly shop is the differential cover assembly shop whichincorporates the gear pump assembly. And the direction control valve. The DI cover iscollected from the conveyor and the various attachmentsSuch as Power Cylinder, Piston Assembly., Oil Pump, DCV Valve etc. ismade, and the cover is tested for its efficiency on the testing jig. After which it is sent tothe first stage where the whole unit is assembled to the Dc assembly. And further sentto the 5 stages of the assembly.
Gear Box Assembly
The Gear Box Assembly is the third stage of the assembly unit in which thegear box is assembled. Firstly, the gearbox cage is collected from the conveyor roller and successively parts such as the counter shafts, clutch shafts, main shaft along withthe ball bearings are assembled to the unit. There is separate sub unit assembling theplanetary cage and gears, which is then attached to the Gear Box output shaft to obtainthe duplex speed ratios of the tractor. The box after being tested for its efficiency is sentto the 5 stages.
Steering G ear Box + Gear Shifting + BrakeAssembly
:
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This unit consists of 4 stages of the assembly unit. In this unit the subassembly of the steering gear box, gear shift mechanism on gear cover + the brakemechanism is assembled of these mentioned sub assemblies, the brake assembly issent to the 1 stage of assembly and the steering gear box and gear box cover assemblyis sent to the 3 stage of assembly. Apart from these sub assembly unit also producesthe KPS assembly.
Assembly of Gear Box Differential Hs and other accessories
In the 5 stage of assembly, the Gear Box is mantled to the differential Apartfrom this; various other accessories such as Foot Board, Battery Clamp and other linkssuch as Accelerator Pedal Link, Clutch link, Brake Link etc are mantled in this section.
Assembly of Engine + Clutch Mechanism
This unit is separate 6 stage of assembly in which the engines are receivedfrom the stores and fitted with the clutch mechanism and lay beam along with thecounter weights.
Assembly of Engine with the rest transmissionsection
The assembly of the engine and rest of the transmission is done within the 7stage. In this stage the whole of the chassis is formed as an integral unit. The variouslinks 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. In all the abovestages of assembly, the skilled workers are used to accomplish all the stages of assembly. But they are also held by the pneumatic bolt guns and the over headautomatic conveyors and the alarm conveyor etc to make their job easy. Also the wholeof the assembly is done on the assembly jigs or stands which is kept moving at a speedof about 7cm/mm. Also it is to be made in mind that any spill of the sub parts such asbolts, nuts etc. by mistake is not going to spoil the working space as all these spills gets
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underneath the working space and as a result the working space remains clean andtidy.
Heat treatment
INTRODUCTION:
Heat treatment shop plays a very important role in every industry. In automobile industrythe important components are gears, shafts etc. these need to be heat treated to impartdesired strength and increase the life of components. The heat treatment shop at PTL isequipped with several gas carburising furnaces, quenching tanks, induction hardeningmachines and shot blasting furnaces. The shop is manned by a highly skilled workforce.
List of components heat-treated in this shop
• All gears produced in LMS• All shafts produced in LMS
List of machines in heat treatment shop
Following are the machines, which are used in the heat treatment shop:• Gas carbursing furnace• Induction hardening machine• Quenching tank• Shot blasting machine• Tempering machine• Lapping machine• Hydraulic press
Commonly used terms and operations
Carburising :-
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Process of adding carbon to the large surface layer of the component is calledcarburising. It is the process of case hardening, which is the addition of some elementslike carbon, nitrogen to the surface by diffusion from the surrounding medium at hightemperature. It can be done in three ways: -
➢
Gas carburising
➢
Liquid carburising
➢
Pack carburising
Tempering :-
It is the generally the final operation of all the steel components after they have beenhardened. These processes consist of heating to marten site state for a scheduledperiod to an indicated temperature in a range between room temperature and criticaltemperature, followed by cooling. It reduces the internal stresses and stabilizes theinternal structure of the component. It converts hard brittle steel into metal of hardnessas well as ductility by reducing grain size. Cooling rate after temperature rise alsoaffects the residual stresses, slower the cooling rate lesser the stresses.
Normalizing :-
Normalizing is a type of heat treatment applicable to ferrous metals only... In thisprocess iron alloy casting is heated to about 50-60 degrees above the criticaltemperature range, holding the casting for definite time and then letting it cool in still air.The treatment is same as annealing and it eliminates casting from cooling stresses. Theyield strength of annealed components is more than that of unannealed one.
Induction hardness: -
It is employed for increasing the surface hardness of steel. High frequency current ispassed. High voltage current, which is transformed into current of low voltage and highampere, is passed through induction coil surrounding the surface to be hardened. Thecoil induces the current into the component, which gradually raises the temperature of
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the component. It is then cooled rapidly by spraying water from water jacket. Depth of hardness generally varies from 2.2- 2.7 mms.
Quenching:
-
Heat may be removed or quenching can be done by immersing the hot component intoa bath of water or dressed oil. At PTL special type of oil is used for quenching purpose.It is metaquench 40 or servo quench 11. When the hot component is dipped in thequench tank it is immediately surrounded by oil vapor envelope. To avoid this a motor isrun to remove the oil. The transfer of heat slows down and hence the internal stressesalso come down.
Shot blasting: -
Bombarding the component with lead fillings does it. The reason for shot blasting is toclean the surface i.e. removes scales and material from the component. A clean uniformand in some cases final finished components is obtained after shot blasting
.
Few components on which heat treatment is done are:
1.Bull gear: -• Case carburising: - it is electrically heated to 910 degreeCelsius for 13-14 hours along with liquid feed.• Quenching: - it is then cooled at 810-degree Celsius followed by quenching inmetaquench oil.• Tempering: - after quenching bull gear is heated to 220 degreeCelsius for 2-3 hours and then gradually cooled in air.• Shot blasting: - it is done to remove the carbon layer formedon the surface of the bull gear.Gear Z-42, input shaft, and intermediate shaft, drive shaft: -•
Case carburising
: - it is electrically heated at 910 degree Celsius for 13-14 hours along with liquid feed.
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•
Quenching
: - it is then cooled at 810 degree Celsius followed byquenching in metaquinch oil.•
Tempering
: - after quenching it is heated to 180 degree Celsius for 2-3 hours and gradually cooled in air.•
Shot blasting
: - it is done to remove the carbon layer from thecomponent surface.
PAINT SHOP
Operations performed in paint shop are:
• Surface Preparation (Pre Treatment Cell)-carried out for sheets and rims.• Painting• Inspection• Rejection (Reprocessing)-for sheets and rims.• Pre Treatment Cell
Various procedures followed here are
:• Degreasing• Water Rinsing (part which is degreased is alkaline in nature so rinsed with water due to its being good solvent).• De Rusting• Surface oxidation• Phosphating (done so as to form a thin layer of coating on part so thatno surface remains unpainted).
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• Passination (done so as to avoid paint penetrating through certainsection of part body’s surface)
Painting
Chassis Paint Line:- Operations carried out here are:-
• Washing: Here chassis is first washed with a chemical cleaner, concentration of whichis 5% and auto sprayed in a chamber.• Drying: The chassis is then dried by hot air whose temperature is up to 60 to 70°C.• Primer Painting: A thin layer of primer paint is sprayed on the chassis so that the finalpaint is strongly fixed on.• Flash Off: This is the distance given so as to allow paint to dry.• Final Painting• Flash off.• Baking: Chassis is allowed to bake for around 30 minutes.• Sheet and rims Painting: After surface preparation in PTC, sheets andrims are first of all cleaned with ordinary cloth.
There after following operations are carried out:
• Primer painting (full primer in addition to single coating of paint)• Flash off.• Baking (at temperature of around 120-130°C)
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• Wet Rubbing and cleaning with tack rag.
Quality Control Inspection
If painting in both sheets and rims is satisfactory the piece is selectedotherwise rejected.
Various parameters checked are-:
• Depth of penetration of paint.• Thickness of paint coating• Smoothness• Uniformity
Rejection
If piece is rejected it is either again processed whereby is again send toPTC or discarded.
LAYOUT:
Layout in the plant is the combination of the line and the batch layouts.
MATERIAL HANDLING EQUIPMENTS:
• Trucks of different types• Trolleys• Cranes of different types• Belt conveyors, overhead conveyors• Roller conveyors- most common in use• Chain conveyors
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• Hoists
MAINTENANCE DEPARTMENT
INTRODUCTION
Many changes have taken place in the maintenance system and practice used in theindustries with the progress made by technology. Along with production, maintenanceplays vital role. In fact production and maintenance go side by side If a machine isunder breakdown, it cannot be subjected to the production process with the advent of new and modern technology, the entire concept of maintenance has changed. Earlier maintenance practices were only confined to the breakdown maintenance, but nowdifferent 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 break down level and to achieve the production target atlow cost.• To keep the plant in proper working condition.• 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 facilitiesnecessary for the performance of functions at optimum return of investment
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IMPORTANCE OF MAINTENANCE
1. Equipment breakdown leads to inevitable loss of production time, which isprevented by maintenance department.
2.
Plant maintenance plays an important role in production management bypreventing breakdowns which caves inevitable shortfall of target, needs of sub-contracting work,rescheduling of production, need of over time etc.3. Routine check-up of facilities ensure safe and efficient operation of machinery.4. Maintains optimum production efficiency of machinery5. 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. With rise in thetechnology, not only predictive and preventive action bus the concept of costcutting, proper utilization of resources ,better spare parts planning, training havealso become important now.This can be made possible to cent percent by systematic maintenance. In Punjabtractors limited systematic maintenance operations are practiced to improve the plantavailability and to achieve the goal at a reasonable cost. i.e. to achieve availabilityperformance at the lowest cost and within the safety constants.At present the maintenance deptt. of PTL have five subsections.1. Electrical maintenance cell2. Engineering machine maintenance cell3. Material handling equipment maintenance cell.
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4. Spare part planning and control cell.5. Engineering utility maintenan
BIBLIOGRAPHY
My training was the most versatile experience. I had the pleasure to do the work withone of the most reputed factory in their field-“PUNJAB TRACTORS LTD.” I received theblend of experience in Private as well as in Govt. sector. It was a good learning timeduring my training as we were fortunate to be placed in the department related tomanufacturing. I feel training has give me exposure to undergo projects in theManufacturing field as well help me a lot to understand the company work culture,working with teams and much more. In the end I will like to thank all persons whohelped me throughout my training to enhance my experience. I also pay my regards tomy Lecturers for their guidance during my training and my Academics helped me to doa lot during my training.
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