1

ACKNOWLEDGEMENT
I would like to thank to all those with whom I worked and whose thoughts and insights helped me in increasing my knowledge and understanding of working in the organization. I would like to pay my sincere gratitude to MR. SATISH KUMAR SHARMA & all employees, who helped me during the course of my training by providing his valuable suggestion, ideas and guidance which proved beneficial for completion of my training.

Besides I would also thank to all the supervisors, Foreman and workers who helped me to understand the depth of my training, what they want out of the project. These people made me comfortable to understand the functioning of each machine & about the operation occurring on the machines.

They tried their best to make me understand about the fixtures, tools and gauges used on the machine. These peoples never made me feel as a trainee in the department rather provide an atmosphere like a family and feel proud being the part of their through for short while. Without their help this training would never have taken its present form. Lastly, but not least I thank one and all who have helped me directly or indirectly in completion of the report.

I have been really opportunistic to be a part of the Escort Group during my summer training, which is one of the leading tractor organizations in todays scenario. I am once again, thankful to members of ESCORTS Group for their co-operation.

ABSTRACT
Practical training is a way to implement theoretical knowledge to practical use. To become a successful engineer it is necessary to have a sound practical knowledge because it is only way by which one can acquire proficiency & skill to work successfully in different industries.

It is proven fact that bookish knowledge is not sufficient because things are not as ideal in practical field as they should be.

Escorts Ltd. is one of the best examples to understand the production process and productivity in particular of Tractor and its parts.

This report is an attempt made to study the overall processes KMC, Assembly plant. This report presents the Escorts Ltds introduction, technical collaboration, Products. This report also reflects the brief introduction of Engine and Tractor testing and metrology lab. This is also includes Assembly Line of Farmtrac Tractor. Machine shop is the focused part as it was the department allotted to me in Escorts agri machinery group.

CONTENT Certificate Acknowledgement Abstract List of Figures List of Abbreviation

Sr. No 1.

Chapter name Introduction

1.1 About escorts Ltd 1.2 Mission 1.3 Quality policy 1.4 History 1.5 Logo 1.6 Key persons

Page No 8-14

2.

Agri machinery Group

2.1 Features of AMG 2.2 Turn over 2.3 Product 2.4 Awards

15-18

3.

KMC
3.1 Design 3.2 Testing 3.3 Metrology

19-24

4.

Assembly Plant
4.1 Assembly Layout 4.2 Real assembly 4.3 Transmission Assembly

24-30

4.4 Assembly of Engine and Clutch Mechanism 4.5 Front axle and accessories and paint 4.6 Rear and Front wheel fitting 4.7 Final Testing

LIST OF FIGURES
Serial No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 Figure No 3.1a &b 3.2 3.3 3.4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 Figure Name Real axle and differential Engine Track Test Trimos Height measuring system Assembly layout Clutch and brake pedal fitting Engine and fuel tank Front axle fitment Painted body of tractor Rear wheel fitting Fitment of radiator

LIST OF ABBREVIATIONS
1. AMG Agri machinery group.

2.

KMC - Knowledge Management centre HSS-High speed steel

3.

BSM - Block straight milling HMC- Horizontal Milling Centre

4.

BNR - Block Nut Turner.

5.

VMC - Vertical Milling Centre.

6.

BSB - Block straight Boring.

7.

BWT - Block Washing Machine.

8.

BBP-Block Bush Pressing

9.

PTO - Power take off.

10.

FTP - Full throttle performance

11.

TGS - Time gear side.

12.

TCS - Tappet cover side BHS-Bell housing side.

13.

NPS - Name plate

CHAPTER 1

INTRODUCTION
In todays competitive world with fast depleting material resource, and with all its limitations, it has become imperative to develop human resources and its effectiveness. The continued effectiveness and efficiency of an organization to some extent depend on the ability of its employees to produce at high levels of efficiency, and to keep abreast with role, which the job demands. Training should be a long terms investment in human resources.

1.1 About the Escorts Ltd.

Escorts Limited is all set to face the future by drawing on its 50 years of experience, its inherent strengths and a strong presence in the core sector providing complementary product line and a vast marketing network combining them with Indias intrinsic cost advantages to become a global source point for high value engineering products.

In order to meet the challenges in the future and to leave an indelible mark on the industrial scenario, Escorts has restructured the group along six business lines, each headed by an independent CEO. The business groups are as follows:-

1. Agri- Machinery Group 2. Construction-Equipment 3. Automotive Ancillaries 4. Financial Services

1.2 Mission
Escorts Endeavours to transform lives in rural and urban India by leading the revolution in agricultural mechanization, modernization of automotive and railway technology, as well as transformation of Indian construction industry.

1.3 Quality Policy

We shall strive to continuously improve to meet the ever rising expectation of our customers at the lower cost. Each one of us must fulfill the need of our customer, both internal and external with the highest degree of commitment thereby creating a quality organization geared to ensure total customer satisfaction and the sustained health and prosperity of our business.

1.4 Company History

The genesis of Escorts goes back to 1944 when two brothers, Mr. H. P. Nanda and Mr. Yudi Nanda, launched a small agency house, Escorts Agents Ltd. in Lahore. Over the years, Escorts has surged ahead and evolved into one of India's largest conglomerates. In this journey of six decades, Escorts has had the privilege of being associated with some of the world leaders in the engineering manufacturing space like Minneapolis Moline, Massey Ferguson, Goetze, Mahle, URSUS, CEKOP, Ford Motor Company, J C Bamford Excavators, Yamaha, Claas, Carraro, Lucky Goldstar, First Pacific Company, Hughes Communications, Jeumont Schneider, Dynapac .These valued relationships be it technological or marketing, are our highly cherished experiences treasures, which have helped us inculcate best in class manufacturing practices and to emerge as a technologically independent world class engineering organization.

1944 - Launch of Escorts (Agents) Ltd.

1948 - Pioneered farm mechanization in the country by launching Escorts Agricultural Machines Limited, with a franchise from the U.S. based Minneapolis Moline, for marketing tractors, implements, engines & other farm equipment. Launch of Escorts (Agriculture and Machines) Ltd.1949 - Franchise of Massey Ferguson tractors for northern India.

1951 - Escorts established India's first private Institute of Farm Mechanization at Delhi.

1953 - Escorts (Agents) Ltd. and Escorts (Agriculture and Machines) Ltd. merged to form Escorts Agents Pvt. Ltd.

1954 - 1st industrial venture of Escorts to manufacture piston rings in collaboration with Goetze of Germany, in an era when joint ventures of Indian firms with foreign companies were virtually unheard of.

1958 - Started importing Massey Ferguson tractors from Yugoslavia for marketing the same in India

1959 - Collaboration with Mahle of Germany to manufacture pistons. Soon, Escorts became the largest producer of piston assemblies in India.

1960 - Set up of Escorts Limited.

1961 - Setting up of manufacturing base at Faridabad for manufacture of tractors in collaboration with URSUS of Poland and 50% indigenous components. Launch of Escort brand of tractors collaboration with CEKOP of Poland for manufacture of motorcycles and scooters. Escorts moves into high gear by nurturing the two wheeler culture. The first Rajdoot motorcycle rolls off the assembly line.

1969 - Escorts Tractors Limited was born a technical and financial joint venture with the global giant Ford Motor Company, USA, to manufacture Ford tractors in India. The years ahead saw Escorts grow as the largest tractor manufacturer in India. Escorts Institute of Farm Mechanization (EIFM) established at Bangalore. Escorts Employees Ancillaries Ltd. (EEAL), a unique venture in industrial democracy comes into being.

1971- 1st February, the first tractor FORD 3000 rolled out of the factory. Escorts diversify and start manufacturing construction equipment. 1974 - Crossing national boundaries, Escorts exports for the first time. After winning a global tender, 400 tractors were exported to Afghanistan, which was perhaps the worlds Largest ever airlift of tractors.

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1977 - Escorts enter the world of self-developed technology by setting up its first independent R&D Center. Escorts Scientific Research Centre marked its beginning at Faridabad by developing its own Engines for E-27 and E-37. Due to constant technology absorption, indigenization level touched 72% for FORD tractors. 2nd plant at Bangalore for manufacturing piston assemblies was set up.

1979 - Collaboration with JCB Excavators Ltd., UK for manufacture of excavators. 1980 - Foray into healthcare, Escorts Hospital and Research Center set up in Faridabad.

1983 - Escorts Tractors Limited (ETL) established a state-of-the-art research and development center to spearhead newer breakthroughs in Farm Mechanization and to maintain industry leadership. Line concept introduced for engine block machining. 11,000 ton floating dry-dock Escorts I launched. 1984 - Signing of agreement with the Japanese bike giant Yamaha to manufacture motorcycles with Yamaha technology. Collaboration with J e u m o n t Schneider of France to manufacture EPABX systems Collaboration with Dynapac of Sweden to manufacture vibratory road compactors.

1988 - Escorts Heart Institute and Research Centre (EHIRC), a world class cardiac care facility launched in New Delhi.

1989 - Joint Venture with Claas of Germany to manufacture harvester combines.

1990-91 - First Public Issue in February 1991, over-subscribed four times. Shares Listed on Delhi and Bombay Stock Exchanges.

1993 - FORD 3620 tractor launched.

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1996 - Disengagement of joint venture collaboration with New Holland and launch of FARMTRAC Tractor.

1997 - Joint Venture with Carraro of Italy for manufacturing and marketing of transmission and axles. Joint Venture with First Pacific Company of Hong Kong - Escotel Mobile Communications.

1998 - POWERTRAC series of tractors launched. MoU was signed with Long Manufacturing Company, USA for setting up a Joint Venture in USA.

1999 - MoU for Joint Venture with a Polish Company POL-MOT was signed for assembly, manufacturing and marketing of Farm Machinery.

2004 - Divested Escotel Mobile Telecommunications to Idea Cellular TS16949 certification for Agri Machinery Group 2005 Divested Escorts Heart Institute and Research Centre (EHIRC) to Fortis Healthcare.

2006 - Divested in Carraro India Ltd.

2008 - ECEL launches Fully Hydraulic Crawler Cranes

2009 - ECEL has recently commissioned its state-of-art manufacturing plantrolling out pick-ncarry cranes and vibratory compactors.

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1.5 COMPANY LOGO

A hexagonal nut (in red) representing a geometric perfection. The nut has been a functional device that has stayed at the core of mankinds engineering adventures. In spite of modern technologies coming in, it still remains unarguably a symbol of technology and all that holds it together. Locked into the nut is a spanner (in white), the turning force for the symbol of technology. The two pictorial elements are configured together to form an 'E', a pneumonic for Escorts.

1.6 KEY PERSONS

Name Designation

Rajan Nanda G B Mathur Hardeep Singh M G K Menon Nikhil Nanda O K Balraj P S Pritam Rajan Nanda S A Dave S C Bhargava

CEO Secretary Director Director Joint Managing Director Exe. VP & Group Chief Financial Officer Director Chairman and Managing Director Director Director

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SUBSIDIARIES
Escorts Asset Management Ltd. Escorts Automotive Ltd. Escorts Agri Machinery Escorts Class Ltd. Escorts Construction Equipment Ltd. Escorts Heart Institute and Research Centre Ltd Escorts Hospital and Research Centre Ltd. Escorts Securities Ltd. Escorts Telecommunication Ltd. Esconet Services ltd. Cellnext Solutions Pvt. Ltd. I Serv India Solutions Pvt. Ltd. Escosoft Technologies Ltd. Escosoft Technologies (USA) Ltd. Escosoft Technologies (UK) Pvt. Ltd. Escosoft Singapore Pvt. Ltd. E-Soft (Mauritius) Holdings Ltd. Escotel Mobile Communication Ltd. Escotel Telecommunication Ltd.

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CHAPTER 2 Agri machinery group

Introduction
Agri machinery group is the part of Escorts Ltd. In 1960, parent company, Escorts, set up the strategic Agri Machinery Group (AMG) to venture into tractors. Having pioneered farm mechanization in the country, Escorts has played a pivotal role in the agricultural growth of India for over five decades. One of the leading tractor manufacturers of the country, Escorts offers a comprehensive range of tractors, more than 45 variants starting from 25 to 80 HP. Escort, Farmtrac and Powertrac are the widely accepted and preferred brands of tractors from the house of Escorts.

2.1 Features of AMG

Escorts - AMG has Tractor manufacturing capacity of 72000 / annum which is the highest in Asia at one location. Its manufacturing operations are divided in four plants as

KMC Component Plant Tractor Assembly Plant Crankshaft & Hydraulic Plant

Component Plant consists of Machine shops in which all major castings such as Engine blocks, Gear Box housings, Differential housings are being machined along with Gears & Shafts. Machine shop consists of State of the Art machines such as CNC Horizontal Machining Centers, CNC Turning Centers and variety of other precision machines, including Gear Hobbing and Shaving machines, etc. It is important to note that all critical components are machined in house.

Tractor Assembly Plant is divided into two lines as Farmtrac Line and the Powertrac Line. Farmtrac Line is a composite line that has machining as well as assembly activities of Engine, Transmission & Tractor whereas on Powertrac line only Assembly activities of Engine, Transmission& Tractor are being carried out. Tractor Assembly Plant has State of the Art Paint Shop that has CED paint shop facilities. Engine Shop has State of the Art testing facilities that includes AVL make Eddy Current Dynamometers in Engine Test House. Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft Line and Hydraulics Line. Crankshaft line consists of machine shop where crankshafts of all Tractor models are being

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machined. It has State of the Art machines such as Rotary Miller, Pin Grinder, Journal Grinder, etc. Hydraulic line consists of Machining as well as Assembly activities where critical parts of tractor hydraulics such as Distributor, Hydraulic Cylinder, etc are being machined and assembled. It has State of the Art Honing and other precision machines.

2.2 Turn Over

Present Turn over US$ 30 million. Presently Production 72,000 tractors per annum. Production will rise to 100,000 tractors per annum in 2 years. Procurement value will rise to almost US$ 45 million in that period. Presently 387 suppliers of which over 95% are India domestic.

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2.3 Products
Table 2.1 Product

Product

Brand

Model

ESCORT Tractors

E-325 Josh, E-335, MPT JAWAN

FARMTRAC

Hero, Champion, FT-40, FT-45, FT-50, FT-60, FT- 70

Powertrac

PT- 445, PT-4455, PT 425, PT434, PT-439, FT Hero, FT Champion

Rotavator

Laser leveler CROP SOLUTION MB Plough

Farmtrac 60 ,Farmtrac 65

Combine Harvester

FT 65, FT70

Engines

Escorts Farmtrac Gear oil,

G15, G20, G25, G30

Lubricants

Transmission Oil, Engine oil

FT15W40

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2.4 Awards
a). Greentech Environment Excellence Award-2011-Knowledge Management Centre (KMC) has bagged the Gold Category award in Engineering Sector instituted by Greentech Foundation, Delhi for outstanding performance in Environment Management.

b). Escorts Agri Machinery (EAM) wins accolades at INSSAN-Employees of EAM participated in various competitions organized by the Indian National Suggestion Scheme Association New Delhi (INSSAN) at ESSEX farms, Convention Centre, New Delhi on 3rd and 4th June 2011. INSSAN is a platform to recognize the value of employees for their intelligence, experience, attitude and feelings. c). Escorts won Flower Festival Awards 2011 organized by Haryana Urban Development Authority.

d). Recognition of Escorts R&D Centre renewed for next five years i.e. up to 31st March 2016 based on R&D Projects under taken during last three years.

e). Company was the First Winner in Solid Model Contest 2011- this award is about the focus on 3D imaging and predictive analysis to reduce the number of physical prototype to save time, cost and energy consumption.

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CHAPTER 3 KMC Introduction

Escorts Knowledge Management Center unites professional expertise with long practical experience in Product Design, Computer Aided Engineering (Simulation & Virtual Testing), Product Evaluation & Testing. It is in about 10000 s.m area. Escorts expertise in this area has been developed from nearly six decades of knowledge & experience in designing and innovating products and machines for escorts group's own manufacturing companies. Knowledge management centre have many depart as Design, testing, metrology etc.

3.1 Design
In this section there are design of engine, transmission, vehicle are being done. For this purpose they use

I-DEAS / NX 3-D Modeling & Assembly Pro Engineer AUTOCAD (2-D) Preprocessing (Meshing)

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Figure: Design Simulation & Verification Using FEA Tools

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Structural analysis Thermal analysis Nonlinear analysis Dynamic analysis Fatigue analysis Optimization of structure Multi-body dynamics including flexible body

3.2 Testing
In testing department testing of engine, transmission and tractor testing are done. It Includes engine test lab, transmission lab and tractor lab.

3.2.1 Engine - Rigorous testing

The state of art Engine Test Lab includes the following tests:-

Friction Measurement- For friction measuring motoring dynamometer is used.

In this test the engine is first run up to the desired speed by its own power and allowed to remain at the given speed and load conditions for some time so that oil, water, and engine component temperatures reach stable conditions. The fuel supply is then cut-off and dynamometer is converted to run as a motor to drive for the engine at the same speed at which it was previously running. The power supply to the motor is measured which is a measure of the friction of the engine. It is about 22kW for 34hp engine.

Governing Test-This test is performed at high idle speed, rated speed and an
intermediate speed. RPM is decreased in steps of 20 and it is observed at what RPM maximum power is obtained. For a good engine, the difference between maximum power RPM and the RPM at which the test is being performed should not be more than 100-120 RPM. Gaseous & Particulate Emission Evaluation- Flame Ionization Detector is used for HC emission. Bosch smoke meter is used for smoke Measurement.

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Endurance Test - This test is done to estimate the life of the engine. This test is
generally performed on a new engine or an engine with some part modified. The test procedure depends on type of modification done. A new engine is run continuously for 3000 hours. After every 40 hours engine oil is checked, every 100 hours FTP test is done and in every 500 hours engine oil is checked.

Oil Consumption Evaluation- This test is done for oil consumption

evaluation. In this test power is measured by dynamometer and fuel consumption is measured.

3.2.2 Vehicle testing For vehicle there are mainly fatigue test, hydraulic lift
testing, field test and noise test are done. Some of them are:-

Track test- In this test tractor is runs on a track having cleats, or grousers.

Figure 3.3: track test

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PTO performance-This is done by the help of power take off dynamometer

which measure engine power at the power take-off. This dynamometer has range of power and torque. PTO is 540 rpm at 1710 rpm.

Power lift- This test is done by power lift set up. In this test lift is continuously
lifting the weight of 1050 kg.

Noise testing- Sound meter are used for this purpose. This gives the 81 dB. Vibration testing Vibration testing is done using Vibration Measurement
instruments consists of

B&K 3560 Pulse Multi Analyzer System 16 channel Data Acquisition I-DEAS Test Data Analysis Software (TDAS)

This set up gives frequency in 1 to 100 Hz.

3.3 Metrology
Facilities for the measurement of component dimensions using the following equipment:

3D CMM with software-A coordinate measuring machine is a 3D device for measuring the physical geometrical characteristics of an object. This machine may be manually controlled by a computer control.

Trimos Height measuring system- Trimos height gauge is used for height measurement. Profile Projector with optical eye & software- It employed for inspecting and comparing very small and complex parts. Portable Surface roughness measuring equipment Conventional instruments

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Figure 3.4: Trimos Height Measuring Instrument

CHAPTER 4

ASSEMBLY PLANT

INTRODOUCTION
The final processed parts from the various parts of production shop and Heat Treatment reach the assembly Shop. Escorts have two assembly shop different for each powertrac and farmtrac. In farmtrac assembly line assembled 120 tractor per day and powertrac capacity is 80 tractor per day. For lifting the component there are hydraulic lift are used and for small part the used roller. Conveyor is used for moving in forward direction. The various parts reaches

The assembly shop only after being washed, cleansed and dried, which takes place when the different parts are on their way to assembly shop. The above washing process takes place automatically i.e. the machinist has to drop the final Part on the roller conveyor, and the parts reach the assembly shop after being automatically washed and dried.

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We were advised to walk within the yellow line boundary because of the safety measures. The assembly shop can be divided into various subparts being assembled. These groups are: Rear Line Transmission Assembly Engine Assembly Line Front Line Paint Shop Wheel Assembly

4.1 Assembly Layout

Figure shows the typical assembly layout of ESCORTS WORKSHOP:

Figure 4.1 Assembly Layout

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4.2 Real assembly

Real assembly line is starting of assembly shop. Before the various differential parts such as bp shaft, differential cage etc. are assembled, the various sub-assembly 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 circular clips, bearings etc. to be able to be assembled to the differential Cage. This constitutes the assembly of cross bar, planetary gear, planetary gear cover, and crown wheel etc.

The various bolts required making the assembly of about parts and integral one are bolted using a pneumatic bolter gun. After this, the differential cage is collected from the conveyor firstly fitted with the necessary bearing races. Then the differential Cage unit and the bp shaft are assembled, making up a complete one unit.

The Axles are assembled in a different sub assembly shop. First rear axle wash and dry and then fixed wheel side bearing and there on the whole unit along with the bull gears is assembled to the differential Cage. Differential cover assembles after these assemblies.

4.3 Transmission Assembly

The gear box assembly is the third stage of the assembly unit in which the gear 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 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. First gear on main shaft with 38 teeth and reverse gear with 38 teeth, second gear with 35 and and third with 28 teeth. This is the constant mesh type transmission. After assembly of the transmission there is leakage testing is perform.

In this test first gear box is full of oil and then sealed. After that the pressure is increase up to 10 bar. Then the by the motor power the clutch shaft is revolve at 2700 rpm. This test checks meshing of gears. After that whole unit is assembled to the main line and make a complete one unit.

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4.4 Assembly of Engine and Clutch Mechanism

First there is clutch assembly. Single clutch organic coil type clutch are fitted. Before the engine assembly there is assembly of various other accessories such as Foot board, battery clamp and other links such as accelerator pedal link, clutch link, brake link etc.

Engine from sub assembly are assembled to the main line. A four stoke 3 cylinder diesel engine first assembled at the engine sub assembly.

The various links and mechanism between the engine and the gear box is fastened together and the whole integral unit is checked for its complete accessories etc. In all the above stages 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 overhead automatic conveyors and the alarm conveyor etc. to make their job easy.

4.5 Front axle and accessories

After engine fitting there is assembly of front axle. After front axle there are steering assembly of the steering and accessories. Then clutch pedal and break is fitted. Fuel tank is fitted after this. After the whole assembly goes the lift for painting in the paint shop. The painting purpose there is cap fitted on bolts of wheel hub to protecting from paint.

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Paint shop
Paint shop is completely automatic. In the paint shop first there is digressing, water rinsing and demineralized water rinsing. After that air blowing is done. Paint Baking Oven removes the moisture from water-based coatings and adhesives. After that unmasking and touch up and painted the body.

4.6 Rear and Front wheel fitting

After painting there is fitting of rear wheel with tire size of 12.428 and front wheel fitment with the tire size of 616. After fitting the wheels there is following fitment are fitted:

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Figure 4.6 Rear Wheel Fitting

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Fan and Motor Rear hood Radiator and coolant Steering wheel Mirror Air filter Front light Seat and Silencer

4.7 Final Testing

Final testing of tractor is lift testing and the test of track. At there a hydraulic force of 1050 kg applied and testing is done.