BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)
SESSION 2011-2015
Submitted To
ER. RASHPINDER SINGH
Mechanical Engineering
Submitted by
KARANVIR
1151648
ACKNOWLEDGEMENT
KARANVIR
2
DECLARATION
The information and data given in the report is authentic to the best of my knowledge.
This six months industrial training report is not being submitted to any
other University for award of any other Degree, Diploma and
Fellowship.
TABLE OF CONTENTS
Name
Page No
Abbreviations
List of Models
14
Agro Products
15
16
Conclusion
32
Suggestion
33
Bibliography
34
ABBREVIATIONS
CNC
DNC
DI
Direct Injection
CA
Crank Angle
CAD
CAM
TIG
CO
Carbon Monoxide
MIG
HP
Horsepower
manufacturers in India. Apart from tractors its product line includes multi utility vehicles, three
wheelers, engines and various farm equipments and implements. Established in 1969, Sonalika
group since the inception has tried to understand customer need to be facilitating them with its
value for money products. The Company has a state of art manufacturing facilities, spread in
acres, located in the free shrubs of Punjab and Himachal Pradesh.
Sonalika is the one of the top 3 tractor manufacturing companies in India, other products
include of, Multi utility vehicles, engines and various farm equipments. Today the group stands
tall with an approximate turnover of 5000 Crore INR. An average growth of 30% makes it one
of the fastest growing corporate in India. It is also one of the few debt free companies. Group
has strength of about 2000 employee technocrats. The company works on the maxims of low
production cost and clean and safe environment. Such efforts have fetched the company the
accreditation like ISO 9001 and ISO 14001. History reveals that innovation is the key to
continued progress and when applied to technology that touches human life, it can unfold a
whole new economic phenomenon that has the power to change the world. With unique
initiatives like the Thought leadership Forum, Leadership Forum, we have been able to create a
unique platform for learning through success stories of industry leaders. The success saga of
Sonalika Group a business conglomerate having prime interest in agricultural & auto
machinery goes back to nearly 5 decades. The corporate philosophy embedded in trust, quality
and commitment has helped the group to carve out a niche for itself in the highly competitive
world of Machinery. Sonalika is the fastest growing tractor company registering growth over
growth since its inception has crossed 1.80 lac merely in 10 years & has attained one of the
position in top three in India
Sonalika groups products exist in various international markets. Companys product exported
to Algeria, Angola, Armenia, Australia, Bangladesh, Cameroon, Ethiopia, Ghana, Ivory Coast,
7
Malawi, Malaysia, Mauritius, Mozambique, Nepal, Oman, Republic of Benin, Senegal, South
Africa, Srilanka, Sudan, Canada, Zambia, Syria, Togo, Tunisia, Ukraine and Zimbabwe.
Shareholding:
Sonalika Group = 80%
Renault Agriculture = 20%
Annual Turnover = Rs.2098 Million approx.
MISSION
International Tractors Ltd. offer quality product with distinctive features at reasonable price.
The company ensure better than the best after sale service for the satisfaction of the
customer.The firm is ranked as best in terms of its quality and production front. Company is
exporting its tractors to different Asian as well as African countries.
FUTURE PLANS:
To provide superior quality tractors over all world with new technology at reasonable rates,
and to become No. 1 in automobile industry within five years.
COMPANY PROFILE
Details of top executives
Turnover
The total turnover of the group stands for 3200crore INR. An average growth of 30% makes it
one of the fastest growing corporate in India. It is also one of the few debt free companies.
10
SONALIKA
GROUP
INTERNATIONAL INTERNATIONAL
INTERNATIONAL
SONALIKA AGRO
CARS AND MOTOR AUTOTRAC
TRACTOR LIMITED
INDUSTRIES
LIMITED FINANCE LIMITED
11
International Tractors Limited was incorporate on October 17, 1995 for the manufacture of
Tractors and has since then built a distinct position for itself in the Tractor industry. ITL is
manufacturing various Tractors of Sonalika brand between 30 H.P to 90 H.P, and CLASS
brand between 70 hp to 90hp. The tractors manufactured by company have secured a
reputation of performance, quality and reliability in the market because of their maximum
pulling power, minimum fuel consumption and low emission. All this makes ITL one of the top
five tractor selling companies in India. These tractors are also exported to various countries
including South Africa, Australia, Zimbabwe, Sri Lanka, Canada, Bangladesh, Algeria,
Zambia,
Senegal,
Ghana
etc.
ITL has entered into strategic alliance with YANMAR of Japan for joint manufacturing tractors
in India. ITL has a marketing arrangement with TATA International for development of
selected South American and African market. The companys marketing efforts are promoted
by dealer network of 600, and 450 sub dealers. Such a networking has enabled the company to
grow like a well-knit family whose roots lie in its customers, who have providing constant
feedback and support to allow the company to turn their dreams into products.
They are also manufacturing tractors, meeting norms of Smoke & Mass Emission, Tested and
certified by ARAI, Pune. United States Environmental Norms Agency, Washington DC has
also certified our Engines. These certifications enabled SONALIKA Tractors to enter into
world Market. All the Models of Tractors and Combines Harvesters manufactured by us are
tested & approved by central Farm Machinery and Tractors Training & Testing Institute, Bundi
(MP) India, (the Government of India Institute authorized for issuing test reports).
Address-
(India)
12
Pin-146022
13
MODELS:TRACTOR NAME
HORSE POWER
LIFTING CAPACITY
DI-750III
DI-730II
DI-735
DI-55
DI-750II
DI-90
DI-75 2WD
DI-750
DI-60 SENIOR
DI-75 4WD
DI-740III
DI-60 2WD
DI-740
50
30
35
55
50
90
75
50
60
75
40
60
40
1600Kg
1200 Kg
1200 Kg at lower links
1200 Kg at end of lower links
1200 Kg
1600 Kg at end of lower links
1600 Kg
1200 Kg at end of lower links
1200 Kg at end of lower links
1600Kg
1200Kg
1600Kg
1200 Kg at end of lower links
14
Combine Harvestors
Threshers
Potato Planters
Maize Sheller-cum
Seed-cum-Fertilizer Drills
Straw Reapers
Ploughs
Harrows
Tillers
15
.
A farm tractor is a multipurpose power unit. It has a drawbar for drawing tillage tools and a
power takeoff device for driving implements or operating a belt pulley. The acreage to be
worked, type of crops grown, and the terrain all impose their requirements on tractor design.
Accordingly, models vary in such details as power generated, weight, ground clearance,
turning radius, and facilities for operating equipment. All models can, however, be grouped
under four general types: four-wheel, row-crop or high-wheel, tricycle, and crawler.
Tractors are rated by their horsepower they deliver at the drawbar and at the belt. On small
models, the drawbar and belt horsepower may run as low as 10 (7.5 kW); on large models
the drawbar horsepower runs as high as 132 (98 kW), while belt horsepower reaches about
144 (107 kW).
The major components are engine, clutch, and transmission. These components are intimately
related and designed to work in conjunction with each other to accomplish specific work.
Tractor engines are relatively low-speed; their maximum horsepower is generated at
crankshaft speeds in the neighborhood of 2000 rpm. These engines have one, two, three, four,
six, or eight cylinders and operate on gasoline, kerosene, liquid petroleum gas, or diesel fuel.
They are of the spark-ignition or diesel type, operating on the four-stroke-cycle principle, and
16
17
MANUFACTURING
Introduction
Tractor assembly shop is main shop of sonalika international tractor Ltd. In this shop the
different machining parts, housing and other components which are finished or machined in
other departments of the industry and other components which are purchased from outside are
assembled here. Then assembled components like differential housing, gearboxes, rear covers,
Trumpet housing and other housing are send to main line for Tractor assembly. In main Tractor
assembly line tractors are send to paint shop through overhead endless chain rotating conveyor.
It is supported from ceiling and has a fixed path to travel which saves valuable floor space. The
arrangement is such that lifting mechanisum (with help of hook) lowers down for loading and
unloading of tractors.
Press shop
18
Crank Case
Differential housing
Clutch Housing
Trumpet Housing
This infrastructure is equipped with the advanced CNC Machining Centers, Special
Purpose and General Purpose Machines. All the components are thoroughly checked and
inspected for its Geometrical accuracy on the imported 3D Coordinate Measuring
Machine.
The sections are highly equipped with modern machinery and equipment. Each section has a
process layout i.e. the raw material is received at one end and the finished component is
dispatched from the other. The material received is in form of casting. The machining process
is carried out under strict quality norms. There is inprocess inspection at each workstation.
The component is made to go through final inspection before it is dispatched for assembly.
The Material handling System in the H.M.S shop consists of hydraulic lift trucks, power
hoists, roller conveyors, overhead crane, fork lift trucks, bins etc. the shop has well designed
network of roller conveyors. The castings from the truck are loaded onto these conveyors and
the material travels to reach the respective section. At the end of each conveyor a section for
inspection has been made so as to make the component through the inspection process. Each
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workstation is provided with a power hoist of 500Kg (load carrying capacity). These are used
to pick casting from conveyor and load them onto the machine and vice versa. There is also a
provision of a 2-ton carrying capacity overhead crane in each section.
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Control Valve
Composite Valve
Feathering Valve
Relief Valve
Release Valve
Honning & Lapping Machines and Special Inspection & Testing Facilities.
All parts are ultrasonically cleaned before assembling in controlled dust free conditions.
21
L.M.S. is shop for manufacturing small components of the tractor in Sonalika. International
tractors limited. This is a small shop where light components operations are performed on the
light components of tractors. There are about different types of machines where different
operations are performed on different components for production work. Main operations
performed in L.M.S. are as follows: -
DRIILING FACING
TAPPING
TURNING
REAMING
BORING
MILLING
GRINDING
Relief valve
Release valve
22
Having World Class manufacturing facilities to deliver best quality of transmission gears,
shafts & assemblies for automobile and tractor applications. The Facility delivers all types of
gears & shafts like Main Shafts, Lay shafts, Input Shafts, Synchromesh Gears, Gears with Dog
Teeth, Shifter Sleeves, Synchro Hubs & Cones.
Heat treatment
CNC Turnings, CNC Hobbings, CNC Shavings, CNC Multi-Axis Grinders, Gear
Shapers, Broaching, Roofings, Swaging and Tooth Rounding machines.
Heat Treatment Sealed Quench Furnaces with CNC control, Gas Carburizing
Furnaces, Rotary Furnace, Plug Quenching, Vibratory Debburing, Shot Blasting, Shot
Peening and straightening Presses.
Well-equipped standard room having computerized Lead & Profile Testers, Surface
Roughness Testers, Contour Testers and Gear Roll Testers etc.
Press Shop
Stamping facility is equipped with Ultra modern presses from internationally renowned
24
suppliers. This facility delivers all type of sheet metal components i.e. Skin Panels, Inner
panels, Floor Panels, Pillars, Reinforcements, Cross Members, Oil Pans, Fuel tanks etc. It
includes
Laser Cutting
Rapido 5 Axis Laser Cutting machine from M/S Prima (Italy) with a travel of 3.5 X 1.7 x 0.8
Mtrs. and can cut thickness up to 5 mm. 2 Nos.
Welding
Spot Welding, Projection Welding, Seam Welding, MIG Brazing, MIG, TIG & Arc Welding.
Testing Facilities
Cupping Tester
25
Assembly
Assembly Engine:
The State of Art assembly line for Engines is one of the best lines fitted with high quality
automated slat conveyor system having various safeties and DC Multi Nut Runner systems
on the different stages which ensures consistent production. The diesel engines assembled
here are from 28 Hp to 90 Hp.
Engine can be called as heart of automobile. Engines are used for different purpose The engine
used in INTERNATIONAL TRACTORS is of these types. The engine fitted in 740 DI is made
by SYMPSONS, which are exported.The engine in 50 & 60 H.P. are of two types one is
standard model and its design is taken from ZETOR of Check-osolavia and other is fuel
efficient model in which crank case and head design is taken from AVL (Auto Vehicle Ltd.0 of
Austria. Due to better performance of F.E. model engines the production of standard engines is
stopped now.
The engine shop of INTERNATIONAL TRACTOR LTD. Is well furnished with latest
fitting and checking instruments. .
The workers in this shop are of high skill level and have lot of experience. The production of
shop is about 80-85 engines per day and can be increased if required. All the component of
engines except crankcase is brought from outsides. The shop is having latest engine testing
shop and having latest equipment. In testing shop engine is checked for efficiency, specific
fuel consumption power, torque, leakage, rpm and other faults like below from crankcase The
finally tested are sent to the assembly.
26
The conveyor is fitted with 28 fixtures for mounting of all engine models with
facility for 360 degree rotation for various assembly operations.
All Stages are equipped with DC Multi Nut Runners for optimized and consistent
production.
The Complete Shop is Air Pressurized to ensure dust free environment for
the quality production.
Washing Machine
Emission test cell for conducting emission measurement Installed by AVL, imported
from AVL Austria.
27
Assembly Tractors:
Sonalika Group possesses two state of art assembly lines in India and two abroad. In India
assembly lines are situated at Punjab and Himachal Pradesh.
International Tractors Ltd. has tractor assembly line equiped with capacity of 80,000 tractors
and engines per year. The plant has in house facilities for producing transmission hydraulic
components and engines. To further enhance the quality of Tractors, Gears, Shafts and other
important components are manufacturers in house and are tested on high end testing facilities.
Automated conveyors
Toe-in conveyors
Slat conveyor
Overhead conveyors
28
Tractor assembly shop is main shop of sonalika international tractor Ltd. In this shop the
different machining parts, housing and other components which are finished or machined in
other departments of the industry and other components which are purchased from outside are
assembled here. Then assembled components like differential housing, gearboxes, rear covers,
Trumpet housing and other housing are send to main line for Tractor assembly. In main Tractor
assembly line tractors are send to paint shop through overhead endless chain rotating conveyor.
It is supported from ceiling and has a fixed path to travel which saves valuable floor space. The
arrangement is such that lifting mechanisum (with help of hook) lowers down for loading and
unloading of tractors.
Quality Control
"To us at Sonalika Group, Quality is not something that we engineer, inspect and input into
our tractors. It is an innate desire to attain the best that comes from within each of us. It
defines our lives at work and at home and ripples out into the world around us".
Q.C. shop firstly we are talk about what is the quality control? It is Systematic control of those
variables encountered in a manufacturing process, which affect the excellence of the product.
Such variable result from the Application of material, men, machine and manufacture-ring
conditions only when these variables are regulated to the extent that they do not detract unit is
main shop of sonalika international tractor ltd .In necessarily from the excellent of the ringring process as reflected in the quality of the finished product, can the control of quality be said
to exist. Generally, inspection, which is the process of sorting good from bad, is the process of
sorting good from bad, is considered as a form of quality control. But quality control and
inspect-ion are different. Conceptually, a Q.C. aim of prevention of defects at the very source
relies on effective held back system and corrective action procedure. Acceptance of material
after subjecting them to in section at inward goods store is inspection concept. Q.C.concept is
to take early step to ensure that the material to be supplied is going to be manufactured to the
plant's requirements. So as to ultimately eliminate the in ward goods inspection. Discovering
that the components produced are not as per required dimensional specifications due to wrong
tool or improper settling after the production is over is inspection concept.
29
To prevent the issue of a wrong tool and to have a set up approval procedure prior to
starting continuous production and keeping a simple check during production, are Q.C.
concepts.
Q.C.uses inspection as a valuable tool. In quality control programmed inspection data are
effectively used to take prompt corrective actions to arrest the incidence of defects in the job
on hand to plan the prevention of occurrence of the same or similar defects in future.
Quality Policy
Creating a culture among all Employees towards Total Quality Control Concept.
International Tractors Limited is an ISO 9001: 2008 for Tractor Assembly and TS16949 for
In-house Gears and Shafts manufacturing.
Sonalika Group firmly believes in matching the international Quality Standards to meet the
Customer Satisfaction. To achieve this, Sonalika Group is always working on continuous
focus on Quality for both its inhouse manufacturing as well as chain of suppliers, and
thrives to achieve excellence in Product Quality.
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PRODUCTION
ITL has fully integrated and state of the art assembly facilitation for producing world class
tractors. Several productivity improvements in assembly line over the years have made it
possible to manufacture nearly 37000 tractors per Year. Atomization of assembly line not only
increased production capacity, but also provided a quantum jump to the quality of assembled
tractors. ITL assembly line producing tractors in broad range from 30HP to 90HP.
Hydraulic presses
A unique 3-Stage oil filtration system having modern facility of centrifuge filtration
Batch type Special purpose machines (SPM) at various locations for washing of heavy
castings, components & subassemblies
Road testing
31
SWOT Analysis
STRENGTH:
Human Resource
Availability of finance
Investors Relationship
WEAKNESS:
OPPORTUNITIES:
THREATS:
Competitors
New Holland
John Deere
TAFE
32
CONCLUSION
Sonalika has various advantages over its competitors such as low initial cost, low fuel
consumption, high speed, low maintenance cost, & easy availability
As tractor is meant for pulling load, sonalika has all these qualities to pull maximum load due
to high backup torque They basically affected by the displays in providing information
regarding new products so company should create some awareness regarding this and make
some hording on roads to attract tractor users with new features mention on it.
SUGGESTIONS
Through tractor market is highly competitive in India and Sonalika is relatively new brand.
Hence Sonalika need a strong positioning. As sonalika tractor is capable of pulling more load
and unbeatable and unchallengeable features. Sonalika must be positioned as a tractor, which is
most economical and ideal for heavy load work.
Product awareness:
For promotion of a new product awareness is most important factor. As all the farmers
contacted are aware of sonalika tractors and their features and specifications. This can be done
through organizing kisan melas, exhibitions and effective demonstration at village level.
Provide better after sale service to develop better relation with dealers
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BIBLIOGRAPHY
1.
WWW.SONALIKA.COM
2.
3.
4.
NEWSPAPERS
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