OF
SIX MONTHS INDUSTRIAL TRAINING, UNDERTAKEN
AT
MAHINDRA & MAHINDRA LTD. SWARAJ DIVISION LTD.
PHASE IX MOHALI
ACKNOWLEDGMENT
On every step there is need of proper guidance, support and motivation. The encouragement
enables the person to give his or her best performance and thus to
Through this acknowledgement I wish to thank every person who facilitated my training at
Mahindra & Mahindra Ltd., Swaraj Division Ltd Mohali. I feel indebted to many who
provided me knowledge at this prestigious institution.
I wish to thank Mr.Jagdish Singh for providing me the opportunity to work here.
I also wish to express my deepest gratitude to Mr. Balbir Singh and Mr. Kawaldeep Dang who
proposed me this extremely interesting project and have provided me with excellent guidance
and encouragement.
I register my gratitude to Mr. Saurav Vig, Mr. Dharamveer Kumar, Mr.Umesh Malhotra,
Mr. Sanjeev Prabhakar and Mr. Parikshat Wadera for helping me at every point
during the training. Their assistance during the training has been invaluable.
Finally I thank all the staff, especially Mr. U.D.Sharma, Mr. Mam Chand and Mr. Hari Ram
Sharma for their kind co-operation and great help extended to me. Their guidance and in-depth
knowledge was of utmost importance and accordant throughout the training period.
PREFACE
This report includes the work done during my industrial training at Mahindra & Mahindras j
Swaraj Ltd Mohali. The 6-month industrial training gives us an opportunity to learn and practice
new technologies that are relevant in the present scenario. It gives an opportunity to build an
industry interface. These 6 months provide us with many new experiences which help to increase
and build upon our practical knowledge. It is like a precursor to the real job which is to be started
in a short while. As I have been selected to join this very organization, this training was like onthe-job training. The first hand experience of working in the hardcore production field has been
most satisfying.
My experience at the plant has been an enriching one. I wish to portray the same through this
report.
Swaraj group came into existence with the establishment of Punjab Tractors Limited on 27 June
1970 . It was Indias first large scale establishment in tractor industry which pave the way for
other indigenous production houses completely based on indigenous design and technology.
Punjab State Industrial Development Corporation (PSIDC) promoted the programme by
sanctioning loan of Rs. 1 cr. With the help of Govt. of India.
It is located at Phase -4 S.A.S. Nagar (Mohali) . The construction work at P.T.L. started in March
1972 and the first batch rolled out on 14 Nov 1973 . In the starting the plant was producing 5000
tractors with a capital of Rs.37 million . In 1974 it entered commercial production introducing
Swaraj 724 a 26.5 B.H.P. Tractor as its first model. During the span of 36 yrs it has capacity of
producing 45000 Tractors per year.
It was Indias first indigenously built HC called H-8100. ASHOKA LEYLAND supplies its
engine. It is six-cylinder engine developing a power of 105 BHP.
Fork Lfts are also called lift trucks. They are used for loading and unloading of heavy equipm
ent and articles in an industry. It has very short turning radius so that it can move easily in
limited space. The heart of fork lifter (FD) is a 48 BHP engine by KIRLOSKAR OILS
LIMITED. The fork lifter is manufactured by SWARAJ in collaboration with a Japanese firm
KOMATSU. These fork lifters have power steering system and have partial automatic drive.
These can be either battery operated or diesel operated. Following is the list of fork lifters
manufactured:
FD-20
FB-20
FD-25
FB-25
FD-30
FB-30
MODELS:S15
Single Cylinder
RV2
Two Cylinder
RV3
Three Cylinder
RB30
Three Cylinder
RB33
Three Cylinder
22 bhp
24 bhp
39.5 bhp
44 bhp
55 bhp
With more than 4 lacs of tractors & harvester combines operating in Indian farms, SWARAJ are
now a well-established brand name in country. SWARAJ is now an internationally recognized
name in the developing world.
The products of SWARAJ are not only restricted to Indian market but they had entered in
international market. SWARAJ tractors find an important place in developing countries like
Ghana, Tanzania, Zambia, Kenya, Sudan, Uganda, Indonesia & Malaysia, etc. they are also
sending their combines to South Korea having first A.C. cabin
India being a predominantly agricultural country where agriculture is the life and blood of the
economy has been a traditional manufacturer of different types of farm machinery and
implements. However the use of advanced agricultural techniques in India started only in early
sixties. Modernization and tractorization in Indian agriculture is only post independence
phenomenon. One of the achievements of green revolution has been that the farmers increasingly
realized the advantage of tractorization for obtaining the timelines of operations. This would
happen only because of awareness of new farm technology among the farmers, rise in the level
of their income and education., Tractors were introduced to Indian agriculture in early twenties.
Jogindera Singh was the first farmer to use a tractor called a steam plough then on the 12000
acres estate he had inherited in the remote Kheri district of Uttar Pradesh. But the demand of
tractors rose sharply in last two decades. However the rate of adaptation of tractors is different in
different parts of the country. Punjab occupies number one rank in this regard. Punjab possesses
only 1.5% of the geographical area of the country; the density of the tractors in Punjab is the
highest (85 tractors per hectare) as compared to national average of 10.5 tractors per hectare.
India is primarily an agrarian nation, with more than 50 per cent of our GDP being contributed
directly or indirectly by agriculture. No wonder, India is considered the largest tractor market in
the world. If that sounds great, let us face hard facts. In terms of total tractors in use in the
country, we are ranked a distant eighth. In terms of penetration, India has a tractor density of
10.5 tractors per thousand hectares of Gross Cropped Area (GCA) as compared to the
international average of close to 30 tractors per thousand GCA.
Figuratively speaking, Indias large gross cropped area (GCA) is next only to the big two USA
and Russia. That and the highly fragmented land holdings in India have helped our country to
become the largest tractor market in the world. Thus the Indian tractor market, per se, has to be
viewed only after considering its position in the world (see Box 1).
Description
Units
World Total/Avg.
India
Indias rank
Arable land
Million hectare
1,444
170
Irrigated area
Million hectare
249.6
45.8
Tractors in use
Tractor/000 hectare
28
10.5
Despite a phenomenal increase in tractor population in the country, the tractor density is very low
at about 10.5 tractors per thousand hectares of GCA in comparison to the international average of
about 28 tractors. Also, the small size of land holding in India, have led to low average power of
tractors at 35 horse power (HP), which is far lower than the global average of above 80 HP.
Easy availability of bank finance coupled with declining interest rates has propelled the demand
for tractors. Furthermore, a good monsoon, a strong growth in agricultural production and an
increase in the irrigated area are expected to lead to a secured long-term growth of 7-8 per cent in
the next century.
There has been a boom in the tractor industry since 1997. The sales of tractors are not evenly
distributed. They are mainly concentrated in the North and Northwest where Punjab, Haryana
and UP account for nearly 50 percent of the entire tractor sales. Punjab alone accounts for 26 per
cent. The main reason is comparatively larger land holdings and the affluence of farmers in
these states. New markets like Madhya Pradesh, Tamil Nadir, Andhra Pradesh, Maharastra and
Gujarat are also growing at a faster pace.
Punjab Tractors (PTL) leads in the North, while Tractors and Farm Equipment (TAFE) dominate
in the South. High transportation cost is one of the main factors preventing brands from going
national.
HISTORICAL PRECIDENTS
Indian lives in villages, and villages depend upon agriculture. Agriculture provides livelihood to
about 64% of labor force and contributes nearly 27.1% of GDP. Indian agriculture till
independence followed obsolete methods. Continuous increase in population has been on
stressing the demand of more output from agriculture and to meet this demand we need 225
million tones of food grains by 2000 AD.
In the first five-year plan agriculture was accorded top priority. Furthermore, since irrigation
was recognized as key to agriculture, irrigation was accorded great importance in the planned
development, which started in 1950. Major initiatives were also taken in agricultural education
and research.
All these developments made mechanization mandatory for agriculture and import of tractor
began. Acceptance of mechanization was however slow and by 1960, population of tractors in
the country barely exceeded 10,000.
The decade of 60s India saw green revolution resulting in increase in both production and
productivity. With the parallel emphasis on industrialization, the birth of Indian Tractor Industry
took place in 1959-60 when the imports were restricted and 5 tractor manufacturing units set up
in the private sector,. Date of commencement of commercial production and collaboration are
given in table (attached). Total indigenous production of tractors by 1965 was just 6000.With the
successful introduction and acceptance of the high yielding seeds, however, there was a sudden
upsurge in the demand for tractors after 1967 and demand started multiplying at an annual rate of
nearly 50% (1967: 18,000, 1970: 33,000). A natural consequent of this sharp upsurge and
consequent shortage was heavy price premium on tractors. Recognizing the situation, import of
tractors into the country was liberalized and over and above the domestic production of 20,000 in
1970, 13,000 tractors were imported.
SR.
Manufacture
Collaborator
Year of
commencement of
production
Eicher Tractors
Gebr, Eicher
Tractorenfabric, West
Germany
1959
2.
Motokov-poraha,
Czechoslovakia
1963
3.
Massey Fergusion UK
1963
4.
Escorts Ltd.
Motoimport warazawa
Zaklady Mechaniczne
Ursus, Poland
1964
5.
International Harvester
Company USA
1965
NO.
1.
Since the pace of indigenization of the five tractor-manufacturing units already set up was far
below expectation, the government decided to diligence the Tractor Industry in 1968 and invited
new entrepreneurs. Seeing the sharply growing demand, Tractor Industry became the most
sought after industry in the country and as many as 18 fresh entrants approached the Government
for setting up manufacturing units. The interest of a large majority, however, lay in quick profits
through sales of imported tractors. Nevertheless six new manufacturers did enter the Tractor
Industry; four in private sector and two in the government. Combined output of 11 units had
risen to 32000 by 1975.
The Governments decision to freely invite new entrepreneurs to tractor manufacture in 1968 and
sudden upsurge in demand, with the green revolution, led to a scramble, of new entrepreneurs for
new collaborators 6 units, eventually, established the actual manufacturing facilities. They were
as follows:
S.No.
1.
2.
HMT
Govt.
3.
Ltd.
Collaborators
Year of
commencement of
local production
FORD UK
Central Motokov
Czechosolovakia
1971
praha,
1971
Klochner
Humboldt
Deutz, West Germany
1974
4.
Motoimport USSR
1975
5.
CMERI India
1974
6.
1974
With the entry of new units in 1970 and increasing Government pressure towards indigenization
picked up substantially after 1970 and by 1978 almost all the tractors manufactured were nearly
indigenous. A fillip to indigenisation was also given by the overall industrialization of the
country, when a large number of ancillary manufactures had also established themselves and
were in a position to supply a wide variety of components to the tractor industry.
The sharp liberalization of imports in 1970 had given the nascent Indian Tractor Industry a
substantial setback in 1970-73, when low cost import particularly from East European countries
had become far more attractive.
Recognizing that such was not the intention, the government decided to ban imports in 1973.
Banning of imports and increased competition not only led to growth of local production but also
spread pace of indigenisation. While domestic demand was growing sharply from 1975 onwards
(compound growth rate of 18%), tractor industry suffered another major setback in 1982 when
due to severe credit restrictions by the Government, bank credit for retail purchase of tractors by
farmers was drastically curtailed and demand fell sharply. But after 1987, the situation again
changed and the demand of tractors picked pace because of the priority given by Government to
agriculture side.
The buoyancy, in the tractor market, experienced in the late seventies, led to the setting up, of
two more units, for the manufacture of tractors, one in the public sector, in collaboration with a
UK firm and the other, a private sector unit, with indigenous know how. These units are:
S.N
o.
Collaborators
Year of
commencement of
local production
1.
British Leyland
(UK)
1981
2.
Ownknow how
1983
Punjab Tractors Ltd. (PTL) is the second largest (after the 1 st quarter of FY 1999-2000) player in
the industry with a market share of 18.45. Unlike M & M, 90% of PTLs turnover comes from its
tractors business. During the year 1998-99, the company had a sale of 48336 tractors as against
40,425 tractors last year. Over the last five years PTL has grown at a rate of 17%. During the last
year PTL had a growth rate of 22.4%. It was during this period that PTL managed to improve all
this because of its strong dealer network, low cost structure and high employee productivity
turnover.
. On the financial front the companys performance has been satisfactory. Punjab Tractors has
undertaken an expansion programme to enhance its installed capacity from its hitherto capacity
of 36,000 tractors to 60,000 tractors per annum
Swaraj Tractors Ltd (PTL) is one of the leading manufacturers of tractors in India. PTL has been
known as the industry out performer since inception. Even when the industry grew at a CAGR of
6.1% during 1991-2000, PTL grew at the CAGR of 11.9%. In terms of market share, PTL is the
second largest player after M & M in FY2001 with a market share of 18.1%. PTL tractors are
sold under the Swaraj brand name. PTL has strong market share of around 20% in the northern
region with the highest share in Punjab and Haryana and 16% in the western regions and
southern regions of India. In the east the company accounts for 11% market share. The tractor
sales accounted for 83.3% of PTL's turnover in FY2001 whereas the harvester-combines,
forklifts and spare parts accounted for the balance. Industry basics The Indian tractor market is
dominated by low price, rugged, versatile and low to medium powered tractors; the main reason
being the inability of farmers to invest in farm mechanization. Tractors are categorized on the
basis of horse power (HP) of the engine. In India, the popular range of tractors is 20-40 HP
compared to 60 HP in Europe and 90 HP in the USA. Though large tractors were economically
unviable in India, there has been an increasing demand for high-powered tractors due to soil
conditions, particularly in states of MP, Gujarat and Maharashtra. But more recently, higherpowered tractors are also being sold in states like Punjab where it is considered as a status
symbol. Tractors available in India are 1/4th of the prices of similar powered tractors
internationally or in developed countries. Availability of credit is the most crucial factor
impacting tractor demand, as in India 90% of the tractors are financed by bank credit at
concessional rates. Increased use of irrigation facilities, shift towards multi-cropping,
consolidation of lands holdings, promotion of co-operatives and higher investment in agriculture
also contributes to higher tractor demand. The tractor segment comprises players like Eicher,
Escorts, HMT, Punjab Tractors, M&M, TAFE, Sonalika, which control about 98% market share.
India is the worlds largest market in tractors since 1996. A few international players like Case
New Holland, John Deere and Steyr have also set up facilities in India. But these players have
entered the higher-powered category and, thus, pose little threat to the existing players who enjoy
advantages of established distribution/service network and strong brand equity. Punjab Tractors
is promoted mainly by Punjab State Industrial Development Corporation Limited and has
acquired the second highest market share in the tractor segment from 9.1% in 1975. In 1970,
PTL had major competition from other companies like Eicher, Tractors and Farm Equipment
(TAFE), Mahindra & Mahindra (M&M), Escorts and HMT. PTL is one of the leaders in its
business and has put up a heady performance in contrast to other private sector players. As
against other players, which report a ROCE of 15% on an average, PTL has consistently
remained at about 50% in the last few years though the industry is capital-intensive. Punjab
Tractor is the only major tractor company, which entered this business without any foreign
collaboration. The company has beefed up its R&D capabilities in the last two to three years.
PTLs Swaraj-735 is in a class of its own and has been benchmarked by its competitors to which
16 new features have been added. PTL has single mindedly focused on increasing its market
share in tractors. Current Scenario During the first half of 2001-02 PTL increased its market
share from 18.5% to 21.4%. With the total industry volumes plummeting by 16.6% the sales of
PTL fell only a trifle 3.1%. Under these circumstances, though the revenue has fallen by a 0.38%
the operating profitability has risen by 1.03%. PTL garnered the operating margins of 19.4% in
the first half of FY2001-02, while the lead players like M&M Escorts and Eicher have reported
operating margins of 4.4%, 0.7% and 2.9% respectively. The Net Profit has increased by 1.4% to
Rs.564 million and the contribution of 40-50HP tractors has increased by 30%, which indicates
higher margins from bigger tractors due to a strong foothold in Punjab and Haryana markets.
1985: SWARAJ Industrial Forklift Trucks developed by own R&D, commercially introduced.
1986: SWARAJ ENGINES Ltd. promoted in technical and financial collaboration with Kirloskar
Oil Engines Ltd.(KOEL) for manufacture of diesel engines. PTL's equity participation is Rs. 6.9
million (33%) and that of KOEL's Rs 3.6 million (17%).
1995: Setup of tractor Plant II at Village Chappercheri with annual capacity of 12,000 per
annum.
1998: Commencement of expansion to 60,000 tractors (30,000 at each plant). Capital outlay of
Rs1000
million,
funded
mainly
through
internal
accruals.
1999: 5th and 6th tractor models - SWARAJ 733 (34 HP) & SWARAJ 744 (48 HP) developed by
own R&D, commercially introduced.
2000: Expansion of annual tractor capacity to 60,000 completed.
2001: PTL won National Championship trophy in competition organized by All India
Association Management (AIMA) for young managers. Economic times and Boston Consulting
Group selects PTL as one of the India's finest 10 companies out of Economic times top 500
Companies.
2003: PSIDC's disinvestment of its entire Equity holding (23.49%) in PTL in favour of CDC
Financial Services (Mauritius) Ltd. With this, total holding of CDC & its associates in PTL
stands at 28.48%.
2004: 7th & 8th tractor models - Swaraj 939 (41 HP) & Swarj 834 (34 HP) developed by own
R&D, commercially introduced.
2005: PTL disinvested 15,73,000 equity shares of Rs. 10/- each of Swaraj Mazda Ltd.
(constituting approx. 15% of SML's paid up capital) in favour of Sumitomo Corporation, Japan,
a joint venture partner in Swaraj Mazda Ltd. at a total consideration of Rs. 629.2 million
2007: CDC/Actis Group and Burman Family's disinvestment of their Equity holding in PTL
(43.3%) in favour of Mahindra Group (M&M).
M&M made open offer to shareholders for another 20% equity of the
Company.
Mahindra Group's equity holding in the Company stands at 64.6%
Cumulative Tractor Sales cross 600,000.
Swaraj Track Type Combine designed and developed by in-house R&D, commercially launched.
2008: Swaraj 3 Tonne Battery forklift, designed and developed by in-house R&D, commercially
launched
Punjab Tractors Ltd. (PTL) has commercially launched another model - Swaraj 939 FE
at a function in Indore.101 units of this new generation tractor were delivered to farmers
from all over Madhya Pradesh and Chhattisgarh, by Mr. R.Gopalan, Managing Director,
State Bank of Indore in the presence of PTL's Mr. Yash Mahajan (VC & MD) and Mr. A.M.
Sawhney (SVP-Mktg).
Powered by a future ready, fuel - efficient 41 HP SAE, three-cylinder water-cooled diesel
engine, Swaraj 939 FE has a constant mesh gear box, diaphragm clutch and neutral safety
switch. Upgraded variants of this model can also be supplied as per customer
needs/requirements.
S-724
MODELS
H.P.(SAE)
26.5
MAX PTO H.P.(PS)
22.4
MAX
TORQUE 9.5
KGM
NO.
OF 2
S-733
S-735
S-744
S-855
34
28.6
12.2
39
34.4
14.2
48
39.4
55
44.9
18.5
CYLINDERS
TYPE
BOREX
DI
100X110
DI
110X116
DI
100X110
DI
110X110
DI
110X116
STROKE(MM)
DISPLACEMENT
1728
2204
2592
3136
3308
ENGINE 2000
2000
2000
2000
2000
WATER
WATER
WATER
WATER
WITH OIL
WITH OIL
SC/305
(CC)
RATED
SPEED
COOLING
WATER
SYSTEM
TEST
REPORT
(AWAITED)
CLUTCH
TYPE SC/254
WITH OIL
SC/280
SC/280
SC/305
SYZE (MM)
NO OF GEARS 8+2
8+2
8+2
8+2
(fwd+rev.)
FWD.SPEEDS
2.1-24.9
2.3-24.9
3.1-29.3
3.4-31.6
RANGE (km/hr)
PTO RPM AT RATE 976
976
976
976
976
SPEED
TYPE
ADDC-
ADDC-
ADDC-
ADDC-
2.3-28.3
OF ADDC-
CONTROLS
STEERING
LIVE
MECHA-
LIVE
MECHA-
LIVE
MECHA-
LIVE
MECHA-
LIVE
MECHA-
BRAKES
NICAL
MECHA-
NICAL
MECHA-
NICAL
MECHA-
NICAL
MECHA-
NICAL
MECHA-
TYPES
NICAL
NICAL
NICAL
NICAL
NICAL
OF DRY DISK DRY DISK DRY DISK DRY DISK DRY DISK
BREAKES
TYPE
TRACTOR WEIGHT 1715
WHEEL
BASE 1815
TYPE
1750
1810
TYPE
1785
1955
TYPE
1930
1955
TYPE
1915
1950
(MM)
TYRE
6X16
6X16
6X16
6X16
12.4X28
12.4X29
13.6X28
13.6X28
SIZE 6X16
(FRONT)
TYRE SIZE (REAR)
12.4X27
The SWARAJ brand tractor has developed several series of models. These models are listed with
their bhps and other specifications:MODEL NAME
SWARAJ 855
SWARAJ 735
PARTICULARS
DUAL CLUTCH
(used for pouching)
SINGLE CLUTCH
(Used for harvester
combine.)
STANDARD MODEL
BHP
55 bhp introduced in 1983
SWARAJ 724
SWARAJ 720
SWARAJ 722
SWARAJ 744
SWARAJ 733
BIHAR SPECIAL
JALGAON SPECIAL
SOUTH SPECIAL
(depending upon the soil)
STANDARD MODEL
HARYANA SPECIAL
STAY BAR SPECIAL
STANDARD MODEL
STANDARD MODEL
STANDARD MODEL
STANDARD MODEL
Mahindra Group
64.64%
LIC/GIC/IFCI/BANKS
22.76%
Mutual Funds / Banks
2.07%
Other FIIs
0.53%
Public
10.00%
LEVEL 1: CHAIRMAN
LEVEL 2: WORKING DIRECTOR
LEVEL 3: EXECUTIVE DIRECTORS
LEVEL 4: VICE PRESIDENT
Production
Tool room
Quality Engineering
Maintenance
Construction
Support services
Management system
Finances
Purchase
LIGHT MACHINE SHOP
INTRODUCTION :
LMS is the largest section in the factory. All transmission components viz. shafts and gears used
in Tractors are manufactured here. It has 117 machines. Facilities of this shop include Equipment
for blank operation, boring drilling etc. Except the bevel gear generator & gear shaver, which
have been imported from WMW & Churchill of West Germany respectively, all other machines
are from HMT Ltd. The rupees thirty one million plant and machinery of this shop installed in
area of 33,000n sq. ft. and casting/forging and high standard of quality. This shop is manned by
160 highly experienced Operators & inspectors
Gear manufacture and grinding, machining of bull gears, bevel gears cutting of all rounds on
power hacksaws, facing and centering, all type of grinding inner and outer gears, hobbing and
broaching machine .Gear shaving, Gear deburring machine, drilling of all gears reporting
system, number of workmen shifts operations.
Gear Shaper
Drilling Center
Deburring Machine
Tuning Center
Power Hacksaw
Boring Machine
C N C lathe
C N C Grinding Machine
MACHINE SPECIFICATIONS
Identification number, type, make, broader specification viz. Machine no., make, type, overall
dimensions, no. of speed, speed range, no. of feed m feed range and other special information.
S.NO
COMPONENTS
S.NO
COMPONENTS
29
IDLER CLUSTER
30
INPUT SHAFT
BULL PINION
31
INTERNAL GEAR
BEVEL WHEEL LT
32
KPS ASSY
BEVEL WHEEL RT
33
LAY SHAFT
34
LT CAGE
CAGE ASSY
35
PLANET
CARRIER(744/855)
C.M GEAR
36
INTERMEDIATE GEAR
CONNECTING SHAFT
37
RT CAGE
10
CROSS
38
11
DRIVE SHAFT
39
GEAR TIMING
12
GEAR Z-18
40
GR IDLE ASSY
13
GEAR Z-24
41
BUSH
14
GEAR Z-25
42
GEAR IDLE
15
GEAR Z-26
43
16
GEAR Z-28
44
GR FIP
17
GEAR Z-29
45
G OIL PUMP DR
18
GEAR Z-30
46
19
GEAR Z-30
47
GEAR REV
20
GEAR Z-31
48
GR MAIN DRIVE
21
GEAR Z-34
49
GR COUNTER SHT
22
GEAR Z-35
50
PINION DIFF
23
GEAR Z-36
51
FLANGE COMPANION
24
GEAR Z-42
52
CASE DIFF GR LT
25
GEAR Z-49
53
BRG HSG
26
54
27
55
SHAFT MAIN
28
GEAR COUNTER(4WD)
56
GEAR OUTPUT(4WD)
Facing: It is the operation of finishing the ends of the work, to make the ends flat and
Tool room: jigs, fixtures and cutting tools, maintenance: attending breakdowns and carrying
out preventive maintenance of machine tools etc, Industrial engineering: provision of process
charts for machining operations, Assembly: ensuring proper fitment of components on a day to
day basis. Quality control and inspection, storage and inspection R&D. Heat treatment: Shot
blasting operations, lab testing, inspection etc
INTRODUCTION:
HMS & LMS both collectively have 161 machines that are used for manufacturing 90
components (Gears,shafts and housings) All heavy castings of tractors are machined in this shop
with the help of variety of special machines (SPM).These machines are tailor made by HMT to
suit component requirements. In addition, facilities of this shop include general-purpose turning,
drilling and milling machines. About 20 SPM and 30 GPM are installed in a covered area of
47,000 sq. ft. at a cost of 20 million, 2600 tones of castings are machined every year on a two
shift basis. In addition to the machining of castings for the tractor, some jobs are also performed
for Swaraj Mazda Limited.
Machining of heavy castings like differential housing, gear box housing, rear
cover, trumpet housing, steering housing of tractors, machining of tractor parts, machining of
some components for Mazda.
S.No.
Instruments
Size
Components
1.
Vernier calliper
0-100
2.
Vernier calliper
0-400
Gearbox hsg.
3.
Vernier calliper
0-600
Trumpet hsg.
4.
Micrometer
0-25
5.
Micrometer
25-50
6.
Micrometer
50-75
7.
Micrometer
75-100
8.
Micrometer
100-125
9.
Micrometer
125-150
10.
Micrometer
150-175
Cage assembly
11.
Depth vernier
0-200
Trumpet hsg.
12.
Bore gauge
10-18
13.
Bore gauge
18-35
14.
Bore gauge
35-60
Rear cover
o Rear Cover
o Trumpet Housing
TYPES OF MACHINES
Drilling: It is a process of making hole in an object by forcing a rotating tool called drill.
Boring: It is a process of enlarging a hole that has already been drilled.
Facing: It is the operation of finishing the ends of the work, to make the ends flat and
smooth & to make the piece of required length.
Chamfering: It is the operation of beveling the extreme end of the work piece. Chamfer is
provided for better look/ to rough turning: in this operation max. Metal is removed & very
little dimensions are left for further machining.
INTRODUCTION
SWARAJ TRACTOR DIVISION deals in the assembly of tractors SWARAJ 722, SWARAJ 724,
SWARAJ 735, SWARAJ 733 and SWARAJ 834.The assembly process is carried out on a main
line that has the various subassemblies along its length
The major work this shop undertakes is the over all assembly of the tractor. Various
components from the other shop are transported to this for their assembly. It consists of 100
highly skilled workmen. Their main work area includes
SECTIONS IN ASSEMBLY
o Cage Assembly
o PTO shaft assembly
o BPS L/R assembly
o Diff assembly and testing
o Trumpet housing and assembly
o Diff assembly and Trumpet housing assembly
o Gear box assembly and Testing
o Steering assembly
o
o Battery fitment
o Oil filing and battery filling
o Testing
The Assembly shop is the production shop where assembly and subassembly of all the parts take
place. The final processed parts from the various parts of production shop such as HMS, LMS,
and AND HEAT TREATMENT reach the assembly shop. The assembly shop can be divided into
various groups depending on subparts being assembled. These groups are:
If the car travels in a straight line, the two rear wheels turn on the road exactly at the same speed.
There is no relative movement between the two rear wheels. The propeller shaft may be geared
rigidly, in the case, with the rear axle to rotate the rear wheel together. But when the car takes the
turn, the outer wheel travels on the longer radius than the inner wheels. The outer wheel turns
faster than the inner wheel, i.e., there is the relative movement between the two rear wheel. If the
two rear wheels are rigidly fixed to a rear axle, the inner wheel will slip which will cause:-
Steering difficulties.
Therefore, there must be some devices to provide relative movement to the two rear wheels
when the car takes a turn. And here comes the purpose of differential.The differential is a
device that splits the engine torque two ways, allowing each output to spin at a different speed.
The differential is found on all modern cars and trucks, and also in many all-wheel-drive (fulltime four-wheel-drive) vehicles. These all-wheel-drive vehicles need a differential between each
set of drive wheels, and they need one between the front and the back wheels as well, because
the front wheels travel a different distance through a turn than the rear wheels.
Part-time four-wheel-drive systems don't have a differential between the front and rear wheels;
instead, they are locked together so that the front and rear wheels have to turn at the same
average speed. This is why these vehicles are hard to turn on concrete when the four-wheel-drive
system is engage
act as the final gear reduction in the vehicle, slowing the rotational speed of the
transmission one final time before it hits the wheels
DIFFERENTIAL ASSEMBLY
It consists of following sub-assemblies:1. Cage Assembly:
a. Left Cage: It consists of following parts:1
housing. PTO shaft transfers the torque from the gear box to other agricultural
equipments like Reaper, generator, etc.
2. Two Bull Gear:
These gears transfers torque from the Bull Pinion Shaft(BPS) to the rear axle
through trumpet assembly.
3. Differential Housing:
It is the casting that houses all the above Sub-Assemblies.
TESTING
Gearbox
Assembly
shafts Assembly
Assembly
Fork, gearshift
Steering assembly/
(f) Gears.
(j) Bearings.
Intermediate shaft:- It is the splined shaft consist of three gear which are axially movable
on the shaft. All the gear are provided with the collar, so that forks are fitted in these collars
and helps the gears to move axially. These gears are meshed with the gears on the lay shaft to
have the correct gear pair with required gear ratio. Only one pair is in mesh at one time so to
avoid
double
engaging.
4. Three forks:
5. Epicyclic gear train:- It is used to have high speed ratio between input shaft and output or
intermediate shaft. This is done by engaging hi-low gear. This gear train consist of
following sub-assemblies:
Internal gear.
Planet carrier.
Hi-low sleave.
Hi-low shaft.
Gears in neutral: When the engine is running and clutch is engaged, the CM gear drives the
layshaft gears. The layshaft rotates opposite in direction of the clutch shaft. Note that in
neutral position, only the CM gear is connected to the CM gear of the layshaft. Other gears
are free, and hence the transmission intermediate shaft is not turning. The vehicle is
stationary.
First or low speed gear: By operating the gear shift lever, the larger gear on the intermediate
shaft is moved along the shaft to mesh in the first gear of the layshaft. The intermediate shaft
turns in the same direction as the input shaft. Since the smaller layshaft gear is engaged with
the larger intermediate shaft gear, a gear reduction of approximately 3:1 if obtained. That is,
the input shaft turns three times for each revolution of the input shaft. Further gear reduction
in the differential at the rear wheels produces a still higher gear ratio, approximately 12:1,
between the engine crankshaft and the wheels.
Second speed gear: By operating the gearshift lever, the larger gear of the intermediate shaft
is demeshed from the first gear of the layshaft and then the smaller gear of the input shaft is
meshed with the second gear of the layshaft. The intermediate shaft turns in the same
direction as the input shaft. A gear reduction of approximately 2:1 is obtained. The
differential gear reduction increases this gear ratio to approximately 8:1.
Third, top or high speed gear: By operating the gear shaft lever, the second gear of the
intermediate shaft and layshaft are demeshed, and then the second and top gear of the input
shaft is forced axially against the CM gear of the input shaft. External teeth on the input shaft
gear mesh with the internal teeth in the second and top gear. The intermediate shaft turns with
the input shaft and the gear ratio of 1:1 is obtained. The differential reduction reduces a gear
ratio of about 4:1 between the engine crankshaft and the wheels.
Reverse gear: by operating the gear shaft lever, the larger gear of the intermediate shaft is
meshed with the lever idler gear. The reverse idler gear is always in mesh with the layshaft
reverse gear. Interposing the idler gear between the layshaft reverse gear and intermediate
shaft bigger gear, the intermediate shaft turns in the direction opposite to that of the input
shaft. This reverses the rotation of the wheels so that the vehicle backs.
High/Low Gear: High/low gear shifter enables to achieve either high torque-low speed or low
torque-high speed with the help of planet gear & carrier assembly.
High Gear: Low torque-high speed is achieved when hi-lo shifter is shifted in high gear position.
Coupling intermediate shaft and output shaft with the help of sleeve transmits the power.
LOW GEAR: High torque-low speed is achieved when hi-lo shifter is shifted in low gear
position. The power is transmitted to output shaft from intermediate shaft, planet gear and carrier
assembly and sleeve. The planet gear & carrier assembly reduces the high speed and
subsequently torque is increased.
Front tyres
Rear tyres
Fuel tank: its capacity is 60 lts (depending on the model)
Radiator: its function is to cool the engine by means of water.it cools the water and again
supplies it to the gallery for cooling.
Fan
Battery:12 v batteryis used . its function is that it helps in starting the engine.
Wiring
Dashboard : indicators are their for observing the performance.
Fender
Steering wheel
Air cleaner : it is situated at the front . its function is that it supplies the clean air to the
engine.
Sheet metal
Bonnet
Seat
Side seats
Filling up oil : 6 lts.
Stickers
HEAT TREATMENT
INTRODUCTION:
The heat treatment shop lays a very important role in the automobile Industry. Various parts such
as axles, gears, shafts etc. if not heat- treated will not work for a longer time. Heat treatment shop
at STD is adjoining the LMS. Most of the parts of tractors and Mazda manufactured in LMS are
heat treated here. The shop is equipped with several heating furnaces and testing machines. The
shop is manned by skilled staff and workers
All Transmission components after undergoing machining operation are subjected to heat
treatment. Heat treatment is done so as to improve hardness and strength of these components viz
gears and shafts.
TYPES OF FURNACES
MACHINE NAME
NO OF MACHINES
3. Quenching Tank
5. Tempering Machine
6. Lapping Machine
7. Hydraulic Press
8. Cutting Machine
(5). QUENCHING: -Quenching or rapid cooling from above the critical temp. by immersion in cold water or other cooling
medium, is a hardening treatment . It increases the strength of the metal and increases the wear resistance,
but makes the metal brittle and has low ductility.
(6). WASHING: -
After quenching the washing of the component is done. The washing us done to remove oil dust and
small chips from the surface of the components. The mixture of water and caustic soda is used for
washing. It is carried out in the washing tank where number of nozzles throws the mixture of water
and caustic soda at a very high pressure on the surface of components.
(7). TEMPERING: Tempering consist of reheating below the critical temperature. The quenched metal to restore some of
the ductility and to reduce the brittleness. Increased toughness is obtained at the expense of high
strength. The table representing the tempering of an intermediate shaft is shown below:
S.NO
TEMP.
D.F.A
1.
Loading
920-930 c
Nil
2.
Heating
600-650 c
Nil
cycle
At temp.
750-770 c
0.1-0.4 LPH
At temp
850-870 c
0.8-1.0 LPH
At temp.
910-930 c
3.
910-930 c
LPH
1.0-1.2LPH
Checked by carbon
0.4-1.2 LPH
Apparatus or by oxy
Probe.
4.
Diffusion
910-930 c
LPH
910-930
Nil
0.4-1.2
LPH
(Note)
6.
7.
Cooling
cycle
910-930 c
To
Of Quenching.
800-830 c
180-220 c
0.2-0.4
LPH
The process is carried out in 12min for bull gears, 19min for small gears. This time variation is given
according to the hardness of the gear or shaft e.g. if the hardness of the simple gear is from 30-35 we
will give 3-4 min for its shot blasting. If the hardness varies from 60-70 we will give 10-20 min for its
shot blasting no matter what is the size of gear.
PAINT SHOP
o Surface preparation(Pre Treatment Cell) carried out for sheets and rims
o Painting
o Inspection
o Rejection(Reprocessing)of sheets and rims
PRE TREATMENT CELL
1. Degreasing-1
2.
Degreasing-2
3. Water rinse-1
4.
De rusting
5. Water rinse-2
6.
Water rinse-3
7. Activation
8.
Phosphating
9. Water rinse-4
11 Passivation.
After components is rejected and repainted through the previous procedure.
1)
Sanding improper.
2)
10)
5)
6)
7)
Paint cloat.
8)
Orange peal.
9)
Denting on surface.
PAINTING
Primer Painting: A thin layer of primer paint is sprayed in the chassis so that the
final paint is strongly fixed on.
Final painting
Flash off
Smoothness
Uniformity
REJECTION
Thin coating
Vendor defect
Presence of dust
METHODS OF SURFACE PREPERATION
Washing
Drying
Primer painting
Flash off
Final painting
Flash off
Baking
PARAMETERS CHECKED
shade variation
Dust
Vendor fault
MATERIAL TESTING LABORATORY
Paint Testing
Rubber Testing
Forging and Casting
Forgings and Castings are pre-inspected before machining.
Check Dimension
as per drawing.
Metallurgical Test:
Depending on the criticality and size of lot, certain numbers of castings and forgings are selected
for testing. Thereafter a small piece is cut from each of these selected forgings and casting and
each of these piece undergoes following testing.
Chemical Composition Testing
Done using Computerized Spectrometer Here Argon gas is used and spark is produced. Thus
wavelength of spectrum produced is recorded in order to obtain chemical composition of the
forgings. Chemical Composition is generally Carbon, Tin, Chromium, Iron, and Nickel.
Microstructure Testing
Done on Microstructure Testing Machine. This test gives the arrangement of grains in the
chosen piece.
Hardness Testing
Done on Hardness tester Machine. Brinell hardness is checked prior to machining operation for
each of these castings and forgings. Thereafter heat treatment, Rockwell hardness is checked. For
extremely soft materials hardness testing is carried out on Microstructure Tester Machine.
PRODUCT SERVICE
1)TOOL ROOM:
In industry various types of tools are used. The tool room caters to the needs for
manufacturing of gigs, fixtures, gauges, dies, etc. During machining wear & tear of the tool
takes place. The tool room is provided in order to re-sharpen these tools.
FUCTIONS
Re-sharpening of the tools- whose wear & tear has taken place. This ensures that
there is no delay in production due to blunt tools.
New Jigs & Fixtures- In order to improve the production rate & quality of the work
& to decrease the job setting time, new jigs & fixtures are developed in the tool room.
Maintenance of old jigs & fixtures- Old jigs & fixtures that lose their accuracy due
to breakage or wear & tear are repaired in the tool room.
New development work- Any modification & development work is carried out in
tool room, for e.g. a new component is to be installed in a tractor, its die assembly is
developed in the tool room.
Manufacturing of measuring tools- Certain measuring tools used in the metrology
lab for quality check are manufactured in the tool room.
MACHINES USED IN TOOL ROOM.
Process planning
Plant and machinery
Work- study
APPLICATIONS OF M.E. DEPARTMENT:
Earlier it was mainly applied to manufacturing industries for improving methods of production,
to develop work standards or to formulate production control and wage policies.
Later on, the use of M.E. also spreaded to non-manufacturing activities such as construction and
transportation, farm and air-line operations and maintenance, public utilities, government and
military operations.But today it finds its major application in manufacturing plants and
industries.In an industry besides the production, other departments utilization M.E. concept is
marketing, finance, purchasing and industrial revolution etc.
2.98
8.56
11.54
(R.P.MTORQUE)/(7023.746)
H.P.
If the power calculated from above formula comes lower than prescribed limit than
usually fuel timing is altered. The fuel timing is altered with the help of F.I. pump. Usually the
engine is tested on 18 Celsius advancement By revolving the pump away from engine the
timing is reduced and by revolving F.I.P. toward the engine the time is advanced.
S.F.C.: It is one of the most important parameter for engine comparing. It is defined as the
ratio of amount of kg of fuel used per hour by the engine to power produced by the engine.
S.F.C.
Constant
297000
4.
Organization and interpretation of information received from the selling, purchasing and
engineering departments.
2.
What production steps have to be performed as well as where and when to perform them.
3.
Calculation of materials requirements
Development of detailed production schedules
CO-ORDINATION
This activity consists of initiating action, which brings the needed materials, tools etc to the
proper machines and at the scheduled times.
EVALUATION
It consists of constantly reviving of production materials, methods, tooling, operating times etc.,
so that the planned manufacturing results are realized in terms of quantity, quality, time, and
location.
OBJECTIVES OF PPC
From the above discussion it is clear that there are basically two major and important objectives
of PPC:
1.
Translate the information collected above into production schedules, such that the
over-all plant facilities are economically used and the production requirements of each
department are satisfied.
2.
Controlling the production activities
Trolleys
Chain conveyors
Hoists
Monorails
ROLE OF QA:
Audit compliance to Quality Systems for manufacturing and allied operations as apart of
Management Information System on quality.
SCOPE OF AUDIT:
Finished product quality
Inplant components quality
Output quality and compliance to quality systems at each stage/area of inplant
manufacturing operations
Outsource components quality
Compliance to specified quality systems by the Venders in their manufacturing
operations.
AUDIT CONCERN:
Audit from periodic check on conformance to quality systems,audit concerns arise from feed
back on
Warranty
Field failure
Dealer pre delivery inspection
In house pre delivery inspection
Quality engineering reports on inplant and out sourced components
KEY AREAS:
Tractors ready for dispatch to dealers after final quality certification by Quality Engineering
(QE) department.
1
2
3
4
5
6
7
Tractors as dismounted from assy. Line before any rework is carrie3d out on them. this is
in pursuit of the operations objective of Zero defect dismount and dispatch
Stage wise audit of assembly shop operations.
Paint shop operations.
Outsource components reaching the assembly line.
Machine shop operations.
Inplant components reaching the assembly line.
Audit at Vender premises to check on compliance to prescribed Quality System in their
manufacturing operations.
AUDIT METHODOLOGY:-
Step-1: Refer to quality systems pertaining to the subject under audit in terms of
-Drawing / Specifications for output quality
-process sheets/job description for job contents,method , tools and measurement criteria.
-Quality Engineering specipications like controls charts and check lists.
Step-2: Prepare check lists specifying attributes to be audited and sample size.
6) MAINTANENCE DEPARTMENT
INTRODUCTION:
Many changes have taken place in the maintenance system and practice used in the industries
with the progress made by technology. Along with production, maintenance plays vital role. In
fact production and maintenance go side by side if a machine is under breakdown, it can not
subjected to production process with the advent of new modern technology, the entire concept of
maintenance has changed. Earlier maintenance practices were only confined to breakdown
maintenance, but now different types of maintenance practices are followed like:
1. Scheduled maintenance
2. Break down maintenance
3. Preventive maintenance
4. predictive maintenance
To achieve the minimum breakdown level and to achieve the production target at
low cost.
Machine and other facilities should be arranged so that they can be used to their
max capacity
The maintenance division of the factory ensures the availability of all the facilities
necessary for the performance of functions at optimum return of investment.
IMPORTANCE OF MAINTANENCE
1. Equipment break down leads to inevitable loss of production time ,which is prevented by
maintenance department
2. Plant maintenance plays an important role in the production management by preventing
breakdowns which caves inevitable shortfall of target, needs sub contracting work,
rescheduling of production, need of over time etc.
3. Routine check ups of facilities ensure safe and efficient operation of machinery
4. Maintains optimum production efficiency of machinery.
5. Helps in maintaining the operational accuracy and reduces the work content
6. Reduce breakdowns and concerned downtimes thus achieving the target of max
production at min cost.
7. Ensure safety of life and limbs of workers and machine operators.