Mahindra and Mahindra Limited | Swaraj Division

PROJECT Report

Submitted by: Name:- Anish rohilla Roll no.-5305 /2k11 Registration no: - 110095302541 Trade:- Mechanical Engineering

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The Indian Tractor Industry Introduction and Business DescriptionSwaraj Tractor Division - Mahindra and MahindraLimited Background of the company Timeline of the company Company Organization chart Manufacturing facilities at plant -1 Light machine shop. Heavy machine shop. Paint shop Assembly shop Heat treatment shop Quality Engineering Products and specifications Project Reports 1. Project 1 (Elimination / reduction of watermixing in the engine oil ). 2. Project-2 (Elimination / reduction of diesel leakage from fuel cock)

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Many people have contributed to the success of this. Although a single sentence hardly suffices. I extend my sincere and heart felt thanks to Mr K.L Meena, Lecturer, for providing us the right ambience for carrying out this work. Express my immense pleasure to all the teachers and staff of the C.C.E.T for their cooperation and support. Last but not the least, I thank all others, and especially my classmates who in one way or in another helped me in the successful completion of this work.

India is mainly an agricultural country. Agriculture accounts for approximately 25 percent of Indias GDP. Agriculture in India is the means of livelihood of almost two thirds of the workforce in the country and employs nearly 62 percent of the population. It accounts for 13 percent of Indiasex ports. About 42 percent of Indias geographical area is used for agricultural activities. It is therefore considered a vital sector of the Indian economy.

The Indian tractor industry is the largest in the world, accounting for one third of global production.The other major tractor markets in the world are China and the USA. The global spotlight on tractormanufacture in terms of unit volume seems to be swinging away from the USA, UK and Western andEastern Europe towards India and China, where growth in the number of producers and the totalvolume of production in recent years has been impressive. Until 1960, the demand for tractors was met entirely through imports. Indigenous manufacture of tractors began in 1961, but India continued to import tractors to bridge the total volume needs up to the late 1970s. The Indian Tractor Industry has come a long way since then. Volume growth in the past four decades show a compound annual growth rate of 10 percent, despite seasonal variations that cause natural fluctuations in the demand for tractors, subsequently impacting the industry volumes. The Indian Tractor Industry has numerous challenges, some of them being:1. Reducing the average age of tractor buyers from the age group of above 40 to younger people. 2.Development of new products using latest technology and advancements in the field of electronics and mechatronics and making the tractors more comfortable, stylish and yet keeping them in range of a farmer. 3.Reduction of emissions in accordance with the new international emission standards

A number of manufacturing facilities are available at the Mahindra and Mahindra, Swaraj Division, Plant -1The whole manufacturing system is divided into a number of departments 1.Light machine shop 2.Heavy machine shop 3.Paint shop 4.Assembly shop 5.Heat treatment shop 6. Quality Engineering

LMS is the largest section in the factory. All transmission components including 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 Rs. 31 million plant and machinery of this shop are installed in an area of 33,000 sq. ft. and casting/forging and bar worth Rs. 24 million are machined annually. In view of complexity of operation and high standard of quality this shop is manned by 160 highly experienced operators and inspectors.

All heavy casting of tractors are machined in this shop with the help of variety of special machine(SPM). These machines are tailors made by IIMT to suit component requirements. In addition, Page | 8facilities 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 casting for the tractor, some jobs are also performed for Swaraj Mazda Limited

Paint Shop is the place where the different sheet metal components are painted. They are made to pass through various chemicals before they are actually painted. The painting method opted is that of Spray Painting. The paint shop at the plant is equipped with the washing and drying facility for the engine and transmission section of the plant as well as the sheet metal components of the tractor.

The Assembly line at Swaraj Tractor division deals with the assembly of tractor models 722, 724, 733, 735FE, 735 XM, 744, 834. Assembly is the joining of various constituents to form a final product. The assembly process is carried out on the main line, which has various sub assemblies along its length. Assembly shop can be divided in two main areas: 1. Before paint area 2.After paint area. Before paint area The area before painting can further be divided into sub assemblies/ loops namely a)Differential loop. b)Gearbox loop

C ) Rear cover loop.

D) Engine assembly loop

Quality engineering is that department of the plant that deals with the analysis of a manufacturing systemat all stages, to improve the quality of the production process and of its output. It is divided into two parts:1.Suppliers quality Suppliers section consists of maintaining the quality of products that are being supplied bysuppliers. It contains inspection of the raw materials being supplied by suppliers. It alsoincludes discussion regarding delay of raw material and defective parts supplied.Subsequent actions are taken if the supplied products being supplied are found defectiveand inspectors from the industry are sent regularly to avoid such defects. This inspectionis regularly done by the industry so maintain good quality supply and sound relationshipwith suppliers. 2.In-House Quality It is said the prevention is better than cure. To eliminate any problem in the furtherstages, In house quality is embedded into every department of the industry. As such thereare six in-house quality check posts: Q.E.L.M.S (Light Machine Shop) Q.E.H.M.S (Heavy Machine Shop) Q.E.H.T (Heat Treatment)

 Q.E.P.M (Plant maintenance) Q.E.A (Assembly) IQS Pre-Dispatch inspection (Final check post)

P.D.I (Pre Dispatch Inspection) is the final quality post which carries a major responsibility of dispatching the tractors as manufactured by the assembly line of plant-1. This is similar to giving final touches to the jewellery being sold. This department carries rigorous checks as per the pre-designed checklist prior to dispatch of machinery. P.D.I acts as one of the major diagnosing center for every daily to daily outgoing failure and scrutinizing them and hopefully trying to remove these failures. This way forthcoming problems reported by dealers are reduced. This helps to maintain a healthy relationship with dealers and customers.

1. TRANSMISSION FLUID LEVEL 2. ENGINE OIL LEVEL 3. FUEL INJECTION PUMP OIL LEVEL 4. WATER LEVEL IN RADIATOR 5. ELECTRICAL FUCTIONING 6. COMPONENT STORAGE 7. CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER

Transmission oil dipstick

Fuel Injection Pump

This washing of the tractors with high pressure takes place on the assembly line before the Paint shop, where the engine assembly is washed, dried and then painted.

In certain cases oil level in oil sump is found high and water level in radiator low. In other cases there is no rise in oil level. In all the cases engine oil red colour turns whitish ( milky ) as shown in the photograph

The water-mix paste turns to a milky colour when it comes in contact with water in the oil

Air leakage test is done to find out any points of leakage in the equipment. In the present situation the air leakage test was performed on the engine assembly to find out and leakage point from where water was supposedly getting mixed with the engine oil in the sump. After the test was performed, following results were observed. -Air leakage observed from breather pipe joint in three cases-2 KOEL engines & 1 SEL engines. Air leakage observed oil filler cape in one case SEL Air leakage observed from dipstick one caseASSEMBLY

1. Sealant not applied properly between Breather Pipe bush Outer Diameter and Oil Fillerbody Inner Diameter. 2. Rubber Plug (Bellow) eccentric and not perpendicular w.r.t. cap. (Oil filler cap). 3. Rubber Plug head Diameter less as per Design.

4.Steel Washer ineffective in Oil Filler Cap Assy. 5.Dipstick design not adequate. 6.Flash over Plastic Outer Diameter due to plastic molding (Dipstick).

Sr.No Root Cause

1 Sealant not applied properly (breather pipe bush ) Rubber plug eccentric and not perpendicularw.r.t. cap (oil filler cap)

Remedial Action
SOP provided and operators were educated as per SOP at the suppliers end New welding fixture designed( J68080 ). Alternate design for nut welding provided(vides drawing no.V085633/1) Diameter changed from 61mm to 63.5 Design changed 1 ) Steel washer replaced with O rin Dipstick head made cupshaped O ring thickness increased from 2mm to 2.15 mm Dye re-work schedule made(50,000 cycles

Rubber plug head diameter less

4 Steel washer ineffective in oil filter cap assembly

5 Dipstick design inadequate

Flash over plastic molding (dipstick)