ANIKET

1

PREFACE If you know the laws of buoyancy it doesn’t mean that you know

how to swim. It is only through jumping in the water that you getthe

feel of the depth. This is applicable to every aspect of life.Therefore

practical training is of utmost importance.The object of undergoing

this training was to get familiar with the weary waters of the industry

and to learn how to put theory into practice. I have been greatly

privileged to have undergone training at MAHINDRA &

MAHINDRA SWARAJ TRACTORS DIVISION.

This report contains the extract of things I learned during my

training period.

INDUSTRIAL TRAINING REPORT BY : ANIKET CHOUDHARY

2

ACKNOWELEGEMENT

Any endeavor cannot lead to success unless and until a proper platform is provided for the same. This is the reason I find myself very fortunate to have undergone my industrial training of four weeks at MAHINDRA & MAHINDRA SWARAJ DIVISION, MOHALI. The persons of my department and all other departments have extended a warm and helping hand. I am very fortunate to have had a chance to feel the gravity of what role Mechanical Engineering plays in the industry. It was a golden opportunity for me to get a chance to experience what t feels to be in a company where discipline, quality and hard work are the motto. This training helped me a lot in bridging the gap between the theoretical and the practical aspects of my knowledge. First of all I would like to thank Mr.Vishu Sharma for his valuable guidance & encouragement as a teacher and a friend throughout my training period.I am also thankful to MR. J. SINGH for giving me an opportunity to undergo training in such a renowned company. In the end I would like to thank my head of department MR. GURDEV SINGH for giving us permission for the most valuable experience of my life.Their experience & knowledge motivated me to bring out the best in times. I am sure that the knowledge & information that I have gained during this period would be of immense value for my growth in the field of Mechanical Engineering.


3

ANIKET CHOUDHARY

CONTENTS

INTRODUCTION TO TRACTORS

TRACTOR DESIGN, POWER AND TRANSMISSION.

INDIAN TRACTOR INDUSTRY.

THE MATURING YEARS IN INDIAN TRACTOR INDUSTRY.

HISTORY OF SWARAJ.

MILESTONES.

TECHNICAL COLLABORATIONS AND PRODUCTS & SERVICES

WEEK # 1

WEEK # 2

WEEK # 3

WEEK # 4

SPECIFICATIONS OF THE PRODUCTS.

BIBLIOGHRAPHY


4

INTRODUCTION TO TRACTORS

A tractor is a vehicle specifically designed to deliver a high tractive effort (or torque) at slow speeds, for the purposes of hauling a trailer or machinery used in agriculture or construction. Most commonly, the term is used to describe the distinctive farm vehicle: agricultural implements may be towed behind or mounted on the tractor, and the tractor may also provide a source of power if the implement is mechanized. Another common use of the term, "tractor unit", describes the power unit of a semi-trailer truck (articulated lorry).

The word tractor was taken from Latin, being the agent noun of trahere "to pull”. The first recorded use of the word meaning "an engine or vehicle for pulling wagons or ploughs" occurred in 1901, displacing the earlier term traction engine

The first powered farm implements in the early 1800s were portable engines – steam engines on wheels that could be used to drive mechanical farm machinery by way of a flexible belt. Around 1850, the first traction engines were developed from these, and were widely adopted for agricultural use. The first tractors were steam-powered plowing engines. They were used in pairs, placed on either side of a field to haul a plow back and forth between them using a wire cable. Where soil conditions permitted (as in the United States) steam tractors were used to direct-haul plows, but in the UK and elsewhere plowing engines were used for cable-hauled plowing instead. Steam-powered agricultural engines remained in use well into the 20th century until reliable internal combustion engines had been developed.[4]

In 1892, John Froehlich invented and built the first gasoline/petrol-powered tractor in Clayton County, Iowa, USA. After receiving a patent Froelich started up the Waterloo Gasoline Engine Company, investing all of his assets which by 1895, all would be lost and his business resigned to become a failure.[5][6][7]


5

After graduating from the University of Wisconsin, Charles W. Hart and Charles H. Parr developed a two-cylinder gasoline engine and set up their business in Charles City, Iowa. In 1903 the firm built fifteen "tractors". A term with Latin roots coined by Hart and Parr and a combination of the words traction and power. The 14,000 pound #3 is the oldest surviving internal combustion engine tractor in the United States and is on display at the Smithsonian National Museum of American History in Washington D.C. The two-cylinder engine has a unique hit-and-miss firing cycle that produced 30 horsepower at the belt and 18 at the drawbar.

In Britain, the first recorded tractor sale was the oil-burning Hornsby-Ackroyd Patent Safety Oil Traction engine, in 1897. However, the first commercially successful design was Dan Albone's three-wheel Ivel tractor of 1902. In 1908, the Saunderson Tractor and Implement Co. of Bedford introduced a four-wheel design, and went on to become the largest tractor manufacturer outside the U.S. at that time.

While unpopular at first, these gasoline-powered machines began to catch on in the 1910s when they became smaller and more affordable.[8] Henry Ford introduced the Fordson, the first mass-produced tractor in 1917. They were built in the U.S., Ireland, England and Russia and by 1923; Fordson had 77% of the U.S. market. The Fordson dispensed with a frame, using the strength of the engine block to hold the machine together. By the 1920s, tractors with a gasoline-powered internal combustion engine had become the norm.

Tractor design, power and transmission

Tractor configurations

Tractors can be generally classified as two-wheel drive, two-wheel drive with front wheel assist, four-wheel drive (often with articulated steering), or track tractors (with either two or four powered rubber tracks).

The classic farm tractor is a simple open vehicle, with two very large driving wheels on an axle below and slightly behind a single seat (the seat and steering


6

wheel consequently are in the center), and the engine in front of the driver, with two steerable wheels below the engine compartment. This basic design has remained unchanged for a number of years, but enclosed cabs are fitted on almost all modern models, for reasons of operator safety and comfort.

In some localities with heavy or wet soils, notably in the Central Valley of California, the "Caterpillar" or "crawler" type of tracked tractor became popular in the 1930s, due to superior traction and floatation. These were usually maneuvered through the use of turning brake pedals and separate track clutches operated by levers rather than a steering wheel.

A modern 4-wheel drive farm tractor

Four-wheel drive tractors began to appear in the 1960s. Some four-wheel drive tractors have the standard "two large, two small" configuration typical of smaller tractors, while some have four large powered wheels. The larger tractors are typically an articulated center-hinged design steered by hydraulic cylinders that move the forward power unit while the trailing unit is not steered separately.

In the early 21st century, articulated or non-articulated, steerable multi-track "tractors" have largely supplanted the "Caterpillar" type for farm use. Larger types of modern farm tractors include articulated four wheel or eight wheel drive units with one or two power units which are hinged in the middle and steered by hydraulic clutches or pumps. A relatively recent development is the replacement of wheels or steel crawler-type tracks with flexible steel-reinforced rubber tracks, usually powered by hydrostatic or completely hydraulic driving mechanisms. The


http://en.wikipedia.org/wiki/File:Modern-tractor.jpg

7

configuration of these tractors bears little resemblance to the classic farm tractor design.

Engine and fuels

The predecessors of modern tractors, traction engines, used steam engines for power. Since the turn of the 20th century, internal combustion engines have been the power source of choice. Between 1900 and 1960, gasoline was the predominant fuel, with kerosene and ethanol being common alternatives. Generally one engine could burn any of those, although cold starting was easiest on gasoline. Often a small auxiliary fuel tank was available to hold gasoline for cold starting and warm-up, while the main fuel tank held whatever fuel was most convenient or least expensive for the particular farmer. Dieselization gained momentum starting in the 1960s, and modern farm tractors usually employ diesel engines, which range in power output from 18 to 575 horsepower (15 to 480 kW). Size and output are dependent on application, with smaller tractors for lawn mowing, landscaping, orchard work, and truck farming, and larger tractors for vast fields of wheat, maize, soy, and other bulk crops. Liquefied petroleum gas (LPG) or propane also have been used as tractor fuels, but require special pressurized fuel tanks and filling equipment so are less prevalent in most markets.

Transmission


http://en.wikipedia.org/wiki/File:Wheat_Planting_Rig_May_2007.jpg

8

Older farm tractors use a manual transmission. They have several gear ratios, typically 3 to 6, sometimes multiplied into 2 or 3 ranges. This arrangement provides a set of discrete ratios that, combined with the varying of the throttle, allow final-drive speeds from less than one mile per hour up to about 25 miles per hour (40 km/h), with the lower speeds used for working the land and the highest speeds used on the road.

Slow, controllable speeds are necessary for most operations that are performed with a tractor. They help give the farmer a larger degree of control in certain situations, such as field work. However, when travelling on public roads, the slow operating speeds can cause problems, such as long queues or tailbacks, which can delay or annoy motorists in cars and trucks. These motorists are responsible for being duly careful around farm tractors and sharing the road with them, but many shirk this responsibility, so various ways to minimize the interaction or minimize the speed differential are employed where feasible. Some countries (for example the Netherlands) employ a road sign on some roads that means "no farm tractors". Some modern tractors, such as the JCB Fastrac , are now capable of much higher road speeds of around 50 mph (80 km/h).

An older model European farm tractor.

Older tractors usually have unsynchronized transmission design, which often requires that the operator stop the tractor in order to shift between gears. This mode of use is inherently unsuited to some of the work that tractors do, and has been circumvented in various ways over the years. For existing unsynchronized tractors, the methods of circumvention are double clutching or power-shifting, both of


http://en.wikipedia.org/wiki/File:OlderModelTractor.JPG

9

which require the operator to rely on skill to speed-match the gears while shifting. Both of these solutions are undesirable from a risk-mitigation standpoint because of what can go wrong if the operator makes a mistake – transmission damage is possible, and loss of vehicle control can occur if the tractor is towing a heavy load either uphill or downhill – something that tractors often do. Therefore, operator's manuals for most of these tractors state that one must always stop the tractor before shifting, and they do not even mention the alternatives. As already said, that mode of use is inherently unsuited to some of the work that tractors do, so better options were pursued for newer tractor designs.

Cutaway of modern tractor

Hitches and power applications

The power produced by the engine must be transmitted to the implement or equipment in order to do the actual work intended for the equipment. This may be accomplished via a drawbar or hitch system if the implement is to be towed or otherwise pulled through the tractive power of the engine, or via a pulley or power takeoff system if the implement is stationery, or a combination of the two.

Drawbars

Until the 1950s, plows and other tillage equipment usually were connected to the tractor via a drawbar, or a proprietary connecting system. The classic drawbar is simply a steel bar attached to the tractor (or in some cases, as in the early Fordsons,


http://en.wikipedia.org/wiki/File:John_Deere_3350_tractor_cut.JPG

10

cast as part of the rear transmission housing) to which the hitch of the implement was attached with a pin or by a loop and clevis. The implement could be readily attached and removed, allowing the tractor to be used for other purposes on a daily basis. If the tractor was equipped with a swinging drawbar, the drawbar could be set at the center or offset from center to allow the tractor to run outside the path of the implement.

The drawbar system necessitated that the implement have its own running gear (usually wheels) and in the case of a plow, chisel cultivator or harrow, some sort of lift mechanism to raise it out of the ground at turns or for transport. Drawbars necessarily posed a rollover risk depending on how the tractive torque was applied. The Fordson tractors (of which more units were produced and placed in service than any other farm tractor) was extremely prone to roll over backwards due to an excessively short wheelbase. The linkage between the implement and the tractor usually had some slack which could lead to jerky starts and greater wear and tear on the tractor and the equipment.

A large modern John Deere model 9400 four wheel drive tractor with tripled wheels and a drawbar-towed tool chain including one-pass tillage equipment, planter and fertilizer applicator

with tanks

Drawbars were appropriate to the dawn of mechanization, because they were very simple in concept and because as the tractor replaced the horse, existing horse-drawn implements usually already had running gear. As the history of


http://en.wikipedia.org/wiki/File:Modern_John_Deere_Tractor_IMG_0401.JPG

11

mechanization progressed, however, the advantages of other hitching systems became apparent, leading to new developments. Depending on the function for which a tractor is used, however, the drawbar is still one of the usual means of attaching an implement to a tractor.

Fixed mounts

Some tractor manufacturers produced matching equipment that could be directly mounted on the tractor. Examples included front-end loaders, belly mowers, row crop cultivators, corn pickers and corn planters. In most cases, these fixed mounts were proprietary and unique to each make of tractor, so that an implement produced by John Deere, for example, could not be attached to a Minneapolis Moline tractor. Another disadvantage was that mounting usually required some time and labor, resulting in the implement being semi-permanently attached with bolts or other mounting hardware. Usually it was impractical to remove the implement and reinstall it on a day-to-day basis. As a result, the tractor was unavailable for other uses and dedicated to a single use for an appreciable period of time. An implement generally would be mounted at the beginning of its season of use (such as tillage, planting or harvesting) and removed only when the likely use season had ended.

Three-point hitches and quick hitches

The drawbar system was virtually the exclusive method of attaching implements (other than direct attachment to the tractor) before Harry Ferguson developed the three-point hitch. Equipment attached to the three-point hitch can be raised or lowered hydraulically with a control lever. The equipment attached to the three-point hitch is usually completely supported by the tractor. Another way to attach an implement is via a Quick Hitch, which is attached to the three-point hitch. This enables a single person to attach an implement quicker and put the person in less danger when attaching the implement.


12

A modern three point hitch

The three-point hitch revolutionized farm tractors and their implements.

Almost every tractor today features Ferguson's 3 point linkage or a derivative of it. The three-point hitch allows for easy attachment and detachment of implements while allowing the implement to function as a part of the tractor almost as if it were attached by a fixed mount. Previously, when the implement hit an obstacle the towing link would break or the tractor could flip over. Ferguson's genius was to combine a connection via two lower and one upper lift arms that were connected to a hydraulic lifting ram. The ram was in turn connected to the upper of the 3 links so that increased drag (as when a plough hits a rock) caused the hydraulics to lift the implement until the obstacle was passed.

Power take-off systems and hydraulics

In addition to towing an implement or supplying tractive power through the wheels, most tractors have a means to transfer power to another machine such as a baler, swather, or mower. Unless it functions solely by pulling it through or over the ground, a towed implement needs its own power source (such as a baler or combine with a separate engine) or else a means of transmitting power from the tractor to the mechanical operations of the equipment.

Early tractors used belts or cables wrapped around the flywheel or a separate belt pulley to power stationary equipment, such as a threshing machine, buzz saw, silage blower, or stationary baler. In most cases, it was not practical for the tractor and equipment to move with a flexible belt or cable between them, so this system necessitated that the tractor remain in one location with the work brought to the


http://en.wikipedia.org/wiki/File:Tractor3pointhitchDubMay04.jpg

13

equipment, or that the tractor be relocated at each turn and the power set-up reapplied (as in cable-drawn plowing systems used in early steam tractor operations).

A PTO shaft connected to a tractor.

Modern tractors use a power take-off (PTO) shaft to provide rotary power to machinery that may be stationary or pulled. The PTO shaft generally is at the rear of the tractor, and can be connected to an implement that is either towed by a drawbar or a three-point hitch. This eliminates the need for a separate implement-mounted power source, which is almost never seen in modern farm equipment.

Virtually all modern tractors can also provide external hydraulic fluid and electrical power to the equipment they are towing, either by hoses or wires.


http://en.wikipedia.org/wiki/File:TractorPTOshaftMay04.jpg

14

INDIAN TRACTOR INDUSTRY

Introduction

As commercialization of agriculture grew in intensity in the mid-to-late 19th century the British Raj and the local legislatures and provinces began investing in agricultural development through support and establishment agricultural research farms and colleges and large scale irrigation schemes yet the level of mechanization was low at the time of independence in 1947. The socialist oriented five year plans of the 1950s and 60s aggressively promoted rural mechanization via joint ventures and tie-ups between local industrialists and international tractor manufacturers. Despite this aggressiveness the first three decades after independence local production of 4-wheel tractors grew slowly. Yet, by the late 1980s tractor production was nearly 140,000 units per year and by the late 1990s with production approaching 270,000 per year, India over-took the United States as the world's largest producer of four-wheel tractors with over 16 national and 4 multi-national corporations producing tractors today. Despite these impressive numbers FAO statistics estimate that of total agricultural area in India, less than 50% is under mechanized land preparation, indicating large opportunities still exist for agricultural mechanization.

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, India’s large gross cropped area (GCA) is next only to the big two — USA and Russia. That and the highly fragmented land holdings in India have helped 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


15

position in the world.

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.

With the successful introduction and acceptance of the high yielding seeds, however, there was a sudden upsurge in the demand for tractors after 1967 and the demand started multiplying at an annual rate of approximately 50% (1967:18,000; 1970: 33,000). The Government’s decision to freely invite new entrepreneurs to manufacture tractor 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:


16

THE MATURING YEARS IN INDIAN TRACTOR INDUSTRY

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 indigenization was also given by the overall industrialization of the country, when a large number of ancillary manufactures had also established them and were in a position to supply a wide variety of components to the tractor industry.

1945 to 1960

War surplus tractors and bulldozers were imported for land reclamation and cultivation in mid 1940's. In 1947 central and state tractor organizations were set up to develop and promote the supply and use of tractors in agriculture and up to 1960, the demand was met entirely through imports. There were 8,500 tractors in use in 1951, 20,000 in 1955 and 37,000 by 1960.

1961 to 1970


17

Local production began in 1961 with five manufacturers producing a total of 880 units per year. By 1965 this had increased to over 5000 units per year and the total in use had risen to over 52,000. By 1970 annual production had exceeded 20,000 units with over 146,000 units working in the country.

1971 to 1980

Six new manufacturers were established during this period although three companies (Kirloskar Tractors, Harsha Tractors and Pittie Tractors) did not survive. Escorts Ltd. began local manufacture of Ford tractors in 1971 in collaboration with Ford, UK and total production climbed steadily to 33,000 in 1975 reaching 71,000 by 1980. Credit facilities for farmers continued to improve and the tractor market expanded rapidly with the total in use passing the half million mark by 1980.

1981 to 1990

A further five manufacturers began production during this period but only one of these survived in the increasingly competitive market place. Annual production exceeded 75,000 units by 1985 and reached 140,000 in 1990 when the total in use was about 1.2 million. Then India - a net importer up to the mid-seventies - became an exporter in the 1980s mainly to countries in Africa.

1991 to 1997

Since 1992, it has not been necessary to obtain an industrial license for tractor manufacture in India. By 1997 annual production exceeded 255,000 units and the national tractor population had passed the two million mark. India now emerged as one of the world leaders in wheeled tractor production.

1997 to 1999

Five new manufacturers have started production since 1997. In 1998 Bajaj Tempo, already well established in the motor industry, began tractor production in Pune. In April of the same year New Holland Tractor (India) Ltd launched production of 70 hp tractors with matching equipment. The company is making a $US 75 million initial investment in a state of the art plant at Greater Noida in Uttar Pradesh state with an initial capacity of 35000 units per year. Larsen and Toubro have


18

established a joint venture with John Deere, USA for the manufacture of 35-65 hp tractors at a plant in Pune, Maharashtra and Greeves Ltd will produce Same tractors under similar arrangements with Same Deutz-Fahr of Italy. Looking to South American export markets Mahindra and Mahindra are also developing a joint venture with Case for tractors in the 60-200 hp range. Total annual production was forecast to reach 300,000 during the following year.

1999 to Present

Facing market saturation in the traditional markets of the north west (Punjab, Haryana, eastern Uttar Pradesh) tractors sales began a slow and slight decline. By 2002 sales went below 200,000. Manufacturers scrambled to push into eastern and southern India markets in an attempt to reverse the decline, and began exploring the potential for overseas markets. Sales remained in a slump, and added to the market saturation problems also came increased problems of "prestige" loan defaults, where farmers who were not financially able took tractors in moves to increase their families prestige. There are also reported increased misuse of these loans for buying either lifestyle goods, or for social functions. Government and private banks have both tightened their lending for this sector adding to the industry and farmers woes. By 2004 a slight up tick in sales once again due to stronger and national and to some extent international markets. But by 2006 sales once again were down to 216,000 and now in 2007-08 have slid further to just over 200,000.

Tractor Manufacturers Association

The Tractor Manufacturers' Association of India (TMA) is housed under The Confederation of Indian Industry (CII), New Delhi. Though not all manufacturers are members TMA is recognized as the main trade group representing the agricultural tractor industry in India. Mallika Srinivasan, Economic Times Businesswoman of the year 2006, and CEO of TAFE Limited, is currently serving as president.

Current Manufacturers of Tractors in India

Angad Tractors, SAS Motors Limited

Balwan Tractors, Force Motors Ltd

Captain Tractors Pvt. Ltd


http://sasmotors.net/

http://en.wikipedia.org/wiki/Confederation_of_Indian_Industry

19

Crossword Agro Industries

Eicher

Escorts (Escort, Powertrac and Farmtrac)

HMT Tractors

Indo Farm

John Deere

Mahindra Gujarat Tractor Limited

Mahindra & Mahindra

MARS Farm Equipments Ltd.

New Holland

Preet Tractors

Mahindra & Mahindra Tractor Swaraj Division

Same Deutz-Fahr Ltd.

Sonalika (International Tractors Ltd.)

Standard Tractor

TAFE

VST Tillers

Asian Tractors Ltd

Ford Tractors

Harsha Tractors

Haryana Tractors Ltd

Kirloskar Tractors


20

Pittie Tractors

United Auto Tractors Ltd.

Future potential

With a total of 140 million hectares and with the performance of around 3.18 lac tractors in the year 2008 - 2009, India today stands as the largest manufacturer of tractors in the world. With the average number of tractors in India per hectare well below the world average, the Indian market is a market with a huge untapped potential. India is the largest market for the below 50 HP tractors in the world. In international markets, the average HP of tractors used is around 80 -100 HP. At present the Indian tractor industry is among the select few in the world that is growing.

HISTORY OF SWARAJ

In the mid-sixties, with the Green Revolution triggering large-scale tractor usage, there was a need for the country to build sufficient indigenous capacity to meet thisgrowing demand

In 1965, the Central Mechanical Engineering Research Institute (CMERI), Durgapur initiated design and development of Swaraj Tractor based on indigenous know how. That is how the idea for development of what was to become Swaraj was initiated. The first prototype was ready in May 1967 and by April 1970, field experience of over 1,500 hours had been gained. At that point, it was decided to christen a name for the product – signifying Indian, easy to pronounce and signifying power and grace. The name `Swaraj', was approved by the then Prime Minister,MrsIndiraGandhi.

In 1970, the Government of Punjab acquired the Swaraj tractor's design and established Punjab Tractors Limited (PTL). The tractors were produced and sold under the brand name of Swaraj. In 2007, Mahindra & Mahindra Ltd. acquired


21

majority stake in PTL, and in Feb 2009, it was merged into M&M as the Swaraj Division of Mahindra & Mahindra.

Origin of the word “SWARAJ”

The word SWARAJ”, in Hindi, means “freedom from bondage”. Since, P.T.L. was the first largest tractor project in India, moreover fully based upon Indian technology. So “SWARAJ” was appropriately chosen as its brand name.

Growth of PTL

Punjab Tractors Limited started with an annual capacity of 5000 tractors and with a capital of Rs. 3.7 crores. It went into commercial production in the year 1974; its first production of 26.6 BHP tractors was given the name SWARAJ— 720. Ever since then P.T.L. has not looked back. In the first twenty year of its existence its capacity has been increased to 24000 per annum, which is a considerable achievement by any standards. PTL is considered as a highly reputated and impressive company in India. It manufactures many products and is helping in to develop India and improving its farming techniques.

Swaraj has become synonymous with tractors that are powerful and reliable because of their long term expertise in delivering such products consistently. We have been manufacturing tractors that serve the need of our buyers in agricultural as well as commercial operations. Our product range starting from a 22 HP category tractor to a 72 HP category tractor straddles every HP category requirement of our customers.

The brand enjoys a strong equity in the market and commands a market share of close to 12%. The brand is known for producing tractors that are powerful and reliable. Presently, there are more than 7,00,000 satisfied customers of Swaraj in the country. Swaraj tractors are also exported to various countries including Bangladesh, Nepal, Sri Lanka, Nigeria, Ghana, Gambia, Zimbabwe, Zambia, Tanzania and the USA.


22

MILESTONES

1970 Establishment of PTL for making Swaraj brand of tractors

1974 Commercial production started with 2 models: 724 FE & 735 FE

1980 Swaraj 8100, India’s first self-propelled combine harvester launched

1983 Swaraj 855 launched in the 50 hp category

1995 Establish of the 2nd plant for manufacturing Swaraj tractors in Chhaparchhedi

1999 Launch of Swaraj 744

2002 Cummulative sales of Swaraj tractors (till date) touches 5,00,000

2007 Swaraj 724 FE Orchard and Swaraj 978 launched

2007 M&M (the leaders in domestic tractor industry) acquires majority stake in PTL

2009Merger of PTL into M&M and subsequent transformation as the Swaraj Division of Mahindra & Mahindra Ltd.

2009 Launch of 735 XM – the first of the XM series of models


23

Financial Information:

Annual Turnover for the financial year 2003-04 = Rs. 641.44 crores

Net Profit = Rs. 43.11 crores

%age turnover spent on Research and development = 1.28%

Market Share = 15 %

Earning per share = Rs. 7.10

After disinvestments of its shares by P.S.I.D.C. shareholding patterns as on December, 2009 are

as follows

1 CDC & Associates

2 Unit Trust of India (UTI)

3 LIC / IDBI / GIC / IFCI

4 Mutual Funds / Nationalized Banks

5 Other FIIs

6 Public


24

Inputs:

1. Raw Materials: The following table shows a detailed analysis of raw material

consumption during the financial year 2008-2009


25

2. Power Consumption: The total power consumption last year was 117.83

lakh units.

3. Water consumption: No records were kept for water consumption as the

net amount spent on water resources was negligible.

4. Diesel Consumption: The average amount of diesel consumed per tractor

last year was 619.11 Rupees. This includes consumption in both assembly and

paint shop.

Technical Collaborations:

For Light commercial Vehicles:

P.T.L. entered into technical and financial collaboration with Mazda Motor Corporation of Japan in the year 1984 to set another company by the name of Swaraj Mazda Limited. It was Rs. 50 crore project with an installed capacity to manufacture 5000 LCVs of up to 3.5 tones payload capacity

For Forklifts

The company entered into technical collaboration with KOMATSU FORKLIFTS COMPANY of Japan in 1985 for the manufacture of high tech forklifts of both diesel and electric at its combine division.

For Diesel Engines

P.T.L. set up Swaraj Engines Ltd. (S.E.L.) in technical and financial collaboration with Kirloskar Oil Engines for the manufacture of diesel engines.


26

Competition within India:

The major competitors for PTL in India are Mahindra & Mahindra Tractors, Massey, Escorts, Eicher and HMT. The trends of market shares for the last 30 years are shown in the figure below. We can see that the market share of Swaraj tractors has increased from 9.1% in 1983 to 15% in 2003. Also the ranking has improved from 6th to 3rd. This is the sign of growing organization well on track to become the largest producers of tractors in India.

On the international scene, Swaraj is now a recognized name in the developing world. Swaraj Tractors find an important place in countries like Ghana, Zambia, Kenya, Sudan, Indonesia, and Malaysia etc


27

MARKET SHARE PERCENTAGE AND VOLUME

Pollutants and Pollution control measures:


28

1. Water Pollution: There are two kids of effluent waste that pollutes water

Industrial effluent : Process water after use is discharged as effluent. Industrial effluent is contaminated with pH imbalance, sulphates, chlorides, dissolved solids, suspended solids, oil and grease.

Domestic effluent : Domestic use consists of drinking and canteen water consumption apart from toilets. Domestic effluent is discharged into public sewer directly.

2. Air Pollution: Major contributors to air pollution are:

Shot-blasting section

Painting booths

Baking oven

D.G. sets

Major air pollutants include SPM, NOx, SO2.

3. Land Pollution: The following solid wastes case land pollution.

· Paint waste scum, sludge from ETP

· Steel scrap

Pollution Control Measures:


29

Plantation of trees.

Expenditure of 5 lakh rupees per year for environmental management and

pollution control activities.

Effluent Treatment Plant for Industrial Effluent Treatment.

Bag House Filter for the Shot Blasting Sections.

Fume Extraction System for the pre-treatment process.

Filter press for the extraction of water contents from the effluent sludge.

Hierarchy of the Organization:


30

1. Board of Directors (B.O.D)

2. Working Directors: Vice Chairman and Managing Director

3. Executive Directors: Finance, Human Resource and Development,

Manufacturing, International Business Division, Material Services, Swaraj

Automotive Limited, Swaraj Motors Limited, Senior Vice-President

(Marketing)

4. Vice Presidents: 3-4 under each Executive Director in level 3

5. Assistant Vice President

6. General Manager

7. Chief Manager

8. Senior Manager

9. Manager

10. Assistant Manager

11. Senior Engineer

12. Engineer

13. Assistant Engineer

14. Junior Engineer

15. Operating Class


31

The level 5-15 are under each vice president of level 4.

Employee Strength:

The total numbers of employees currently under the Mohali division of PTL are around 1600. These comprise of 500 in management staff and rest is working staff.

Products:

The major products of Punjab Tractors limited are divided into two categories i.e. for domestic consumption and overseas consumption.

The domestic products include the following:

1. Swaraj 855

2. Swaraj 939 FE

3. Swaraj 834 FE

4. Swaraj 744 FE

5. Swaraj 735 FE

6. Swaraj 733 FE

7. Swaraj 724 FE

8. Swaraj 722

9. Forklift 15


32

10. Forklift 20

11. Forklift 30

12. Electric Forklift 15

13. Swaraj 8100-Harvester Combine

The products for overseas consumption include:

1. Swaraj 978 FE, 4 Wheel drive




WEEK # 1


33

I spent the first few days of my training period for observational part. I spent time at various shops and tried to understand the various aspects of manufacturing.

The manufacturing includes the following departments:

1. Production

· Light machine shop (LMS)

· Heavy machine shop (HMS)

· Assembly shop

· Heat treatment shop

· Paint shop

2. Product services

· Tool room

· Tool Design

· Tool Control

· Research & Development

· Production planning & control (PPC)

· Material Management & control (stores)

· Quality Engineering

· Maintenance

· Industrial Engineering

3. Support Services


34

· Management systems

· Finances.

· Purchase

LIGHT MACHINE SHOP (LMS)

INDRODUCTION:

LMS is the largest section in the factory. All transmission components viz. shafts and gears used in Tractors are manufactured here. It has more than 120 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 WIv1W & 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 an area of 33,000 sq. ft. and casting, forging and high standard of quality.

TYPES OF MACHINES

Cylindrical grinder, internal grinder, copying lathe, gear hobber, Radial drilling machine, drum turret lathe, turret lathe, Honing machine, Centre lathe, Capstan lathe, Capstan lathe, Vertical pull broaching machine, Chuckmatic, Fay Auto, Centering & facing machine, Vertical Milling machine, Horizontal Milling Machine. Deburring machine, D/E boring machine Gear Shaver GTR machine, Bevel Gear Generator, Gear shaper, CNC machine, Power Hacksaw Special purpose drilling machine, twinchucker, Centre Hole grinding machine.


35

Function of the department

Gear manufacture and grinding, machining of bull gears, bevel gear 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

Inter relations with other departments

• Tool room : jigs, fixtures and cutting tools

• Maintenance: attending breakdowns and carrying out preventive maintenance of machine tools etc.

• Industrial engineering: provision of process charts for machining operations.

• Assembly: ensuring proper fitment of components.

• Production planning and co-ordination: Micro loading of components on a daily basis.

• Quality control and inspection, storage and inspection R & D

• Heat treatment- shot blasting operations lab testing, inspection etc.

Different Manufacturing Operations In LMS

Facing: It is the operations of finishing the ends of the work, to make the ends flat and smooth& to make the piece of required length.


36

Under Cutting: It is similar to grooving operation but is performed inside hole.

Chamfering: It is the operation of beveling the extreme end of the work piece. Chamfer is provided for better look/to rough turning: in this operations max. Metal is removed &very little oversize dimensions is left for further machining.

Finish Turning: Here min. metal is removed &very fine finish is obtained on the work surface.

Grooving: It is the operation of turning the groove or neck in order to terminate a thread or to provide adequate clearance enable nut to pass freely on threaded work piece, to remove burs &to protect the work piece from being damaged.

Knurling: It is a proc of embossing a diamond shaped regular pattern on the surface of the work piece using a special knurling tool.

Broaching: It is a method of metal removal by a tool that has successively higher cutting edges in a fixed path. Each tooth removes a fixed amount of material.

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. Grinding: To grind means to ‘abrade’ to wear away by friction or to ‘sharpen’ .

In grinding, the material is removed by a means of a rotating abrasive wheel. It is generally used for sharpening the cutting tool, for grinding threads, better surface finish etc.

Hobbing: It is the process of cutting teeth on gear &shafts & is performed by a rotating tool called hob on the hobbing machine.


37

Shaping: The process of cutting gears on the shaper is known as shaping. The tool used in shaping for teeth cutting is a multipoint cutting tool.

HEAVY MACHINE SHOP

INTRODUCTION:

All heavy castings of tractors are machined in this shop with the help of variety of special machines (SPM).

These machines are tailor made by HMT to suit component requirements. About 20 SPM and 30 GPM are installed in a covered area of 47,000 sq. ft. at a cost of 20 million, 2600 tonnes of castings are machined every year on a two-shift basis. In addition to the machining of castings for the tractor, some jobs are also performed for Swaraj Mazda Limited.

COMPONENTS MACHINED IN THE SHOP:

• Gearbox housing (Material—R-33, Casting, 180-230 BHN, 76-kg wt.)

• Differential Housing

• Rear Cover

• Trumpet Housing

FUNCTIONS OF THE DEPARTMENT

Machining of heavy castings like differential housing, gear box housing, rear cover, trumpet housing, steering housing of tractors, machining of tractors parts, machining of some components for Mazda.


38

INTER-RELATION WITH OTHER DEPARTMENTS

• Tool room - Requirement of jigs, fixtures and cutting tools.

• Maintenance - Attending breakdown and carrying out preventive maintenance of machine tools.

• Industrial engineering - Provide process charts for machining operations.

• Assembly - Ensuring proper fitment of components, production planning and control, micro loading of components on day-to-day basis.

• Quality control & inspection — Storage and inspection.

• R&D

• Paint shop

TYPES OF MACHINES

• Radial drilling machine• Vertical milling• Horizontal milling• Simplex milling• Duplex milling • Lathe• Double end• T/W boring• Automatic lathe• SPM (special purpose M/c)


39

ASSEMBLY SHOP

The Assembly Shop is the production shop where assembly and sub-assembly I of all the parts take place. The final processed parts from the various parts of production shop such as HMS, LMS and Heat Treatment reach the assembly Shop. The various parts reach the assembly. shop only after being washed, cleansed and dried, which takes place when the different 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.The assembly shop can be divided into various groups depending upon sub-


40

parts being assembled. These groups are:

1. Differential assembly and sub-assembly.

2. Differential Cover assembly.

3. Gear Box assembly and sub-assembly.

4. Main assembly line


41

WEEK # 2

DIFFERNTIAL ASSEMBLY

Working on differential assembly

Before the various differential parts such as BP shaft, differential cage etc. are assembled, the various sub-assembly of parts are performed in the sub units. In the first unit, both the BP shafts are fitted with various components such as circular clips, needle bearings etc. to be able to be assembled to the differential Cage. This constitutes the assembly of Cross Bar, Planetary Gear, Planetary Gear Cover, 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 Trumpet Hsg. and the Axles are assembled in a different assembly shop and there on the whole unit along with the Bull Gears is assembled to the differential Cage. The


42

Assembly of Differential Hsg. is complete with the assembly of lay shaft ext., the oil filter and the brake mechanism

Section of differential

Flow chart for the differential assembly


43

The diferenrial has three jobs:

1. To aim the power to the engine wheels.

2. To act as the final gear reduction in the vehicle, slowing the rotational speed of the transmission one final time before it hits the wheel.

3. To transmit power to the wheels allowing them to rotate at different speeds.

Differential assembly with cage assembly

Cage assembly used in differential Spider cross


44

Gear Box Assembly

Working on gearbox 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 to obtain the duplex speed ratios of the tractor. The box after being tested for its efficiency is sent to the 5 stages.


45

Steering Gear Box + Gear Shifting + Brake Assembly:

This unit consists of 4 stages of the assembly unit. In this unit the sub assembly of the steering gear box, gear shift mechanism on gear cover + the brake mechanism is assembled of these mentioned sub assemblies, the brake assembly is sent to the 1 stage of assembly and the steering gear box and gear box cover assembly is sent to the 3 stage of assembly. Apart from these sub assembly unit also produces the KPS assembly.

Figure showing gear arrangement

Sliding mesh gear box with four gears

1. Main drive gear2. Counter shaft3. Main shaft4. Gear I5. Gear II6. Gear III7. Gear IV


46

WEEK # 3

Differential Cover Assembly

The second stage of Assembly shop is the differential cover assembly shop which incorporates the gear pump assembly. And the direction control valve. The DI cover is collected from the conveyor and the various attachments such as Power Cylinder, Piston Assembly., Oil Pump, DCV Valve etc. is made, and the cover is tested for its efficiency on the testing jig. After which it is sent to the first stage where the whole unit is assembled to the Dc assembly. And further sent to the 5 stages of the assembly.

Flow process chart of rear cover assembly


47

In this assembly of

Ram cyclinder piston Control sector Sensor bracket and ram arm Control valve and response valve Fitment and assembly of sensor tube takes place

Control sector control valve

Ram – cyclinder piston Bracket and ram arm


48

REAR COVER TESTING MACHINE

Rear cover testing rig

In this testing rig all the rear covers are tested before applying them on differential. The rear cover is fixed to the machine temporarily and then the testing is done.

All the oil levels are checked and then the movement of bracket arm and the rocker arm is checked. The pressure is checked abd it should be between 16-17 k pa. the defected cover is again checked and tested so that the customer should get the best machine possible.

Assembly of Engine + Clutch Mechanism

This unit is separate 6 stage of assembly in which the engines are received from the stores and fitted with the clutch mechanism and lay beam along with the counter weights.


49

Assembly of Engine with the rest transmission section

The assembly of the engine and rest of the transmission is done within the 7 stage. In this stage the whole of the chassis is formed as an integral unit. The various links and mechanism between the engine and the gear box or diff is fastened together and the whole integral unit is checked for its complete accessories etc. In all the 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 over head automatic conveyors and the alarm conveyor etc to make their job easy. Also the whole of the assembly is done on the assembly jigs or stands which is kept moving at a speed of about 7cm/mm. Also it is to be made in mind that any spill of the sub parts such as bolts, nuts etc. by mistake is not going to spoil the working space as all these spills gets underneath the working space and as a result the working space remains clean and tidy.

Hydraulic pump Alternator and Self starter


50

KAIZEN

Kai + Zen

Change Good

Kaizen means non-stop improving the quality and the process.

With Kaizen, an involved leadership guides to continuously improve the ability to meet high quality, low cost and on-time delivery.

Kaizen transforms companies into ‘superior global competitors’.

Kaizen costing is a continuing reduction during the manufacturing phase of an existing product.

The Japanese word Kaizen refers to continual & gradual improvement through small betterment activities, rather than large or radical improvement made through innovation or large investment in technology.

Kaizen costing is most consistent with saying “slow & steady wins the race”.

There are two essential elements that make up KAIZEN:

*improvement/change for the better; and*ongoing/continuity.

KAIZEN achieves its effects by working through people. All are expected to be involved. Managers, for example, are expected to spend about half their time on improving what they - and those for whom they are responsible - do.


51

KAIZEN recognizes that improvements can be small or large. Many small improvements can make a big change - so KAIZEN works at a detailed level.

It is adopted by swaraj tractors in order to improve the quality of the production. All the workers are involved in this process which lead to the changes in the root level.

PAINT SHOP


52

Operations performed in paint shop are:

• Surface Preparation (Pre Treatment Cell)-carried out for sheets and rims.

• Painting

• Inspection

• Rejection (Reprocessing)-for sheets and rims.

• Pre Treatment Cell

Various procedures followed here are:

• Degreasing

• Water Rinsing (part which is degreased is alkaline in nature so rinsed with water due to its being good solvent).

• De Rusting

• Surface oxidation

• Phosphating (done so as to form a thin layer of coating on part so that no surface remains unpainted).

• Passination (done so as to avoid paint penetrating through certain section of part body’s surface).

Painting


53

Chassis Paint Line: Operations carried out here are:

• Washing: Here chassis is first washed with a chemical cleaner, concentration of which is 5% and auto sprayed in a chamber.

• Drying: The chassis is then dried by hot air whose temperature is up to 60 to 70°C.

• Primer Painting: A thin layer of primer paint is sprayed on the chassis so that the final paint is strongly fixed on.

• Flash Off: This is the distance given so as to allow paint to dry.

• Final Painting

• Flash off.

• Baking: Chassis is allowed to bake for around 30 minutes.

• Sheet and rims Painting: After surface preparation in PTC, sheets and rims are first of all cleaned with ordinary cloth.

There after following operations are carried out:

• Primer painting (full primer in addition to single coating of paint)

• Flash off.

• Baking (at temperature of around 120-130°C)

• Wet Rubbing and cleaning with tack rag.

WEEK # 4INDUSTRIAL TRAINING REPORT BY : ANIKET CHOUDHARY

54

QUALITY ENGINEERING DEPARTMENT

Discipline that deals with the analysis of a manufacturing system at all stages, to improve the quality of the production process and of its output. Quality engineering receipt (formally known as Quality Engineering Department) is divided into two fields at Swaraj division of Mahindra and Mahindra Ltd.

1. Suppliers Quality2. In-House Quality

SUPPLIERS QUALITY

Suppliers section consists of maintaining the quality of products that are being supplied by suppliers. It contains inspection of the raw materials being supplied by suppliers. It also includes discussion regarding delay of raw material and defective parts supplied. Subsequent actions are taken if the supplied products being supplied are found defective and inspectors from the industry are sent regularly to avoid such defects. This inspection is regularly done by the industry so maintain good quality supply and sound relationship with suppliers.

IN – HOUSE QUALITY

In house quality is embedded into every department of the industry. As such there are five dept. that are:– 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)

Quality Engineering Assembly

Quality Engineering Assembly consists of five quality posts. Each Quality Posts are situated at every intervals of the assembly line. Each Quality post has a certain


55

responsibility of maintaining the quality of the Product being manufactured in the industry. And the final quality post is known as P.D.I (Pre Dispatch Inspection).

P.D.I. (Pre Dispatch Inspection)

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 phase IV. 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.

HOW DOES IT HOLD GOOD?

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.

MEASURES UNDER P.D.I

1. TRANSMISSION FLUID LEVEL2. ENGINE OIL LEVEL3. F.I.P OIL LEVEL4. WATER LEVEL IN RADIATOR5. ELECTRICAL FUCTIONING6. COMPONENT STORAGE7. CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER8. PAINT DEFECTS AND OTHER VISUAL INSPECTIONS9. WATER MIX IN ENGINE AND TRANSMISSION FLUID

TRANSMISSION FLUID LEVEL


56

To check the transmission fluid level, the dipstick from tractor is removed using D/E spanner (24*27). The oil level is checked by using the gauge. If the oil is over or under the required quantity, oil is added or drained respectively to adjust the oil level and it is brought up to the required level.

ENGINE OIL LEVEL

To check the engine oil level, a pull out dipstick is used which is pulled out from the engine block by hand. To check the oil level correctly, the oil is wiped off the dip-stick with a clean cloth. The dip-stick is reinserted and then again taken out. The oil level is again checked using the mark built on the dip-stick. If the oil is above or below the required level, it is added or drained respectively.

F.I.P OIL LEVEL

To check the oil level of the Fuel Injection Pump oil level, we loosen the inspection screw by D/E spanner (14*17) and check the oil in the F.I.P(Fuel Injection Pump). Oil is added in case the oil is not coming out.

WATER LEVEL IN RADIATOR


http://knol.google.com/k/-/-/rw5xe32hu8ia/se2u2v/untitled%20(1).png

57

The water level in the radiator has a very essential role. Without the water the radiator cannot work efficiently. Before the tractors are dispatched, the water/coolant level is checked and filled if the level is not upto the full mark. To check it, radiator cap is opened and so is the cap of the water/ reservoir tank. The level of water/coolant in the reservoir tank can be checked by visual inspection. To check the water levels in the radiator, finger is immersed inside it after removing the cap. If the water level is not fine it is filled up to the required level. This test also checks the seals on the radiator cap.

Level of water in the Reservoir tank

ELECTRICAL FUCTIONING

1) Operation of Brake Switch

Brake switch is a small, brake pedal operated spring loaded switch used to light up the rear stop light (red light) on the application of the brakes. It can have very serious affects if the tractor is on a heavy traffic road. To check if its working properly or not, the electrical switch of thebattery is put on the “on” level and then the brakes are applied. If the stop lights, light up , then the switch is working fine otherwise it is replaced.

2) Battery


http://knol.google.com/k/-/-/rw5xe32hu8ia/se2u2v/reservoir-tank.jpg

58

The battery of the tractor is a very costly and an essential part. The customer should not get a de-charged battery. The battery of the Swaraj 735 FE and above models have a battery with a magic eye. The magic eye has a colour indicator for the indication of the condition of the battery. If the battery is OK - then the colour shows Green If the battery needs charging– then it shows a white indicator If distilled water needs to be added to the battery – It shows a red indicator

3) Fuse box

The fuse box of the tractor is also checked before it is rolled out. To check if any fuse has been broken, the tractor is started and all the electrical functions like the head and the rear lamps, the turn-indicators and the horn is checked. If any component does not seem to work, the first check is to check the fuse connections in the fuse box.

COMPONENT STORAGE

Visually inspect the tractor is done. All the nuts and bolts are checked, the logos and stickers are observed and checked so that they are correctly placed and are appropriate to the product. If the components are missing, deteriorated or wrongly fitted, the needful is done. For example, all the 4 tyres of the tractor are required to be of the same brand. This helps in the proper control of the tractor while in motion.

CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER

The air intake by the engine is done through the air filter. If the air does not goes through the air filter the engine will choke destroying the piston linings and hence causing a massive damage to the engine. The intake of air through the air filter is even more important in case of tractors as they work in dusty environments full of sand and other materials. The air filter is located above the level of the engine on the left side, as seen by the driver. To check if there is any air leakage in the suction tube, the air filter cap is removed and the tractor is started. Hand is placed


59

on top of the air inlet pipe, properly covering it. If the engine stops on doing this, the tractor passes the test.

When the hand is placed and the entry of the air is blocked, the engine stops

PAINT DEFECTS AND OTHER VISUAL INSPECTIONS

A variety of paint defects occur while the tractor is being assembled. These defects are inspected at the IQS (Internal quality study). The IQS area at Swaraj tractors plant has been set up by Mahindra and Mahindra Limited. It involves a thorough check on tractors finish i.e. Buff marks, etc. It involves a very thorough check in very good illumination from each side. They select five random tractors from the assembly line and inspect them thoroughly. Various paint defects that are found at IQS are:1. Dust in paint2. Excessive buff marks3. Metal scratches4. Paint scratches5. Paint run-down6. Poor touch up/ overspray7. Dent / ding

WATER MIX IN ENGINE AND TRANSMISSION FLUID


http://knol.google.com/k/-/-/rw5xe32hu8ia/se2u2v/air-filter-open.jpg

60

Due to various leakage points, water seepage occurs and water seeps into the engine oil and transmission fluid compartments. The water mix levels of engine oil and transmission fluid is checked by two methods:1. Visual inspection of the Dip-sticks of both the engine oil and the transmission fluid compartments can easily tell if water is present or not. If water is not mixed , both the engine oil and the transmission fluid are transparent. If water is present in the engine oil compartment, the drop of the oil which comes out with the dip-stick will be hazy. The same is the case of transmission fluid. If water is present it will turn translucent.2. Water mix paste is used to check if water is present in the engine oil or transmission fluid. The Water mix paste ( green in colour ) is put on the tip of the dip-stick and inserted back into the respective compartments. If water is present, it reacts with the green coloured water mix paste and turns it pink in colour. This gives a proof of the presence of water.Various others tests are performed before the tractors are finally dispatched, which are performed as the need arises.


61

MAINTENANCE 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 be subjected to the production process with the advent of new and modern technology, the entire concept of maintenance has changed. Earlier maintenance practices were only confined to the breakdown maintenance, but now different types of maintenance practices are followed like:

1. Scheduled maintenance2. Break down maintenance3. Preventive maintenance4. Predictive maintenance

The following are the main objectives of maintenance:

• To achieve the minimum break down level and to achieve the production target at low cost.• To keep the plant in proper working condition.• Machine and other facilities should be arranged so that they can be used to their max. capacity.• The Maintenance division of the factory ensures the availability of all the facilities necessary for the performance of functions at optimum return of investment.


62

IMPORTANCE OF MAINTENANCE

1. Equipment breakdown leads to inevitable loss of production time, which is prevented by maintenance department.

2. Plant maintenance plays an important role in production management by

preventing breakdowns which caves inevitable shortfall of target, needs of sub- contracting work, rescheduling of production, need of over time etc.

3. Routine check-up of facilities ensure safe and efficient operation of machinery.

4. Maintains optimum production efficiency of 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.

With rise in the technology, not only predictive and preventive action bus the concept of cost cutting, proper utilization of resources ,better spare parts planning, training have also become important now.

This can be made possible to cent percent by systematic maintenance. In swaraj tractors limited systematic maintenance operations are practiced to improve the plant availability and to achieve the goal at a reasonable cost. i.e. to achieve availability performance at the lowest cost and within the safety constants.


63

At present the maintenance deptt. of SWARAJ TRACTORS have five subsections.

1. Electrical maintenance cell

2. Engineering machine maintenance cell

3. Material handling equipment maintenance cell.

4. Spare part planning and control cell.

5. Engineering utility maintenance

TQM (TOTAL PRODUCTIVE MANAGEMENT)

They follow a policy of TPM-Total Productive Management.

Total productive management contains following aspects:

1. Maximize reliability of plant and machinery by aiming above and eliminating the losses.

2. Nurture teamwork and continous improvement through total employee involvement.

3. Promote healthy, clean and cheerful working environment.

4. Cultivate “MY MACHINE , MY WORKPLACE’’ concept.

5. Making available low cost, trouble free, accident free , customer focused and attractive products.


64

SPECIFICATIONS OF THE VARIOUS SWARAJ PRODUCTS

Specifications:

ENGINE :

Model : 4R1040 ; Kirloskar

HP : 72

Type : 4 Stroke, direct injection, diesel engine.

No. of Cylinders : 4

Bore and Stroke : 105 X 120 mm

Displacement : 4160 cc

Rated Engine Speed : 2200 rev/min.

Air Cleaner : Dry type, Dual element with automatic dust unloader valve.

Cooling System : Water cooled with No Loss tank.Oil cooler for engine oil.

BRAKES :


65

Oil immersed disc brakes.

Parking brake for additional safety.

STEERING :

Power Steering

HYDRAULICS : Live hydraulic

Lifting capacity : 2200 kgf at lower link ends

3 Point Linkage : Category II

Hyd. Pump : 45 litres/min.

Linkage : Automatic depth and draft with position / mix control .

External hyd. :Single spool Double acting DCV. (With provision for single acting applications)

ELECTRICALS :


66

'12 volt, 99 Ah. Battery

Alternator & Starter motor

Parking/Tail lights with turn indicators

Head lights with parking lamps

Rear work light

INSTRUMENTS :

Engine rpm cum hour meter

Temperature gauge

Fuel level gauge

Oil pressure gauge

Ammeter

Air cleaner choking indicator

Trailor light indicator

Hi beam indicator

TYRES :

Front 7.50 x 16


67

Rear 16.9 x 30

WHEEL TRACK :

Front 1560 - 1760 mm

Rear 1600 - 1820 mm

DIMENSIONS :

Overall Length : 4140 mm

Overall Width : 2030 mm

Overall Height : 2440 mm

Wheel Base : 2225 mm

Min.ground Clearance : 370 mm

Weight of Tractor : 3050 kg


Transmission :

CLUTCH : 12"X12" Double Clutch With Dry Discs.

GEAR BOX :12 Forward, 12 Reverse speed Synchromesh Gear box with high, medium and

low selector lever.

68

Specifications:

Engine Specifications :

Model : RB-33 TR KIRLOSKAR

HP : 55 S.A.E.

Type : 4 - Stroke, Direct Injection, Diesel Engine .




Rated Engine

Speed :2000 rev/min

Air Cleaner :

3 Stage dry type air cleaning system comprising of Swaraj Turbo Pre cleaner,

Dust unloader, main paper filter element and safety cartridge to enhance engine

life.

Cooling System : Water Cooled with Oil Cooler for engine oil.

Transmission :

Clutch : Heavy Duty single dry plate type, 305 mm diaDual Clutch, 280 mm dia

No. of Gears : 8 forward, 2 reverse speeds with high and low selector levels.

Heavy Duty Self energizing, water sealed disc brakes with parking brake for additional safety.

Oil Immersed disk brakes (Optional)

Steering :

Heavy Duty single drop arm steering for high efficiency and comfortable drive.

Lifting Capacity :

1000 kgf at Lower Link Ends

1500 kgf at Lower Link ends (Optional)

Electricals :


69

12 Volt, 99 Ah. Battery, starter motor & alternator.

Instruments :

Tractor meter with direction indicators, Fuel Gauge, Ammeter, Water Temp. Gauge & Oil Pressure

Gauge.

Tyres :

Front Rear

6.00 X 16 13.6 X 28

6.50 X 20 (Optional) 16.9 X 28 (Optional)

Wheel Track :

Front Rear

1200-1750 mm 1350-1900 mm

Deluxe Features :

Power steering *

Higher Capacity Hydraulic (1500 kg.) with improved sensitivity. *

Concealed lockable battery near starter.

Aesthetically designed heavy duty telescopic front Axle Bearn.

Telescopic stabiliser bars for easy adjustment and better implement stability.

Adjustable sliding P.U. seat for operator's comfort.

Centrally located horn switch on steering wheel (like cars) - for operational convenience.

Oil immersed (multi disc) wet brakes. *

DC Valve - for external hydraulic application. *

Bigger tyres (front 6.50 X 20 & Rear 16.9 X 28). *


70

(*Optional)

Features :

Dry type air cleaner for longer life of engine.

Most modern oil cooler - for longer life of engine.

8+2 speed gear box (combination of CM & SM Gears) with suitable speeds for haulage, field, straw

making machine and harvester combine operations.

Adjustable front weights (optional on extra payment).

Highly suitable for drilling operations with Compressor.

Higher capacity diesel tank - 60 litres.

Better wheel traction for farm operations.

Ideal for Paddy cultivation.


71

Specifications:

Engine :

Model : RV-3 TR ; Kirloskar

HP : 39 S.A.E

Type : 4 Stroke, direct injection, diesel engine.




Rated Engine Speed : 2000 rev/min.

Air Cleaner : 3 stage Air cleaning system comprising of Cyclonic pre-cleaner, Oil bowl & Paper

element to enhance engine life.

Cooling System : Water cooled with No Loss tank.

Transmission:

Clutch : Heavy duty single dry plate type, 280 mm dia.

No. of Gears : 8 forward, 2 reverse speeds with high and low selector lever.

P.T.O. 21 splines for 1000 rpm

6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)

BRAKES Heavy Duty self energising, water sealed disc brakes

Parking brake for additional safety

Oil immersed disc brakes (Optional)

STEERING


72

Heavy Duty single drop arm steering fo rhigh efficiency and comfortable drive.

HYDRAULICS 2 lever live hydraulic system having automatic position & draft with mix control

a) Position control To hold lower links at any desired height.

b) Automatic Draft Control To maintains uniform draft.

c) Mix Control For optimum field output

Hydraulic lift pump Gear type hydraulic pump delivers 17 l/min at rated engine speed.

LIFTING CAPACITY

1000 kgf at lower link ends.

ELECTRICALS '12 volt, 88 Ah. Battery

Starter motor & alternator

Head light with parking lamps

INSTRUMENTS

Engine rpm cum hour meter, Fuel gauge, Water Temp. gauge, Oil pressure gauge,

Ammeter, Hi beam indicator, Trailer light indicator.

TYRES Front 6.00 x 16

Rear 12.4 x 28

WHEEL TRACK Front 1200 - 1750 mm

Rear 1350 - 1900 mm

DIMENSIONS

O.A.Length 3420 mm

O.A.Width 1675 mm

O.A.Height 2270 mm

Wheel Base 1960 mm


73

Min.ground Clearance 390 mm

Weight of Tractor 1925 kg

Specifications:

Engine Specifications:

Model : RB 22 TR KIRLOSKAR

HP : 34 S.A.E.

Type : 4 - Stroke, Direct Injection, Diesel Engine


74




Rated Engine Speed : 2000 rev/min

Air Cleaner : 3 Stage Air cleaning system compromising of cycolonic pre-cleaner, Oil Bowl and Paper element

to enhance Engine Life

Cooling System : Water Cooled with Oil Cooler for engine oil

Transmission:

Clutch : Heavy Duty single dry plate type, 280 mm dia

No. of Gears : 8 forward, 2 reverse speeds with high and low selector levels.

P.T.O.

21 Splines for 1000 rpm at rated engine speed.

6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)

Brakes

Heavy Duty Self energizing, water sealed disc brakes with parking brake for additional safety.

Heavy Duty single drop arm steering for high efficiency and comfortable drive.

Lifting Capacity

1000 kgf at Lower Link Ends

Electricals

12 Volt, 75 Ah. Battery, starter motor & alternator.

Instruments

Tractor meter with direction indicators, Fuel Gauge, Ammeter, Water Temp. Gauge & Oil Pressure Gauge.

Tyres:


75

Front : 6.00 X 16

Rear : 12.4 X 28

Wheel Track:

Front : 1200 - 1750 mm

Rear : 1350-1900 mm

Dimensions:

O.A. Length : 3290 mm

O.A. Width : 1680 mm

O.A. Height : 2130 mm

Wheel Base : 1820 mm

Min. Ground Clearance : 390 mm

Weight of Tractor : 1750 kg

Deluxe Features

Concealed lockable battery near starter.

Aesthetically designed heavy duty telescopic front axle beam.

Telescopic stabilizers bars for easy adjustment and better implement stability.

Adjustable sliding P.U. seat for operator's comfort.

Centrally located horn switch on steering wheel (like cars) - for operational convenience.

Features

Horse Power - 34 SAE

Most modern air Cooler - for longer life of engine.

8+2 speed gear box (combination of CM & SM Gears) with suitable speeds for all farm operations.


76

Live hydraulics.

Alternator - for powerful headlights and longer battery life.

Water separator in fuel line for extra protection of fuel injection pump.

PTO available in 540/1000 rpm.

Low Diesel Consumption

Ideal for all field and haulage operations.

Specifications:

TECHINCAL SPECIFICATIONS

Engine

Make:Ashok Leyland Model ALU-400

Power : 105 BHP at 2200 r.p.m.

Air Cleaner :Twin Oil Bath type

Cutting Mechanism

Cutter Bar


77

Work widthing : 4.2 meter ( 14 feet)

Min. cutting Height : 60 mm

Reel

Type : Pick up

Speed Adjustment : Mechanical

Height adjustment : Hydraulic

Threashing & Cleaning Mechanism

Threashing Drum

Width : 1274 mm

Diameter : 600 mm

Speed :550-1225 r.p.m

Adjustment : Mechanical

Concave

Clearance : Adjustable Mechanically

Starw Walker

No : 5 , No of steps: 5 , Area 5.2 sq. meter

Cleaning Sieve

Upper sieve area : 1.85 sq meter

Lower sieve area : 1.55 sq.meter

Adjustment Mechanical

Tyres

Fron : (18.4/15-30) 14 PR

Rear : (7.50-16) 12 PR

Road Speed

Forward 1st gear : 1.5 to 3.5 km/hr

2nd gear : 3.5 to 8.5 km/hr

3rd gear : 8.5 to 20 km.hr

Reverse : 3.5 Km/hr.

Track & Base


78

Wheel track : 2400 mm

Wheel base : 3600 mm

Steering & Brakes

Steering : Hydrostatic

Brakes : Disc type mechanical

Capacities

Grain tank : 2.0 cubic meter

Fuel tank : 230 litre

Main Dimensions

Transport

(mm)Working (mm)

Width 2950 4600

Length 12500 8100

Height 3900 3900

Ground

clearance :320 mm

Weight

With cutter bar : 7800 kgs

without cutter bar : 6800 kgs

Optional

Air- Conditioned operator cabin

Features:

Highest yiels in the shortest time with minnimum

grain loss. Suuitable for Wheat, Paddy, Soyabean,

Sunflower, Gram. Safflower, Mustard etc. crops.

Working successfully in diffrent climatic and field

conditions in Punjab, Haryana, Uttar Pardesh,

Madhya Pardesh, Rajasthan, Jammu-Kashmir,

Maharashtra and Gujrat.

Low fuel consumption minimum care and


79

maintenance. Light steering, small turning radius

and varying cutter bar height.

First indegeneously developed combine harvester

based on modren technology.

More than 336 authorised Swaraj dealers spread

across the country are always at the service of

combine

harvester owners in getting business.

Spares readily available.

Area-wise Service Centers

Specifications:

ITEM FB 15 FB 20 FB 25

PERFORMANCE

Capacity kg 1500 2000 2500

Load Center mm 500 500 500

Max. fork height mm 4000 4000 4000

Free Lift mm 375 375 375

Title angle FWD / BWD degree 6 / 12 6 / 12 6 / 12

Lifting Speed Laden/Unladen mm/sec 270/430 270/430 270/430


80

Lowering speed Laden/Unladen mm/sec 450/500 450/500 450/500

Gradability Laden/Unladen % 15/20 16/19 14/17

Min. intersecting aisle (pallet 1000 x 1000)mm 1745 1875 1880

Right angle stacking aisle (pallet 800 x 1200)mm 3080 3420 3425

Outer turning radius mm 1770 2055 2055

Service Weight(approx) mm 3200 3560 3900

BRAKES

Service Hydraulic

Parking Mechanical

Steering Hydrostatic

DRIVE

Battery, 5 hr. rating V/AH 48/550 48/550 48/550

Drive Motor, 1 hr. rating Kw 6.5 6.5 6.5

Pump, motor, 5 min. rating kw 7.5 7.5 7.5

PS motor, 1 hr. rating kw 0.6 0.6 0.6

Motor controls MOSFET / SCR

DIMENSIONS

Overall height to fork face mm 2165 2295 2300

Overall width mm 1150 1150 1150

Overhead guard height mm 2280 2280 2280

Overall ht.(mast lowered) mm 2600 2600 2600

Overall ht.(mast extended) mm 5280 5280 5280

Forks (thick x width x length) mm 45 x 127 45 x 127 45 x 127


81

x 1000x 1000

x 1000

Load distance from front axle mm 450 450 450

Tread front/rear mm 965/960 965/960 965/960

Wheel base mm 1400 1400 1400

Min ground clearance mm 110 110 110

TYRES

Front

7.00 - 12,

12 PR

7.00 - 12,

12 PR

7.00 - 12,

12 PR

Rear

6.00 - 9,

10 PR

6.00 - 9,

10 PR

6.00 - 9,

10 PR

MAST TYPE

wide

viewshort Triplex

Max. Fork Height mm 4000 2400 4300

Free lift mm 375 406 1375

Overall height mast lowered mm 2600 1753 2050

Overall height mast raised

(with load back rest)mm 5228 3654 5520

Capacity

FB 15

Kg

1500 1500 1500

FB 20 2000 2000 1800

BIBLIOGRAPHY


82

My training was the most versatile experience. I had the pleasure to do the work with one of the most reputed factory in their field- “MAHINDRA & MAHINDRA SWARAJ DIVISION.” It was a good learning time during my training as we were fortunate to be placed in the department related to manufacturing. I feel training has give me exposure to undergo projects in the Manufacturing field as well help me a lot to understand the company work culture, working with teams and much more. In the end I will like to thank all persons who helped me through out my training to enhance my experience. I also pay my regards to my Lecturers for their guidance during my training and my Academics helped me to do a lot during my training.

ANIKET CHOUDHARY


ANIKET

Documents

training period

practical training

undergone training

tractor unit

word tractor

tractorsa tractor

indian tractor industry

gasolinepetrolpowered