Final Training Report - Punjab tractors Limited (PTL)

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Report: Report contains an overview of the Quality Engineering Department at Swaraj Tractors Division, Mahindra and Mahindra, Phase IV, Mohali, Punjab. It gives detailed information of the tests performed at Pre-Dispatch Inspection check post and problems faced by the warranty section, pooled in from all the dealers of Swaraj Tractors from

all over India.

Swaraj Tractor Division Mahindra and Mahindra Limited, Mohali,

Punjab

Quality Engineering Department Trainee number: T-055 I have been doing training under Mr. Rajendra Singh, Senior Manager (In House quality).

QUALITY ENGINEERING DEPARTMENTMENT

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 Quality

2. 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 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 HOLDS 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 LEVEL 2. ENGINE OIL LEVEL

3. F.I.P OIL LEVEL 4. WATER LEVEL IN RADIATOR

5. ELECTRICAL FUCTIONING 6. COMPONENT STORAGE

7. CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER 8. PAINT DEFECTS AND OTHER VISUAL INSPECTIONS

9. WATER MIX IN ENGINE AND TRANSMISSION FLUID

TRANSMISSION FLUID LEVEL

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 eng ine

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

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

The open lid of the radiator

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 the

battery 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

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 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

The air enters through this air filter

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 paint

2. Excessive buff marks 3. Metal scratches 4. Paint scratches 5. Paint run-down

6. Poor touch up/ overspray 7. Dent / ding 8. Paint chip off 9. Pettling marks over the engine

10. Improper sticker application 11. Engine (pettling marks / seapage ) 12. Others, etc

WATER MIX IN ENGINE AND TRANSMISSION FLUID

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.

Tests Performed and Performance data

A number of tractors are dispatched daily and all have to pass through all the above and many

other tests at the PDI check post before they are finally allowed to move out. No tractor is

allowed to move out of the premises with the PDI OK sticker.

Although we perform all those tests and carry out research on other warranty related issues,

we were called upon to record and submit few reports regarding some tests by inspecting a

number of tractors in dispatch. Here I like to present few reports:

1st report containing the Chassis Number, Details about water mix in Engine oil, transmission

fluid, radiator coolant level and the colour of the magic eye

Sr. No. Chassis No. of the tractor

Engine oil purity

Transmission Fluid purity

Radiator coolant level

Battery Magic Eye

1 8819 Not ok not ok ok Green

2 10709 ok Ok ok Green

3 10740 ok not ok ok Green

4 21589 Not ok Ok ok Green

5 21703 not ok Ok ok Green



8 78935 ok Ok ok White



















27 79822 ok Ok not ok Green

28 79823 ok Ok not ok Green

29 79831 ok ok not ok Green

30 79837 Not ok ok ok Green

31 79842 ok ok ok Green












43 80029 Not ok ok ok White

44 80033 ok ok ok White

45 80038 ok ok not ok White





50 80090 not ok ok ok Green

51 80097 ok low level ok Green




55 80111 not ok ok ok White

56 80127 ok ok not ok White
























80 80202 not ok ok ok Green







87 85976 ok not ok ok White










97 86021 ok not ok ok White





Checked by Harpreet Singh

ok means that the inspected parameter is found ok

not ok

means that the value of the inspected parameter is either found doubtful or is not ok

2nd report:

Swaraj Tractors Evaluation Sheet

Number Chassis Number Model Number Battery Magic Eye Colour Situation of horn

1 QUTA22705010542 834 FE GREEN OK

2 QUTA30405078926 735 FE GREEN OK

3 QUTA30405078933 735 FE WHITE OK

4 QUTA30405078934 735 FE GREEN OK

5 QUTA30405078936 735 FE GREEN OK

6 QUTA30405079456 735 FE GREEN OK

7 QUTA30605078941 735 FE GREEN OK

8 QUTA30605078943 735 FE GREEN OK

9 QUTA30705079597 735 FE WHITE OK

10 QUTA30705079636 735 FE GREEN OK

11 QUTA30705079649 735 FE WHITE OK

12 QUTA30705079680 735 FE GREEN OK

13 QUTB22705010647 735 FE GREEN OK

14 QUTB22705010717 834 FE GREEN OK

15 QUTB30705079666 735 FE GREEN OK

16 QUTB30705079681 735 FE WHITE OK

17 QUTB30705079683 735 FE GREEN OK

18 QUTB30705079967 735 FE GREEN OK

19 QUTB30705079999 735 FE GREEN OK

20 QUTB30705080002 735 FE GREEN OK

21 QUTB30705080003 735 FE GREEN OK

22 QUTB30705080004 735 FE GREEN OK

23 QUTB30705080008 735 FE GREEN NOT OK

24 QUTB30705085951 735 FE GREEN OK

25 QUTB30705085952 735 FE GREEN OK

26 QUTB30705085954 735 FE GREEN OK

27 QUTB30705179745 735 FE GREEN OK

28 QUTB30705179747 735 FE GREEN OK

29 QUTB31619079903 735 FE GREEN OK

3rd report

The third report was for the leakage of the air-filters

Sr. No. Chassis Number Air filter check

1 80131 ok

2 80133 ok

3 80135 ok

4 80137 ok

5 80138 ok

6 80142 ok

7 80143 ok

8 80145 ok

9 80146 ok

10 80177 ok

11 80179 ok

12 80182 ok

13 80191 ok

14 80192 ok

15 80193 ok

These reports were submitted to Mr. Rajendra Singh, Senior Manager (In House Quality )

Final Training Report - Punjab tractors Limited (PTL)

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