SIX WEEK INDUSTRIAL TRAINING REPORT UNDERTAKEN AT “MAHINDRA & MAHINDRA” IN “SWARAJ TRACTOR DIVISION” ON “STUDY, DOCUMANTATION AND ANLYSIS OF MANUFACTURING DIFFERENT TRACTOR MODELS” Submitted to: Submitted By: Prof.R.K. Handu Bhavya Kapoor Department:Mech. Roll No: 2309612 Mech.Engg. 5 th Sem.
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SIX WEEK INDUSTRIAL TRAINING REPORT
UNDERTAKEN AT
“MAHINDRA & MAHINDRA”
IN
“SWARAJ TRACTOR DIVISION”
ON
“STUDY, DOCUMANTATION AND ANLYSIS OF MANUFACTURING DIFFERENT TRACTOR
MODELS”
Submitted to: Submitted By:Prof.R.K. Handu Bhavya KapoorDepartment:Mech. Roll No: 2309612
Mech.Engg. 5th Sem.
AMBALA COLLEGE OF ENGINEERING AND APPLIED RESEARCH, DEVSTHALI, MITHAPUR
(AMBALA)
ACKNOWLEDGMENT
Firstly I wish to express my deep gratitude to all the concerned persons without whose generous cooperation &coordination, it would have been very difficult for me to have a successful training experience in the organization.
I would like to thank Mr. J.Singh for giving me a golden opportunity of industrial training, which would help me to enhance my technical skills.
I am extremely grateful to the management of Swaraj Division Mohali for giving me an opportunity to pursue six week industrial training in their reputed organization. This provides me a wonderful & learning experience for me to go through this training.
Finely, I would like to thanks all those colleagues who help me out of intensifying my technical knowledge & provide satisfactory solutions to my all queries.
Name : Bhavya Kapoor Mechanical Engineering
PREFACE
In college and industry student learns about the theoretical subject and generalized practical processes, but now a day the industries are much diversified and specialized, that they required the person very suitably in particular field. Every industry has to give the training to the new recruits before putting them onto job. Due to this reason Mahindra & Mahindra Ltd. Mohali projected a scheme under which students go for industrial for six week.
During this period I have written a report about two week training. This report has been written in simple language according to the steps used in manufacturing of Tractors. Any omissions and suggestions for the important of this report will be highly appreciated.
Name : Bhavya Kapoor Mechanical Engineering
TABLE OF CONTENTS
SWARAJ HISTORY
PTL’S BIRTH
GROWTH OF PTL
INTRODUCTION TO PTL
LIGHT MACHINE SHOP
HEAVY MACHINE SHOP
REFERENCING
HEAT TREATMENT SHOP
ASSEMBLY SHOP
DISMOUNTING
PAINT SHOP
ENGINE TESTING
BIBLIOGRAPHY
SWARAJ HISTORY
The Indian Tractor Industries, as it is now, is a major segment of its
engineering industry. However till 1974, Indian firms assembling semi
knocked down (SKD) kits in collaboration with foreign manufactures met the
tractor requirements of the country largely through imports & partly. Though
the first Tractor Company was set up in India in 1960, but the growth in real
terms started from 1974, when the government banned the import of tractors.
Today India is the largest tractor producing and consuming country. In an
effort to reduce imports & develop indigenous technology, the government,
permitted setting up of the major manufacturing companies.
1. Eicher Good Earth 1960
2. TAFE 1964
3. International Tractors 1965
4. Escorts Tractors 1966
5. Ford Tractors 1971
6. HMT 1973
7. Punjab Tractors 1974
8. Kirloskar 1974
9. Harsha 1975
10. Auto Tractors 1981
11. Universal Tractor 1982
GEOGRAPHICALLY
TERRITORY %age of Domestic Sales
North (Punjab, Haryana & Uttar Pradesh) 32%Central (Madhya Pradesh & Rajasthan) 26%East (Bihar, West Bengal, Orissa & Assam) 10%
West (Gujarat & Maharashtra) 12%South (Andhra Pradesh, Tamil Nadu, Karnataka & Kerala) 20%
SEGMENTWISE
HP Range %age of Total Sale
Up to 30 HP
31-40 HP
Above 40 HP
19%
51%
30%
PTL’S BIRTH
Keeping in mind Punjab agrarian economy it was decided by Punjab
Govt. to encourage the growth of industries which complements Punjab’s
agricultural growth. This task was entrusted to P.S.I.D.C. that was played a
major role in bringing Punjab to threshold of industrial revolution. With the
dual objective of industrial & agricultural growth, P.T.L. was established on
27th June 1974.
LOCATION
The factory is located at S.A.S. Nagar, the important industrial town of
Punjab, 5 kms. from Chandigarh. This factory was among the first to be set up
in this industrial town. The company is managed by board of Directors, while
the day to day operations are managed by Vice Chairman & M.D. of the
company.
GROWTH OF PTL
PUNJAB TRACTOR LIMITED started with an annual capacity of five
thousand tractors & with a capital of Rs. 3.7 crores. It went into commercial
production in the year 1974; its first production was 26.6 BHP tractors given
the name SWARAJ-720. Ever since then P.T.L. has not looked back. In the
first twenty years of existence its capacity has been increased to 24,000 per
annum, which is a considerable achievement by any standards. Besides
tractors, it has added a host of other products to its range, which includes:
Harvesting Combine.
Fork Lifters.
Agriculture implements.
Punjab Tractors Ltd (PTL) is one of the leading manufacturers of tractors in India. PTL has been known as the industry out performer since inception. Even when the industry grew at a CAGR of 6.1% during 1991-2000, PTL grew at the CAGR of 11.9%. In terms of market share, PTL is the second largest player after M & M in FY2001 with a market share of 18.1%. PTL tractors are sold under the ‘Swaraj’ brand name. PTL has strong market share of around 20% in the northern region with the highest share in Punjab and Haryana and 16% in the western regions and southern regions of India. In the east the company accounts for 11% market share. The tractor sales accounted for 83.3% of PTL's turnover in FY2001 whereas the harvester-combines, forklifts and spare parts accounted for the balance. Industry basics The Indian tractor market is dominated by low price, rugged, versatile and low to medium powered tractors; the main reason being the inability of farmers to invest in farm mechanization. Tractors are categorized on the basis of horse power (HP) of the engine. In India, the popular range of tractors is 20-40 HP compared to 60 HP in Europe and 90 HP in the USA.
Though large tractors were economically unviable in India, there has been an increasing demand for high-powered tractors due to soil conditions, particularly in states of MP, Gujarat and Maharashtra. But more recently, higher-powered tractors are also being sold in states like Punjab where it is considered as a status symbol. Tractors available in India are 1/4th of the prices of similar powered tractors internationally or in developed countries. Availability of credit is the most crucial factor impacting tractor demand, as in India 90% of the tractors are financed by bank credit at concessional rates. Increased use of irrigation facilities, shift towards multi-cropping, consolidation of lands holdings, promotion of co-operatives and higher investment in agriculture also contributes to higher tractor demand. The tractor segment comprises players like Eicher, Escorts, HMT, Punjab
Tractors, M&M, TAFE, Sonalika, which control about 98% market share. India is the world’s largest market in tractors since 1996. A few international players like Case New Holland, John Deere and Steyr have also set up facilities in India. But these players have entered the higher-powered category and, thus, pose little threat to the existing players who enjoy advantages of established distribution/service network and strong brand equity. Punjab Tractors is promoted mainly by Punjab State Industrial Development Corporation Limited and has acquired the second highest market share in the tractor segment from 9.1% in 1975. In 1970, PTL had major competition from other companies like Eicher, Tractors and Farm Equipment (TAFE), Mahindra & Mahindra (M&M), Escorts and HMT. PTL is one of the leaders in its business and has put up a heady performance in contrast to other private sector players. As against other players, which report a ROCE of 15% on an average, PTL has consistently remained at about 50% in the last few years though the industry is capital-intensive. Punjab Tractor is the only major tractor company, which entered this business without any foreign collaboration. The company has beefed up its R&D capabilities in the last two to three years. PTL’s Swaraj-735 is in a class of its own and has been benchmarked by its competitors to which 16 new features have been added.
PTL has single – mindedly focused on increasing its market share in tractors. Current Scenario During the first half of 2001-02 PTL increased its market share from 18.5% to 21.4%. With the total industry volumes plummeting by 16.6% the sales of PTL fell only a trifle 3.1%. Under these circumstances, though the revenue has fallen by a 0.38% the operating profitability has risen by 1.03%. PTL garnered the operating margins of 19.4% in the first half of FY2001-02, while the lead players like M&M Escorts and Eicher have reported operating margins of 4.4%, 0.7% and 2.9% respectively. The Net Profit has increased by 1.4% to Rs.564 million and the contribution of 40-50HP tractors has increased by 30%, which indicates higher margins from bigger tractors due to a strong foothold in Punjab and Haryana markets.
SWARAJ’S YEARLY PROGRESS
1965: Govt. of India's research institute (CMERI) at Durgapur initiates design
and development of SWARAJ tractor based on indigenous know-how.
1970: Punjab Govt. through PSIDC acquires SWARAJ tractor's design from
CMERI and establishes Punjab Tractors Ltd. (PTL) for its
commercialization.
1971-73: PTL sets up SWARAJ Project for 5,000 tractors per annum at a
capital outlay of Rs. 37.0 million with an equity base of Rs 11.0 million.
Heat treatment shop plays a very important role in every industry. In
automobile industry all the gear and shafts need to be heat treated to impart
desired strength and increase life of the component. The H.T. shop at PTL is
equipped with several gas carbonizing furnaces, quenching tanks, induction
hardening machines and shot blasting furnaces.
Heat Treatment is an operation or combination of operations involving heating
and cooling of metals and alloys in the solid state to produce certain desired
properties. All the heat treatment processes may be considered to consist of
three main parts:
1. The heating of the metal to pre-determined temperature.
2. The soaking of the metal at that temperature until the structure becomes
uniform throughout the mass.
3. The cooling of the metal at some pre-determined rate to cause the formation
of desirable structures within the metal/alloy for the desired purposes.
PURPOSES OF THE HEAT TREATMENT
Changes in properties result from the micro-structural changes in the material
produced by heat treatment operation. However, these serve one or more of
the following purposes:
1. Improve machinability.
2. Relieve internal stresses.
3. Improve mechanical properties such as ductility, strength, hardness, toughness etc.
4. Change in grain size.
5. Increase resistance to heat and corrosion.
METHODS OF HEAT TREATMENT
Various methods depending upon the nature of job .i.e. it material, use etc are
employed for giving then Heat Treatment. These methods used are:
Annealing
Normalizing
Hardening
Quenching
Tempering
Case Hardening
a)carburizing
b)Cyaniding
ANNEALING
Annealing means softening of the material by heating and cooling process.
The cooling stage may be performed by regulating the fall of the temperature
in the furnace or by buried the article in sand or lime, and quenching in oil or
water, according to the material being treated.
NORMALISING
In this process the material is heated steadily through out its mass to just
beyond the critical temperature, and then withdrawn from the furnace and
allowed to cool in still air. With the normalizing process there is not soaking
period, for the work is held at the desired temperature for a period only
sufficient to give uniformity through out the mass.
HARDENING
The operation of hardening is applied to all the tools and some important
machine parts intended for especially heavy duty service, as well as to all
machine parts made of alloy steel. Hardening of steels is done to increase the
strength and wear properties.
QUENCHING
Quenching is the act of rapidly cooling the hot steel to harden the steel. Oil is
used when a slower cooling rate is desired. Oil quenching results in fumes,
spills, and sometimes a fire hazard.
TEMPERING
It is an operation to reduce the internal stress and brittleness. With plain
carbon steel, tempering operation consist in slowly heating the hardened
material from room temperature up to maximum of about 600oC and then
quenching in water or oil, the temperature and length of soaking period being
dependent in service requirement. Thus if plain carbon steel is to be hard
without any appreciable ductility, a temperature of about 150oC will be
required.
CASE HARDENING (CARBURISING)
It is method of producing hard surface on steel. The steel used for this purpose
is usually a low carbon steel of about 0.15% carbon, which does not respond
appreciable to heat treatment. In course of the process, the outer layer is
converted into high carbon steel with a carbon content ranging from 0.9% to
1.2% carbon.
ASSEMBLY SHOP
The Assembly at SWARAJ TRACTOR DIVISION deals
with the assembly of tractor models 722, 724, 733, 735, 744, and
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
Differential loop.
Gearbox loop.
Rear cover loop.
Engine assembly loop.
DIFFERENTIAL LOOP
Differential casting mounted on trolley after washing.
Bull pinion Shaft left and right fitted.
Cage assembly fitted. It consists of:
1. Crown wheel.
2. Tail pinion assembly.
3. Roller bearing.
4. Bevel wheels.
5. PTO shaft fitted.
6. Rear axle/trumpet is fitted.
7. PTO shifter assembly fitted.
8. Gearbox assembly is lifted.
9. Rear cover assembly fitted.
10. Brakes are fitted.
11.Parking brake.
12.Suction pipe
13.PTO cover
14. Trailer hook is fitted.
15. Angle bracket is fitted.
16. Rocket link is fitted.
17. Footboard is fitted.
GEAR BOX LOOP
Gearbox housing mounted on trolley.
Drive shaft & input shaft assembly.
Output shaft assembly.
Lay shaft and connecting shaft assembly
Shifter rod assembly.
Steering assembly.
REAR COVER LOOP
Rear cover mounted on trolley.
Control valve and response valve assembly.
Ram assembly. (This consists of cylinder, piston and piston
rods.)
Testing of hydraulic lift.
ENGINE ASSEMBLY LOOP
Engine mounted on trolley
Dynamo is fitted.
Self-motor is fitted.
Oil pump is fitted.
Front axle beam and bracket is fitted.
Clutch plate is fitted.
After that the chassis is carried to the next level by the lift where
the engine & the 3-point assembly of the tractor along with the other
components are fixed. The parts fitted here are:
3-point linkage which contains the following parts:
Bracket.
Lower link fitted at the left side.
Leveling rod fitted at the right side.
Stabilizer stainer.
Draw bar.
Top link.
Battery frame.
Front frame.
Tie rod attached with the drop arm of the steering system.
Accelerator link.
Delievery pipe.
Engine attachement.
The engine is attached with the chassis system in this level of
assembly. The engine is also carried to this level with the help of the
lift crane, which lifts the engine assembly & delievers it to this level.
Shlug is applied at the corneror we can say at rhe circumference of
the gearbox where engine is attached with studs & bolts. Shlugs
works as gaskets or seals & avoid the oil leakage & water mixing in
the engine. the engine, which is suplied to this level of assemble
where the engine is attached contain the following parts attached on
it:
Front axle.
Extension in the front axle used for the setting of the wheels.
K.P.S.A. (King Pin Shaft Axle) with the wheel disc & nuts
fitted in there for the fitting of the wheels.
Drop arms.
Tie rods.
Bucket.
Clutch plates
Alternator.
Self starter.
Fuel pump.
The above parts are already fitted with the engine when it
comes to the engine chassis assembly. The make of the engine is
KIRLOSKOR or SWARAJ KIRLOSKOR depending upon the
model as 3-cylinder, 2-cylinder or 1-cylinder. The engine was
imported from this company from Pune. SWARAJ also has its own
engine plant where the engines are assembled. After assembling the
chassis & engine arrangement, the fitments are checked by the
workmen appointed there at this level & if there is some part
missing, it is attached here. Then the whole assembly is mounted
over the conveyor, which takes that piece to different chambers of
washing, drying, primering, baking, painting & again baking.
After painting the conveyor takes the assembled piece to the DISMOUNTING STAGE where different parts & components are fitted on the tractor & the tractor was completed. After that the testing of the tractor is done. A tractor has to pass through different tests to claim itselfs to be as perfect & if there is some problem coming out in this stage, the tractor is send to the recovery shop, where the problem of the tractor is recovered. After the recovery the tractor is again tested & after passing the test the tractor finally send to the yard from where it is send to the R & D Complex for further tests.
PICTURES OF ASSEMBLED DIFFERENTIAL
DISMOUNTING STAGE:
After the processes of washing, drying, painting, baking, the
assembled piece is finally arrived to the DISMOUNTING STAGE
through conveyor. This dismounting stage is further divided into
different small stages & in each stage, 2 persons works at a time, on
an assembled piece of chassis & engine. The work is divided
between these 2 men at the different stages. The dismounting stage
is divided into 5 different stages in which the parts of the tractor are
fitted on the assembled piece of chassis & engine & in every 6
minutes, we got a complete tractor, which is removed from the
conveyor of the dismounting stage.
STAGE 1:
Alternator connection
Horn
Brake rod
Brake switch connection
Fan belt
STAGE 2:
Speedometer wire
Rear frame
Fuel tank
Overflow pipes
Felt pads
STAGE 3:
Fan
Radiator
Hose pipes
Dash board (it mainly has instrumental panel which con-
Sheet metal covers (side panel covers, side shield, bon-
net, front grill)
Fenders
Tyres fixing
Batter cover
Torque checking
Engine oil pouring and greasing
Charts and stickers
After completing all the above stages the tractor reaches the
point where it is removed from the conveyor, which is known
as the DISMOUNTING STAGE of the tractor. A platform is
there & when the tractor reaches the platform the conveyor is
removed & the tractor is free. After that the tractor slides down
the platform & reaches the stage, which is the final stage after
the dismounting of the tractor. This stage comes before the
testing of the tractor. In this following functions & equipments
are fitted on the tractor:
Air cleaner
Exhaust
Front tyres distance check and adjust
PAINT SHOP
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.
NEED FOR PAINTING
Long life
Rust resistance
Better look (more appealing)
The various operations performed in paint shop are:
Surface Preparation (Pre Treatment Cell) - carried out for sheets and rims.
Painting – JOST 1(dash board, rear frame, front shield, top bonnet), JOST
2(fenders, side panel), CHASIS BOOTH (washing, primer, washing zones),
FINAL TOUCH UP.
Inspection
Rejection (Reprocessing)-for sheets and rims.
PAINTING
The process (sheet and rim painting) includes
Full Primer + one coat of paint (30-40 microns)
Flash off (This is the distance given so as to allow paint to dry)
Baking (120-130 degree centigrade)
Rubbing
Cleaning with tag rag
Final painting
Flash off
Baking
CHASIS PAINTING
Washing
Drying
Primer painting
Flash off
Final painting
Flash off
Baking
After painting inspection is carried out inspection is carried out and the product is
passed or rejected.
Various parameters checked are:
Depth of penetration of paint
Thickness of paint coating
Smoothness
ENGINE TESTING
After assembly engine is brought to engine testing section. In this section practical checking of engine is done on the engine and water supply is connected to it then the engine is started with external battery power supply. There the proper operating of valves is done, the engine is kept running for two hours. During running the load is also varied and various properties like lubricating oil pressure, load capacity, fuel consumption etc is checked.
The lubricating oil pressure in the engine should be 3.8to 4.2kg/cm2 for proper working load capacity of engine is checked by applying load on the shaft of the engine through water. Brake dynamometer in which water is applied on the roller when is turn the pressure of shaft water. Pressure is controlled by lever. The load is applied in such a way that max, rpm of engine cover by 200.
Supplying a measured quantity of fuel usually also checks the fuel consumption of the engine 100cc of diesel or fuel is supplied to the engine. The time taken by the engine to consume the fuel is noted. During the testing, the engine is kept on load.
FOR TESTING ENGINE IS KEPT RUNNING FOR 1 HOUR AND 55 MINUTES.
BIBLIOGRAPHY
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- “PUNJAB
TRACTORS LTD.” I received the blend of experience in Private as well
as in Govt. sector. 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 throughout 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