sonalika training report

INDUSTRIAL TARININGREPORT

BY

ROHIT THAKUR

ROLL NO. 81404114070

MECHANICAL ENGINEERING

SANT BABA BHAG SINGH INSTITUTE OF ENGG. &

TECHNOLOGY

JALANDHAR- 144020

ITL

(INTERNATIONAL TRACTORS LIMITED)

ACKNOWLEDGMENT

I am highly grateful to the Dr K.D. Mannan, HOD

department of mechanical engineering Sant Baba Bhag

Singh Institute of Engineering & Technology (Padhiana) ,

for providing this opportunity to carry out the six month

industrial training at Sonalika International Limited

Hoshiarpur. I would like to expresses my gratitude to other

faculty members of Mechanical department of SBBSIET,

Padhiana for providing academic inputs, guidance &

encouragement throughout the training period.

The author would like to express a deep sense of gratitude

and thank Mr.D. Mittal Director/CEO of Company,

without whose permission, wise counsel and able guidance,

it would have not been possible to pursue my training in

this manner. The help rendered by Dr. K.D. Mannan,

Supervisor Gurvinder singh for experimentation is greatly

acknowledged.

Finally, I express my indebtedness to all who have directly

or indirectly contributed to the successful completion of my

industrial training.

CERTIFICATE

I hereby certify that Rohit thakur, Roll No 81404114070 of Sant Baba Bhag Singh College of Engineering & Technology Padhiana has undergone six months industrial training from DEC 2012 to JUNE 2012 at our organization to fulfill the requirements for the award of degree of B.Tech. (Mechanical). He worked on HMS project during the training under the supervision of Gurvinder singh. During his/her tenure with us we found him/her sincere and hard working. We wish him/her a great success in the future

Sonalika Group Introduction

Sonalika Group is contributing to green revolution in India Since 1969. Initially it started with Farm Equipments and Machinery. Brand name of the group products is "SONALIKA". Market share in Farm Equipments is 80 % in India. Group turnover is 220 Million USD (INR 1000 Crores). Sonalika Group is one of the top five tractor manufacturers in India. Apart from tractors its product line includes multi utility vehicles, three wheelers,

engines , Hydraulic Systems , Casting , Forging , Brake System , Automotive components manufacturing and various farm equipments and implements.  Sonalika group since the inception has tried to understand customers need to be able to facilitate them with its value for money products. The company has a state of art manufacturing facilities, spread in acres, located in the pollution free suburbs of Punjab and Himachal Pradesh. 

Sonalika is also an environmentally responsible corporate citizen and has developed in-house, the vehicle engines that confirm to Bharat II Norms. It is now in the process of developing the Bharat III engines for its advanced products. No wonder Sonalika products have created a niche for themselves not only in India but also in foreign markets including France, Zimbabwe. 

 An average growth rate of 30% makes it one of the fastest growing corporate in India. It also happens to be one of the very few debt free companies in the world. It employs about 2500 people including some of the renowned names in the industry. The company works on the maxims of low production cost and clean and safe environment. Such efforts have fetched the company the accreditations like ISO 9001:2000 and ISO 14001.  

THE COMPANY BACKGROUND

Sonalika Group started its journey of

success during 1976 when foundation of small-

scale unit to fabricate and assemble Wheat

Harvesting Machines (Thrashers) was laid. With

the passage of time this small initiative was taken

by Mittal brothers in 1976 turned into a great

success due to the undulated efforts of its

promoters and thousands of employees who

worked unaltered throughout. The great success

provided further motivation ultimately resulting in

setting up a new plant in the name of International

Tractors Limited for the production of tractors, the

demand and requirement of which was steadily

growing at that time. The plant which set up at

Chak- Gujran (Hoshiarpur) is now spread over an

area of 65 acres (approx.) Now Sonalika group

consists of 2 companies: International Tractors

limited (JOINT VENTURE WITH RENAULT

FROM FRANCE)

Shareholding:

Sonalika Group = 80%

Renault Agriculture = 20%

Annual Turnover = Rs.2098 Million approx. (As on 31/03/2003)

Group Turnover. The Group Turnover for the Current Fiscal Year is 1000 Crore INR (Indian Rupees)

Tractors Productions Overview:

Year Tractors (Numbers)

1996-1997 396

1997-1998 2770

1998-1999 6211

1999-2000 8773

2000-2001 13496

2001-2002 17002

2002-2003 16464

2003-2004 20020

2004-2005 26082

Agriculture Machinery Production Overview:

YearAgriculture Machinery (Numbers)

1996-1997 5000

1997-1998 7500

1998-1999 12000

1999-2000 18000

2000-2001 24000

2001-2002 32000

2002-2003 17820

2003-2004 16090

2004-2005 18040

Group Units:

International Tractors LTD Sonalika Agriculture Industries

Sonalika Capital Ltd. Punjab Agriculture Industries

Casting Corporation of IndiaInternational Cars & Motors Ltd

International tractor Ltd. was established on

1996 - 1997. Now in JUNE2003, the production rate of

tractor is 60 per day. The total no of employees working

in ITL is 1200.The total no of dealers of ITL in India &

neighboring countries are 548. ITL have introduced 15

models of tractors. There are 5 regional offices in India,

which are at DELHI, PATNA, AHMEDABAD, MANIPUR

and BHOPAL. Turn over of ITL if 400/crore. Company

got ISO 9001 Certificate in April 1999 BY ICL. Company is

also running its own agriculture equipment making

industries, which is producing thrasher, disk harrow,

wheat harvester etc. They have got collaboration with

RENAULT AGRICULTURE LTD. FRANCE in February

1999. Renault Agriculture provided state of the art

technology and latest designs.

The Company And Its Tie Up With Renault:

The company has recently signed a tie with Renault of

France who is the world leaders in the field of tractor

manufacturing and was rated as world’s number one

tractor company at the year’s award in Italy. ITL has

signed an MOU with Renault Agriculture, a 100%

subsidiary of Renault group of France to manufacture

and market tractors of Renault Agriculture design in

India and neighboring countries.

Renault Agriculture designs manufactures &

distributes tractors and agricultural machinery in 1998; it

recorded a scale of more than $ 600 million. It has three

factories and 1883 people working for it and is

represented in 52 countries across the globe.

The MOU signed by ITL with Renault Agriculture

is a three-pronged collaboration, Technical, Financial

and Commercial. It was signed by Mr.I.D.MITTAL

(Chairman) and Mr.B.MORANGE (MD-Renault

Agriculture). A major highlight of agreement is that

Renault will open the European and Asian markets for

Sonalika. The world leader will jointly participate in the

inter-national marketing strategies and efforts to market

products of both the companies. Another special feature

of the agreement is that Renault Agriculture will take

minority equity stake of 20% in present ITL that will

remain under its management control. By joining hands

with the market leaders in France, the world’s biggest

European tractors market, Sonalika is sure to go a long

way.

ITL went into collaboration with Renault agriculture of France in July 2000.Renault Agriculture is a subsidiary of the Renault Group with 51% stake owned by CLAAS, Germany. Renault Agriculture is the largest tractor manufacturing company in Europe. It produces tractors in the range of 50-250 HP, having worldwide distribution ands sales network.

Renault Agriculture - ITL agreement results in the production of Ceres and Solis tractor under Sonalika brand name.

With a turnover of more than € 637 billion (2002), Renault is one of the 30 largest companies in the world. Each year Renault produces over two million vehicles and employs over 140,000 people. Renault has alliance with NISSAN to complement the financial and technical strengths bringing in synergic growth.

CLAAS is a leading manufacturer of farming equipment with a global presence. It is the world market leader in forage harvester. Apart from the farming products CLAAS also produces hydraulic components and transmissions. CLAAS purchased 51% stake in Renault Agriculture in March 2003. It recorded the turnover of over 1,000 million € in the last financial year

MISSION: International Tractors Ltd. offer quality product

with distinctive features at reasonable price .The

company ensure better than the best after sale service

for the satisfaction of the customer .The firm is ranked

as best in terms of its quality and production front.

Company is exporting its tractors to different Asian as

well as African countries.

Memorandum Of Understandings:

The Indian tractor market is dominated by low price, no frills, rugged, versatile and low to medium powered tractors. Tractors have an integral part of farm mechanization and have a crucial role to play in increasing productivity. In India 90% of the tractors are financed by bank credits at concession rates. Availability of credit therefore, is the most crucial factor impacting tractor demand.ITL has signed MoUs with various banks all over the country for tractor retail finance, which is giving a special impetus to company. It has resulted in easy availability of loans to farmers coupled with quick

disposal of cases. The payment rotations have also become faster from the dealers to the company, which helps cost cutting.

Following is the list of banks, ITL alliances with:

Canara Bank ICICI Bank UTI Bank Ltd. Punjab National Bank (PNB)

State Bank of Patiala

Andhra Bank Central Bank of India (CBI)

Allahabad Bank

State Bank of Bikaner and Jaipur (SBBJ)

State Bank of Indore

Corporation Bank Bank of Maharashtra

Union Bank of India

Oriental Bank of Commerce (OBC)

Bank of Punjab (BOP)

WORK CULTURE:

The I.T.L. Seeks to create a culture where each

employee, vendor, and dealer feels himself responsible

and integral part of the enterprises. The work culture at

I.T.L. is open & participative. Learning is encouraged in

the company.

Every member respects 5 F formulas

1. Fast 2. Focused

3. Fair 4. Friendly.

5. Fun

This governs its approach to business and

relationships within the organization. It has designed its

management structure in response to the needs of quick

decision-making and operational flexibility even through

hierarchies and designation does exit. It is a highly

informal organization where communication moves in

all direction, decision-making is quick and to a large

extent delegated

Every member respects 5 S formulas also:-

1. Seiri

2. Seiton

3. Seiso

4. Seiketsu

5. Shitsuke

5s stands for the first five letters of the Japanese words:

S.No. JAPANESE

WORD

Meaning

1s SEIRI sorting out, clearing, segregation, proper

selection, remove the waste

2s SEITON systematic arrangement, keeping things at

proper place.

a place for every thing and every thing in its

place

3s SEISO cleaning (spick and span) quality by the

cleanliness. keep clean all area, equipment and

work place

4s SEIKETSU standardizing, environment, cleanliness. light,

noise, punctuality.(order and save time)

5s SHITSUKE maintain discipline and standards

to maintain above 4s,respect of rules.

The 5s are also five operations to keep a good behavior for

every work place 5s program started in ITL from December

2000 achieving clean floor and organized racks is not an end in

itself. The ultimate goal of house keeping through 5s is to

reduce the cost of product by increasing productivity and

contributing to total quality.

HOW TO ACHIEVE 5 “S”

5’s’ can be achieved very easily by every employee by having

close look at his work-place, he is to ensure that:

By organizing of work place & surrounding area in a better

way.

No rejected/ unwanted items are lying at his work place.

By keeping all items, equipments at identified place.

Everybody should co-operate with each other in keeping

his and other’s area clean.

Follow and respect of rules & regulations and maintain

required standards.

PLEASE CHECK

Do you have any unwanted things around you?

Are all the required things kept at their allocated

places?

Are you following timings and set norms?

Are you following the operating standards?

Are you regularly reviewing 5’s’?

5 S OBJECTIVE:

Productivity high.

Quality high.

Cost down.

Delivery on time.

Safe work place.

Moral high.

GAINS OF CLEANLINESS (5 “S” RESULTS)

work place neat & clean (good house keeping)

clean work place is high in productivity

clean work place has high quality

keeps the cost down (reduces rejection, rework, reducing

down in time)

ensure delivery in time

keeps moral high of people (encouragement)

safe for people to work (preventing accidents, creating

healthier environment etc.)

lowers the defect rate & exposes the quality problem

promptly

sales department will be eager to show the plant to the

customers and feel proud of it

everybody feels free & works proudly

appreciation to the management & the business increase

proper utilization of work place, workmen & machinery

customer satisfaction and continuous improvement

top management hours the commitment

team-work, leadership, motivation and professional

expertise

OBJECTIVES OF 5 “S” LAYOUT:

To minimize the handling & transportation of materials

with safety.

To ensure economic utilization of floor space.

To minimize the cost of production & inventory by

eliminating wastes.

To ensure efficient control over the various processes of

production.

To obtain more utilization of machinery, equipment &

other facilities.

WHY 5 “S” LAY-OUT NECESSARY:

For increasing the out-put of the existing products.

For introduction of new product & diversification.

For switching-over to technological advancements in

machinery, materials, Processes, product design, fuel &

energy etc.

For elimination of wastes.

For environment, discipline and safety.

FACTORS AFFECTING 5 “S” LAY-OUT (PITFALLS):

Area, location

Type of work

Work environment

Repairs & maintenance

Changes in part drawing/ models.

Management job is to continually improve the system in

terms of design, material, method, maintenance, machine

capability and training etc

BASIC CONCEPTS OF 5’S’

Improved house-keeping

Work place organisation

Generating a disciplined work-force

Greater team-spirit

Self-consciousness of improvement

Improved work-flow

Better control of work in processes and product quality

Control and minimization of rework

Improvement in quality and productivity

Cost-reduction

Better working conditions

FUTURE PLANS:

1. to provide superior quality tractors over all world with

new technology at reasonable rates, and to become no. 1

in automobile industry within five years.

2. Itl have plans to market 25,000 tractors during current

financial year.

CAREER GROWTH:

Sonalika group has grown 127% within a period of 3

years, If one shows good performance in the assignments given

to him there is nothing that can stop him from developing new

skills. The management also believes in imparting training on

the job as well as classroom training for improving / developing

the employee in behavioral aspects & functional /conceptual

skills through training. The company believes in developing

human excellence.

ACHIEVEMENTS:

o Company, which has shown about 127% increase in

turnover within a period of 3 years.

o Company has produced smoke free diesel engine.

o Company has increased its production of diesel

engines up to 60 engines a day.

o The company has obtained iso 9001 certification.

o Sonalika tractors have made rapid strides in indian

tractor industry by having sold 13496 tractors during

2000-2001 achieving over 50% growth vis-à-vis

industry drop to the tune of 10% as compared to

preceding year.

o Itl has a network of around 514 dealers all over india.

OBJECTIVES OF COMPANY:

The main objective of the company is to bring the

latest technology of high quality and cost advantage to its

consumers. By having a strong r & d with help of its

technological partner renault agriculture, the fully

computerization manufacturing facility ensures a non-stop

supply of quality tractors.

Apart from the general objective every departments have

their own objectives. Which are in tune with the main objective

of the company? In that sense the main objective of personnel

department is maximum utilization and development of the

human resources available keeping all the aspect of human

being in view?

The personnel department of itl, ensures the welfare

of the employees at the maximum level, and keeps morale of

the company at high.

CORPORATE MISSION OF THE COMPANY:

1. To achieve international standards of excellence in all

aspects of agriculture and diversified business with focus

on customer delight through value of products and

services and cost reduction.

2. To maximize creation of wealthy value and satisfaction for

the shareholders.

3. To attain leadership in developing, adopting and

assimilating state of the art technology for competitive

advantage.

4. To provide technology and services through sustained

research and development.

5. To faster a culture of participation and innovation for

employees growth and conditions.

6. To cultivate high standards of business ethics and total

quality management for a strong corporate identity and

brand quality.

7. To help enrich the quality of life of the community and

preserve ecological balance and heritage through a strong

environment conscience.

8. Hence the vision of the company can be described as

providing latest technology advanced tractors to the

consumers. Maintaining standards of quality and

customers. Maintaining standards of quality and

customers satisfaction. Constantly increasing profits by

achieving higher growth rate. The company had achieved

an impressive over 30% growth rate during last year when

the entire industry was reeling under economic recession.

At present the company has a strong nationwide network of

528 dealers. The distribution in the various states is:

Andhra pradesh 26

Assam 4

Bangladesh 1

Bihar 37

Gujarat 31

Haryana 37

Himachal pradesh 4

Jammu &kashmir 1

Karnataka 18

Kerala 1

Madhya pradesh 68

Maharashtra 35

Mizoram 1

Nepal 9

Orissa 10

Punjab 48

Rajasthan 53

Tamil naidu 19

Uttar pradesh 131

This distribution of dealer network has helped the company to

provide sales and services to its customers. The company is

catering to the market not only throughout India but also various

other countries like Nepal and sri lanka.

Production Of Tractors:

Sr.

No.

Financial year Production

(nos.)

1. 1996-1997 396

2. 1997-1998 2808

3. 1998-1999 6375

4. 1999-2000 6493

5. 2000-2001 13502

6. 2001-2002 16931

7. 2002-2003 16627

8. 2003-2004 19616

9. 2004-2005 26855

10. 2005-2006(Till

November)

16084

THE VARIOUS DEPARTMENTS OF ITL:

1.MATERIALS

2.Q. C.

3.PURCHASE -

4.STORE

5.FINANCE

6.EDP/SAP

7.PRODUCTION

8.PAINT SHOP

9.ASSEMBLY

10. HMS

11. LMS

12. H.T. SHOP

13. REWORK

14. ENGINE DIVISION

15. R & D

16. RSI

INTRODUCTION: -

The Heavy Machine Shop is one of

the most important shops of the industry. It plays a

very important role in the production of the tractor. As

the name suggests all the heavy components namely,

the differential housing, the gear box housing, the

crankcase housing, the cage and trumpet are machine

here. The shop is called the backbone of the industry.

The Heavy Machine Shop divided into five sections.

1. Differential housing line

2. Gear box housing line

3. Cage & trumpet line

4. Crankcase housing line

5. Tool room

All the sections are highly equipped

with modern machinery and equipment. Each section

has a process layout i.e. the raw material is received at

one end and the finished component is dispatched

from the other. The material received is in form of

casting. The machining process is carried out under

strict quality norms. There is inprocess inspection at

each workstation. The component is made to go

through final inspection before it is dispatched for

assembly.

The Material handling System in the H.M.S shop consists of hydraulic lift trucks, power hoists, roller conveyors, overhead crane, fork lift trucks, bins etc. the shop has well designed network of roller conveyors. The castings from the truck are loaded onto these conveyors and the material travels to reach the respective section. At the end of each conveyor a section for inspection has been made so as to make the component through the inspection process. Each workstation is provided with a power hoist of 500Kg (load carrying capacity). These are used to pick casting from conveyor and load them onto the machine and vice versa. There is also a provision of a 2-ton carrying capacity overhead crane in each section.

INSTRUMENTS FOR HEAVY M/C SHOP

S.No

.

Instrument

s

Size Components

1. Vernier

calliper

0-100 Diff. hsg., trumpet hsg., Cage

assembly

2. Vernier

calliper

0-400 Gearbox hsg.

3. Vernier

calliper

0-600 Trumpet hsg.

4. Micrometer 0-25 Gearbox hsg. Cage assembly

5. Micrometer 25-50 Diff. hsg. Gearbox hsg.

6. Micrometer 50-75 Diff. hsg., Gearbox hsg.

7. Micrometer 75-100 Gearbox hsg., Trumpet hsg.

8. Micrometer 100-

125

Trumpet hsg, differential

hsg.

9. Micrometer 125-

150

Diff. hsg. Trumpet hsg.

10. Micrometer 150-

175

Cage assembly

11. Depth vernier 0-200 Trumpet hsg.

12. Bore gauge 10-18 Gearbox hsg. Cage assy.

13. Bore gauge 18-35 Diff. hsg. Gearbox hsg.

14. Bore gauge 35-60 Rear cover

MACHINES IN HMS

DIFFERENTIAL HOUSINING LINE

Following are the machines in differential line:

Vertical Milling Centre (VMC 1200) - II

Duplex Milling Machine - I

Duplex Milling Machine – II

Rough Boring machine

Two Way Boring M/c (Hydraulically Programmable)

Two Way Multiple Spindle Boring, Drilling S.P.M

(Special Purpose Machine)

Fine Boring Machine - I

Fine boring machine – II

Multiple spindle drilling machine - I

Radial drilling machine

Multiple spindle drilling machine - II

Multiple spindle drilling machine – III

Flexi arm (Tapping machine)

VERTICAL MILLING CENTER: -

The machine is called vertical milling

centre because in this the tool is perpendicular to the axis

of the job. VMC is a fully automatic and high precision

machine. The machine is controlled by computer, which

regulates the feed and rpm of the tool and also the

movement of the job. In this machine the tool is

stationery and the job moves horizontally (x-axis and y-

axis). The movement of tool is restricted to z-axis only.

The various operations that are performed on VMC are:

Face Milling Chamfering

Rough Milling Reaming

Fine milling Boring

Drilling

DUPLEX MILLING MACHINE: -

It is a hydraulically controlled

milling machine. On this machine the milling of both the

faces of the differential housing is done simultaneously.

The machine is fitted with two circular cutters having 64

inserts and one wiper each. The 64 inserts are for rough

milling and one wiper is for finishing. The job is fed

between these two cutters. Movement of job is in x-axis

only and movement of cutters is restricted to y-axis only.

The machine is a high precision machine and produces

components with high degree of surface finish.

ROUGH BORING MACHINE: -

It is a hydraulically controlled boring machine. In this machine we can bore the hole for brake housing of dia 109mm Lt & Rt on

differential housing &. also bore the hole for trumpet housing of dia 129mm Lt & Rt on differential housing In this machine we can also bore T.P.Carrier hole of dia 114mm.

TWO WAY BORING MACHINE: -

It is hydraulically controlled boring

machine. In this machine tool is move paralle to the job and

from both side . This machine is used for boring the hole for

P.T.O. shaft of dia 71 mm.

TWO WAYMULTIPLE SPINDLE BORING

DRILLING (S.P.M): -

It is an special purpose

machine .In this machine bore the fine hole for

T.P.Carrier and P.T.O. Shaft and also drill the

hole for mounting the T.P.Carrier and P.T.O.

Shaft cover and other acceseriory on the back

side of the differential housing

FINE BORING MACHINE: -

It is also an hydraulically controlled

boring machine In this machine bore the hole of dia

130mm for trumpet mounting and brake housing

mounting of dia 110 mm. simultaneously by fixing the

fixture with this machine.

RADIAL DRILL MACHINE: -

s. no. OPERATIONS DIAMETER

1 Drill 12 dia.

2 Drilling 16 dia.

3 Hole milling 17.7 dia.

4 Reaming 18 dia + 0.033

This machine is move in a radial

direction of job. The operation done in this machine to

drill the hole for drain plug of dia 10.2mm×24mm and

then tapping is done of dim. 24×1.5mm.

MULTI SPINDLE DRILL MACHINE-I: -

In this machine drill the 20 hole Lt

&Rt on differential housing simultaneously by fix the

fixture with this machine .Drilling is done for mounting

the trumpet & brake housing.

MULTI SPINDLE DRILL MACHINE –II: -

In this machine drill the hole for filter

mounting on the left side of differential housing and

hole for front plate on the right side of differential hous-

ing of dia 6.7×22mm.

MULTI SPINDLE DRILL MACHINE-III: -

In this machine drill hole for

mounting the gearbox on the front side of differential

housing.

FLEXI ARM (TAPPING MACHINE): -

This machine is used for tapping the

all hole, which is done on the differential housing.

GEARBOX HOUSING LINE

Following are the machines in the gearbox housing line:

Rough boring Machine

Fine boring m/c (Special purpose machine)

Heavy duty Lathe

Heavy duty Radial drilling machine

Fine boring m/c

Heavy duty Radial drilling machine

Heavy duty Radial drilling machine

Heavy duty Radial drilling machine

Light duty Radial drilling machine

Light duty Radial drilling machine

ROUGH BORING MACHINE : -

In this machine rough boring for Output Shaft of dia 79mm,Lay- Shaft of dia 89mm & Input Shaft of dia 84mm.is done. It is a hydraulically controlled boring machine. In this machine we can bore the hole for brake housing of dia 109mm Lt & Rt on differential housing &. also bore the hole for trumpet housing of dia 129mm Lt & Rt on differential housing In this machine we can also bore T.P.Carrier hole of dia 114mm

FINE BORING MACHINE : -

In this machine the final boring for

Output Shaft, Lay Shaft & Input Shaft dia is done.

In machining, boring is the process of enlarging a hole

that has already been drilled (or cast), by means of

a single-point cutting tool (or of a boring head containing

several such tools), for example as in boring

a cannon barrel. Boring is used to achieve greater

accuracy of the diameter of a hole, and can be used to cut

a tapered hole. Boring can be viewed as the internal-

diameter counterpart to turning, which cuts external

diameters.

HEAVY DUTY LATHE : -

In this machine facing of front face of

the gear box housing upto dia 418mm and take the total

thickness upto 15mm and total length upto 416mm.is

done

HEAVY DUTY RADIAL DRILLING MACHINE: -

In this machine drill the hole for ideal

gear of dia 23mm. In this machine after drilling boring is

done.

HEAVY DUTY RADIAL DRILLING MACHINE: -

In this machine drill the hole for

clutch shaft and drill the hole on the bottom of the gear

housing for fitting the gear box with chassis and also drill

the hole for drainage of oil. In this machine after drilling

the hole ,boring is done.

HEAVY DUTY RADIAL DRILLING MACHINE: -

In this machine we can first drill the

hole for Z. F. Mounting and also drill the hole for putting

the shifter bush. After drilling the hole for Z. F. Mounting

threading is done.

LIGHT DUTY RADIAL DRILLING MACHINE : -

In this machine drill the hole of dia

13mm on the backside of gearbox for mounting with

differential housing after drilling threading is also done.

CAGE HOUSING LINE

Following are the machines in cage housing line:

Lathe (4 jaw chuck) - Qty. 3

Lathe (Qty. 2)

Radial drilling machine (Qty 2)

Heavy-duty radial drilling machine

Grinding Machine

Boring m/c.

LATHE (4 JAW CHUCK): -

In this machine facing, chamfering,

and turning is done on the inner and outer side of the

left & right cage

LATHE MACHINE : -

In this boring and facing of inner hole

of right and left cage operation is done.

RADIAL DRILL MACHINE : -

In this machine drill the hole on the

spot face of the right cage for mounting the crown

wheel and then match with the left cage and drill the

hole on the spot face of the left cage.

HEAVY DUTY RADIAL DRILL MACHINE: -

In this machine drill the four-hole

perpendicularly for placing the cross.

BORING MACHINE: -

In this machine we bore the entire

hole finally which drill on the right and left cage

TRUMPET HOUSING LINE

Following are the machines in the trumpet

housing line:

Trumpet boring machine

Radial drilling machine

Multiple drilling machinesLathe machine

TRUMPET BORING MACHINE: -

In this machine boring on rear and

front side of trumpet is done of dia 110mm & 80mm.

RADIAL DRILLING MACHINE : -

In this machine threading is done on

the rear side of differential housing for mounting the

axle with them. In this machine drilling is also done on

the front side of trumpet & then threading is done of

that hole for removing the differential with casting.

MULTIPLE DRILLING MACHINE : -

In this machine we can drill the hole

on the front side for mounting with differential housing

and on rear side of trumpet for mounting the axle with

trumpet of dia 10.2mm. .

CRANKCASE HOUSING LINE

Following are the machines in the crankcase housing

line:

Vertical Milling Centre (VMC 1200)

Reference Milling Machine

Gang Milling And Notching Machine

Pump & Starter Face Milling (Special purpose machine)

Multiple drilling Machine

Rough boring Machine I

Rough boring Machine II

Horizontal Boring M/c (Cylinder Boring)

Radial Drilling Machine (Heavy Duty) I

Radial Drilling Machine (Heavy Duty) II

Flexi Arm Tapping Machine

Line Boring S.P.M.

Plano Milling Machine

Van Norman Boring Machine

VERTICAL MILLING CENTRE (V.M.C-1200) : -

V.M.C. Refer as vertical milling centre

& 1200 stands for total transverse of a X-coordinate i.e.

1200 on this machine milling and drilling operation are

done. The operations done on this machine are given

below: -

1) Bearing neat face milling and drilling.

2) Bottom or slam side milling and drilling .

3) Top face or cylinder head side rough milling and

drilling.

4) Compression face milling, drilling and milling.

REFRENCE MILLING MACHINE: -

In this machine milling of the

reference face of crankcase is done.

GANG MILLING & NOTCHING MACHINE : -

In this machine milling of the side of

crankcase and also milling the notch which is used for

location of crankcase lines.

s. no. operation tools description Usage

1 Rib

milling(l)

Mill

cutter

dia.160

ISERT

TRAN

1603r

10

2 Rib Mill ISERT 10

milling(r) cutter dia

160

TRAN

1603r

3 Notching Notching

cutter

Dia 76

width 5

5

PUMP AND STARTER FACE MILLING (S.P.M) : -

In this machine the starter face and

fuel injection pump face is milling.

Operation name :- pump face milling

1. Milling

MULTIPLE DRILLING MACHINE : -

In this machine angular oil gallery

hole and angular water holes are drilled .The oil holes

are used for the lubrication and water holes are used for

cooling the cylinder.

ROUGH BORING MACHINE (I): -

In this machine first drill the hole in

crankcase for fuel injection pump and for starter than

bore it roughly.

ROUGH BORING MACHINE(II): -

In this machine the crankcase, cam,

fuel injection pump and ideal gear hole are bore

roughly.

HORIZONTAL BORING MACHINE (CYLINDER

BORING) : -

In this machine boring for cylinder

hole is bore.

RADIAL DRILL MACHINE (HEAVY DUTY) I: -

In this machine the multi drilling

operation is done with the help of special rotating

fixture. In this machine first tapping is done for bearing

cap on the front, centre and rear side of crankcase and

also drill the hole on the front side of the crank case for

mounting with the gear box housing.

RADIAL DRILL MACHINE (HEAVY DUTY) II:-

In this oil gallery hole drilling

operation is done

FEXI ARM TAPPING MACHINE : -

In this machine tapping of different

hole like 10×15mm, 10×1mm, 8×1.25mm & 12×1.75mm

etc. operation are done.

LINE BORING (S.P.M.) MACHINE : -

In this machine final boring of

crankcase, fuel injection pump and rear side dwell and

counter boring is done

PLANO MILLING MACHINE : -

In this machine milling of front, rear

and bottom face operation is done to maintain the total

height of the crack case housing.

VAN NORMAN BORING MACHINE : -

It is a C.N.C cylindrical boring machine

In this machine the cylinder hole is bore within the 20

micron.

TOOL ROOM

Following are the machines in the tool room:

Two digital jig-boring machines

Tool & Cutter Grinder

Surface Grinder

Universal external Cylindrical Grinder

Power Hacksaw

Metal Arc Disintegrator

Four Centre Lathe

Drill cutter grinder