Tafe Project Report - Final Draft Format

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CHAPTER – IINTRODUCTION

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REPORT ON ORGANISATION STUDY AT TAFE – GEAR DIVISION

CHAPTER – I - INTRODUCTION

ABOUT THE COMPANY Tractors and Farm Equipment Limited (TAFE) is an

Indian manufacturer of tractors and other farm equipment with its corporate headquarters in Chennai. The company was established in 1960 and has reported annual revenue of $ 1 billion and a sales volume of over 100,000 tractors annually. Tractors and Farm Equipment Limited (TAFE) is a member of the $1.6 billion Amalgamations Group. TAFE has collaboration with Massey Ferguson (now owned by AGCO Corporation, USA). TAFE is a renowned manufacturer of tractors and a variety of farm equipment under the TAFE Massey Ferguson and Eicher brands. TAFE acquired Eicher tractors in 2005 through a special purpose vehicle, TAFE Motors and Tractors Limited. It is a unit company of the Amalgamations Group, which is a wholly owned subsidiary. It has major presence in a number of Indian states like Rajasthan, Gujarat, Andhra Pradesh, Karnataka, Madhya pradesh and Uttar pradesh. It is one of India's largest Light Engineering Groups with diverse interests in Diesel Engines , Automobile components , Tractors and related farm machinery, lubricants, panel instruments, hydraulic pumps, Engineering Tools, Storage

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Batteries, Paints , Engineering Plastics , Automobile franchises and Printing apart from interests in Agribusiness , book selling and publishing. The group's leadership technology, built on foreign know how has been nurtured through indigenous efforts.

TAFE was established in 1961 in collaboration with Massey Ferguson, UK to manufacture and market a range of tractors and related farm equipment in India. One of the largest tractor manufactures of tractors in India, TAFE's vision is to be the first choice of customers in India and to also move towards a growing presence in the international markets.

With a network of more than 500 dealers, branches, service outlets as well as its own sales offices and depots covering the entire width and breadth of India, TAFE is committed to providing complete farming solutions to its customers and empowering them to work towards increased farm productivity, prosperity and profits.

TAFE started its production of the popular tractor model, Massey Ferguson 1035 in 1961. Now they manufacture tractors under three brand names, TAFE, Eicher and Massey Ferguson. TAFE has a five decade old collaboration with Massey Ferguson (now a part of AGCO Corporation, USA), which is one of the leading manufacturer of tractors in the world. The company is currently investing in a Greenfield project at Manisa Industrial Estate in Turkey with a capacity to manufacture about 15000

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tractors. TAFE has been a pioneer in the mechanization of the Indian farms. Beginning with the popularizing of tractors in agriculture in the early 60s, TAFE has many firsts to its credit. TAFE was the first company to market a total package of Tractors and farm equipment to not only provides farm power but also interfaces to transform the farm power to increased farm productivity. TAFE was also the first to introduce the Direct Injection technology in India, thereby intiating considerable fuel saving and the resulting economies in tractor operations cost to its customers. TAFE was also the first Indian manufacturer to launch a 75 HP tractor to cater to the emerging needs of very large farms and agri-businesses. With four manufacturing locations at Chennai(Sembiam), Madurai (Kallidaipatti), Bangalore(Doddaballapur), and Mandidheep (Bhopal), TAFE has a large manufacturing base. Its Madurai plant, the latest and possibly the largest such plant in the country is specially tailored to take on short run production batches to the exacting standards demanded by advanced countries. TAFE is also involved in making diesel engines, gears, panel instruments, engineering plastics, hydraulic pumps, plantations and passenger car distribution through other divisions and wholly owned subsidiaries. TAFE Motors and Tractors Limited has, apart from the tractor manufacturing plant at Mandideep mentioned above, a Diesel Engine plant at Alwar, Rajasthan producing a range of air cooled and water cooled diesel engines upto 80 HP with plans are on to increase the product range up to 125 KVA. The

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Transmissions Division located at Parwanoo in Himachal Pradesh produces a range of transmission components both for captive use as well as for sale to OE manufacture and marketing of farm implements, trailers and accessories, distribution of passenger cars, manufacture of hydraulic pumps and panel instruments to discerning customers both in India and overseas. All its plants and sales offices are linked by VSAT links providing fast and efficient communications and data linkage another first of its kind in India.

Apart from its core business of manufacturing and marketing tractors, TAFE is also involved in the following related and unrelated areas.

As a natural sequel to producing tractors, TAFE has developed a range of matching trailers, implements and accessories. These are marketed through TAFE's dealer network by a totally owned subsidiary, TAFE Access Limited (TAL). As a natural corollary, TAFE, through TAL is also involved in the marketing and distribution of lubricants and greases for tractors through its dealer network.

TAFE is also involved in the packaged power industry through its Power Source Division. At its fully automated modern plant at Maraimalai Nagar, near Chennai, it produces a range of automobile batteries, under the AMCO brand name, which find wide OE application in the new generation two and four wheelers manufactured in India as well as in the replacement market. The batteries are marketed through another unit of the

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Amalgamations group viz., AMCO Batteries Limited. As well as for sale directly through a dedicated distribution channel under the brand name of “Speed”.

The tractor's hydraulics is an important part in the transformation of power into farm productivity and the hydraulic pump is a critical component of any tractor. The transmission of power developed in the tractor's engine to the ground is also a major part of the total design of the tractor. TAFE therefore has in-house facilities for the manufacture of hydraulic pumps and also gears for tractors. A related facility for the manufacture of panel instruments, not only for captive use but also for sale to the growing automobile industry in India is an integral part of the company.

TAFE has also diversified into Engineering plastics and production of tools and dies for this industry. Its Doddaballpur plant has clamp capacities ranging upto 1300 tons and is a major supplier of the needs for precision plastic components of the white goods, IT, automobile industries. Its commercial tool room produces tools and dies to international specifications demanded by discerning buyers.

TAFE's vision of being the customer's first choice on offering to the customer’s quality products engineered to perfection using technology that is contemporary and relevant to the market it serves. This approach to quality as being inherent to its existence has obtained for TAFE certification under ISO 9002,

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the quality movement permeates throughout the organization and is apparent from the various laurels won by quality circles from the company in national and international arenas.

TAFE's vision is not just wishful thinking but based on recognized engineering, marketing and financial strengths, built up over the past four decades. In all that it does, TAFE pursues excellence. That this is not a cliche is reflected in the words of TAFE's chairman, "To us in TAFE, excellence is not something that we engineer, input or inspect into our products. It is an innate desire that inspires our hearts at work and at home and ripples out into the world around us.”

TAFE – Gears Division (TGD) was established in 1996 which is located in Pudupakkam 5 kms from Kelambakkam district. Gears division is a supplier machine shop which manufactures Crown wheel and Pinion used in transmission system. Parts manufactured in this division are supplied to the assembling units in Kallidaipatti (Madurai), Doddabalbur (Bangalore) and for spare parts. TGD has total area of 2.83 hectares and the plant is built in 1500 sqmts. TGD functions for 3 shifts in 24 hours. Sunday is holiday.

COMPANY LOGO:

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PRODUCT PROFILE

Crown Wheel & Pinion (CWP)

Product Portfolio : 6T x 37T CWP 7T x 39T CWP 11T x 38T CWP

The above mentioned are the 3 versions of Crown Wheel & Pinion (CWP) manufactured in this TAFE Gear Division

INTRODUCTION TO CROWN WHEEL AND PINION

The final drive components, which reduce the rotational speed of the gearbox output shaft to that supplied to the wheels – sometimes abbreviated as CWP. The reduction ratio (commonly called the final drive ratio) lies in most common automobile applications between 3:1 and 5:1. In all front engines, rear-wheel drive cars with the engine mounted longitudinally, the crown

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wheel and the pinion rotates the drive through 90 deg i.e. from fore aft to transverse.

A crown wheel is a wheel with cogs or teeth set at right angles to its plane and the pinion is a small cogwheel that meshes with the crown wheel. The pinion thread is specially made on the thread gringer to ensure proper fitting. Tooth contact of a crown pinion is insected on a Gleason machine at regular intervals of time for uniform and adequate case depth. They are checked thoroughly for high spots because this ensures premature failure and noise-free operation.

FEATURES

Crown wheel and pinion usually have the following features:

Excellent heat distortion control High strength Wear resistance property and Noiseless and vibration free operation.

In a machine, when any torque is applied to the drive unit, the tendency is for the crown wheel and pinion to be forced into or out of mesh by the sliding contact.

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APPLICATION

Crown wheel and pinion are used widely in automotive industries. They are one of the most stress prone parts of a vehicle. They are used in automobiles to maintain forward motion. To maintain forward motion both output drive shaft sides covers are removed and the pinion and crown wheel are swapped completely with differential.

ORGANISATION CHART

Tractors and Farm Equipment Limited(TAFE)

Senior management Team

MANAGING DIRECTOR

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&

CHAIRMANED – TAFE Motors and

Tractors Ltd.

ED – TAFE Gears Division

ED - TAFE Access Ltd - Instrument Division

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ED - TAFE Power Source Division

ED - TAFE Hydraulic Pump Division

ED - TAL Precision Parts

ED - TAFE Reach Ltd.

ED - TAFE Engineering Plastics Division

ED - AMCO Batteries Ltd.

Chart of TAFE - Gear division – (TGD)

ED – TAFE Gear Division (TGD)

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Directors

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President

Vice President

Sr. General Manager

General Manager

Divisional Manager

Manager Manager Manager Manager Manager

Asst. Manager Asst. Manager Asst. Manager Asst. Manager Asst. Manager

Supervisors Supervisors Supervisors Supervisors Supervisors

Labours Assistants Labours Labours

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Production

HR StoresFinance Maintenance

CHAPTER – IIPRODUCTION DEPARTMENT

PRODUCTION DEPARTMENT

PLANT LOCATIONREGISTERED OFFICE - HEAD OFFICE &MANAGING

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861,Anna SalaiChennai-600 002.

GEAR DIVISION

51/1, Vandalur-Kelambakkam Road,

Pudupakkam, Kelambakkam,

Kancheepuram district, 603 103.

Phone: 0411474647, 74847

TAFE GEAR DIVISION PLANT

The Gears Division of TAFE manufactures BEVEL gears for tractors. The factory which is located at Pudupakkam, 40 kms from Chennai is equipped with Gleasan machinery and highly advanced in-house heat treatment facility to ensure that the gear systems that roll out from here meet international standards.

PRODUCTION PROCESS CHART

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Raw material – semi finished – Pinion

Raw material – semi finished – Crown Wheel

Hobbing – Straight stains

12 - Hole Drilling

Teeth cutting – Roughing Machine

Teeth cutting – Roughing Machine

Finishing Operation – Convex & Concave

cutting

Finishing Operation – Convex & Concave

cutting

Heat Treatment plant – CGCF (or) SQF

Heat Treatment plant – CGCF (or) SQF

Straightening, Diameter & Pilot

Grinding

Inner Diameter Grinding by Boring

Machine

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Testing & Pairing Operations

Lapping Operations

Threading Operation for Pinion

Quality, Diameter & Dimension Inspection

Storing

Packing

PRODUCTION PROCESS

Raw materials:

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Inspection

Dispatch

Raw Materials for Crown wheel is called as blanks and for Pinion is Steel pillars. These raw materials are semi finished raw material. These semi finished raw material are produced by vendors by forging the iron blocks for Crown Wheel and forging iron pillars. These raw materials are purchased by TGD. These purchased raw materials are stored in Stores and distributed to machine shop.

Machine Shop – Soft cell:

These raw materials are delivered to Pinion cell and Crown Wheel cell.

Note: - In the following stages the COOLANT OIL & SOLUTIONS are used to reduce the friction heat of the Crown Wheel & Pinion while drilling, cutting & grinding.

STAGES PINION CELL STAGESCROWN WHEEL

CELLHOBBING The raw materials

will be processed in Hob Cutter to create straight strains in the Pinion. These cuttings of straight strains are done

DRILLING The raw materials will be processed for drilling 12 holes in the Crown Wheel. This drilling process is made by Counter Boring Machine and

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by Hob Cutter Machine and moved it to soft grinding stage.

moved to Teeth cutting process.

STAGES PINION CELL STAGESCROWN WHEEL

CELL

SOFT GRINDING

In this raw material is grinded to bring it to fixed outer diameter. There is chance of irregular diameter shape in raw material. To make a regular shape, the raw material is grinded with fixed outer diameter and passed to rough cutting stage.

ROUGHING MACHINE

In this raw material is processed for cutting teeth. In this process the teeth for the Crown Wheel is formed by Rough Teeth Cutting. This process is done by Rough Teeth Cutting Machine and passed to the next stage for finishing operation

ROUGHING MACHINE

In this raw material is processed for cutting teeth. In this process the

FINISHING OPERTION

In this raw material is processed for Convex & Concave cutting of teeth to reduce the

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teeth for the Pinion is formed by Rough Teeth Cutting. This process is done by Roughing Machine and passed to the next stage of finishing operation for Convex & Concave teeth cutting.

sharpness of the teeth and for finishing touch for the teeth. In this the Convex & Concave teeth cutting is made by a single machine Simultaneously and passed it to Heat Treatment Cell.

STAGES PINION CELL STAGESCROWN WHEEL

CELLFINSHING

OPERATIONIn this raw material is processed for Convex & Concave cutting of teeth to reduce the sharpness of the teeth and for finishing touch for the teeth. In this the Convex & Concave teeth

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cutting is made by 2 different machines (separate machine Convex & Concave Teeth Cutting) and passed it to Heat Treatment Cell.

Heat Treatment Cell:

The Raw Materials of Crown Wheel and Pinion processed in Machine Shop is brought to Heat Treatment Cell to mold those Raw Materials for long life, increase the strength, to withstand heavy load and avoid worning out. This Heat Treatment Cell consists of 2 types of furnaces.

Continues Gas Carburizing Furnace (CGCF) Sealed Quenching Furnace (SQF)

The Heat Treatment Cell will use any One or if needed use both the above furnace.

Continues Gas Carburizing Furnace (CGCF) This is big furnace for continuous operations includes

degreasing, carburizing operations, hardening operations, heating, cooling, press quench operations, etc., This is a continuous operation and takes 22 hours to complete its

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process. The Heat Treatment Cell mostly uses this furnace for operation because of easy and less time consuming.

Sealed Quenching Furnace (SQF) This is a collection of small furnaces and it’s not a continuous process. Its operation are degreasing, carburizing operation, hardening operation, washing, tempering, etc,. it takes more than 23 hours to complete the process. It is time consuming and more labour work compared to CGCF.

The process of both furnaces will be explained in detail in machinery details of the furnaces. After processing the raw materials in heat treatment it is passed to Shot Blasting.

Shot Blasting:

After tempering, the Pinion and Crown wheel are subjected to Shot Blasting to give glossy appearance and to check and impart strength of the Crown Wheel and Pinion. Shots are a kind of small steel balls, having hardness of 30 to 35 HRC. This process is for 10 to 15 minutes per batch. 1 batch contains 45 nos of Crown Wheel or 90 nos of Pinion. After this process again the processed raw materials are passed to Machine Shop – Hard Cell for further Finishing process.

Machine Shop – Hard cell:

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STAGES PINION STAGES CROWN WHEEL

GRINDING

In this raw material is grinded by 3 grinding machines to bring it to required diameter. Those 3 grinding machines are used to process the pinion for grinding minor diameter, major diameter and pilot grinding and passed to testing and pairing process.

BORE GRINDING

In this raw material is processed for bore grinding to bring required & fixed inner diameter of the Crown Wheel. Due to Heat treatment there is a chance of change in the diameter. So to fix the diameter this bore grinding is used and it is passed to testing and pairing process.

TESTING & PAIRING

In this the processed Pinion is tested to ensure its dense, required dimensions and

TESTING &

PAIRING

In this the processed Crown Wheel is tested to ensure its dense, required dimensions and

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finally Pinion will be Paired with Crown Wheel run together for testing to match each other and passed it to lapping process.

finally Crown Wheel will be Paired with Pinion run together for testing to match each other and passed it to lapping process.

STAGES PINION CROWN WHEEL

LAPPING

The Pinion is processed in Lapping Machine for the purpose of polishing, clearing carbon & grinding particles, to improve surface finish using Coolant Oil and Lapping powder by rubbing action and final washing in this process and passed to threading process.

The Crown Wheel is processed in Lapping Machine for the purpose of polishing, clearing carbon & grinding particles, to improve surface finish using Coolant Oil and Lapping powder by rubbing action and final washing in this process. This is the last process for Crown Wheel and it will be moved to Quality Inspection of Finished goods.

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THREADING

The Pinion is processed in threading machine for threading operation for required dimensions on the middle of the Pinion. This threading operation will be a fixed for required diameter. This is the last process for Pinion and it will be moved to Quality Inspection of Finished goods.

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Final Quality Inspection – Finished Goods:

The finished goods Crown Wheel and Pinion will be passed on to Final Quality Inspection. Here final inspection on the quality of the Crown Wheel and Pinion will be inspected by checking all dimensions and diameters of the Crown Wheel and Pinion should be as per the requirements. The critical parameters of the Crown Wheel and Pinion should be 100%. Then the approved and qualified Crown Wheel and Pinion will be moved to Stores for other process.

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The general layout of the TAFE Gear division factory consists of two main divisions viz:

MACHINE SHOP HEAT TREATMENT CELL

MACHINE SHOP: The operation in machine shop includes both soft cell

and hard cell.

SOFT CELL PINION CELL:

1) HOBBING MACHINE: MACHINE MAKE : COOPER 010OPERATION PERFORMED : SPLINE CUTTING MACHINE PROCESS TIME : 332 secHANDLING TIME : 10 secTOTAL TIME : 342 sec

2) SOFT GRINDING MACHINE: MACHINE MAKE : PARISHUDHOPERATION PERFORMED : MAJOR DIAMETER GRINDINGMACHINE PROCESS TIME : 110 secHANDLING TIME : 15 secTOTAL TIME : 125 sec

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3) ROUGHING MACHINE: MACHINE MAKE : GLEASON OPERATION PERFORMED : ROUGH CUTTINGMACHINE PROCESS TIME : 205 secHANDLING TIME : 10 secTOTAL TIME : 215 sec

FINISHING OPERATIONS:4) CONCAVE MACHINING MACHINE:

MACHINE MAKE : GLEASONOPERATION PERFORMED : CONCAVE CUTTING METHOD USED : COMPARATIVE METHOD MACHINE PROCESS TIME : 207 secHANDLING TIME : 10 secTOTAL TIME : 217 sec

5) CONVEX MACHINING MACHINE: MACHINE MAKE : GLEASONOPERATION PERFORMED : CONVEX CUTTINGMETHOD USED : COMPARATIVE METHODMACHINE PROCESS TIME : 223 secHANDLING TIME : 10 secTOTAL TIME : 233 sec

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CROWN WHELL CELL: 1. VMC CNC MACHINE:

MACHINE MAKE : AMSOPERATION PERFORMED : COUNTER BORINGMACHINE PROCESS TIME : 287 secHANDLING TIME : 37 secTOTAL TIME : 324 sec

2. ROUGHING MACHINE:

MACHINE MAKE : GLEASON 608OPERATION PERFORMED : ROUGH CUTTINGMACHINE PROCESS TIME : 337 secHANDLING TIME : 33 secTOTAL TIME : 370 sec

3. FINISHING MACHINE: MACHINE MAKE : GLEASON 610OPERATION PERFORMED : FINE CUTTINGMACHINE PROCESS TIME : 280 secHANDLING TIME : 35 secTOTAL TIME : 315 sec

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** The job from soft cell undergoes heat treatment before it enters hard cell. **

HARD CELL

1. STRAIGHTENING MACHINE:MACHINE MAKE : BEMCO OPERATION PERFORMED : STRAIGHTENING TIME TAKEN : 61 sec

2. GRINDING MACHINE - I:MACHINE MAKE : PARISHUDH OPERATION PERFORMED : MAJOR DIAMETER GRINDINGTIME TAKEN : 298 sec

3. GRINDING MACHINE - II:MACHINE MAKE : PARISHUDHOPERATION PERFORMED : MINOR DIAMETER GRINDINGTIME TAKEN : 225 sec

4. GRINDING MACHINE - III:

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MACHINE MAKE : KAIZON OPERATION PERFORMED : PILOT GRINDINGTIME TAKEN : 211 sec

5. BORING MACHINE : MACHINE MAKE : GCI 300 CNCOPERATION PERFORMED : INTERNAL DIA GRINDING (CROWN) TIME TAKEN : 271 sec

6. TESTING AND PAIRING MACHINE: MACHINE MAKE : GLEASONOPERATION PERFORMED : PAIRING OF PINION AND CROWN WHEELTIME TAKEN : 173 sec

7. LAPPING MACHINE: MACHINE MAKE : GLEASONOPERATION PERFORMED : LAPPINGTIME TAKEN : 184 sec

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8. THREAD CUTTING MACHINE: MACHINE MAKE : SIEMENSOPERATION PERFORMED : THREAD CUTTING TIME TAKEN : 346 sec

HEAT TREATMENT CELL: In heat treatment cell the mechanical properties of the

job is improved by the application of heat. This is done in two types of furnaces viz;

Continues Gas Carburizing Furnace (CGCF)(Or)

Sealed Quenching Furnace (SQF) Shot Blasting

CONTINUES GAS CARBURISING FURNACE :

a) Low carbon alloy steel is used in Heat treatment.b) Sulphur based cutting oil is used in machine shop.c) Endothermic gas is used as a carrier gas in the Heat

treatment process.

PHASES :

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1)Degreasing furnace is operated at 250 Deg C (1 tray)

Degreasing is used to restrict sulphur oil by being combining with CO & CO2.

Duration for waiting degreasing is approximately 8 mins.

Duration for Degreasing is approximately 40 mins.

Operating pushing cycle time is approximately 48 mins for every tray.

2)Main furnace has 18 separate trays at various

zones.

ZONENO.OF TRAYS

TEMPERATURE Deg C

CARBON POTENTIA

LPre heat

zone2 930 0.92 %

Carburizing zone

14 930 0.92 %

Carburizing zone

4 930 0.92 %

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2Diffusion zone 1

4 930 0.90 %

Diffusin zone 2

4 930 0.90 %

The main furnace and reheating zone are operated with a carrier gas (Endothermic gas) and LPG for enrichment of C potential.

3)Air cooling chamber - 1 tray (no heating)

Duration for cooling is approximately 7 mins to refine the core grains.

4)Reheating - 4 trays. Reheating is operated at 820 to 800 Deg C & Cp-

0.70%

5)Quenching

Quenching makes the steel to reach from (Austenite)FCC to BCT structure (Martensite)

BCT - Body Centered Tetrahedron.

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Quenching process is carried out with Quenching oil

(Savsol 001). Quenching process is carried out with Press

Quench machine to minimize Gear teeth distortion and accurate flatness.

After quenching process, the components are sent for washing through alkali bath and water bath.

At Alkali washing bath, oil from the work piece will be removed.

At Water washing both, alkali from the work piece will be removed.

Finally it is sent through Tempering furnace – to relive the stress.

6)Tempering It can accommodate three separate trays (150

celsius for 90 mins).

7)Endothermic gas generator LPG and Air are mixed in the ratio of 1:9.5 to 10.5

and pass through a stainless steel retort at 1070 Deg C. The gas will pass through a Nickel coated Ceramic catalyst in a Stainless steel retort to produce Endothermic gas. The carrier gas

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(Endothermic gas) will have approximately 23% of CO and 0.3% of CO2.

SEALED QUENCHING FURNACE :

PHASES:

1)Degreasing furnace is operated at 150 Deg C. It is operated to remove Sulphur based cutting oil, which is used in machine shop.

Duration for Degreasing is approximately 120 mins.

2)Main furnace is a single chamber and the process is divided into 4 segments.

SEGMENT

TEMPERATURE Deg C

CARBON POTENTIA

L

TIME TAKEN

FUEL USED

Segment 1

930 1.20% 5 minLPG + CO2

Segment 2

930 1.20% 450 minLPG + CO2

Segment 3

930 1.10% 360 min LPG

Segment 4

820 0.92% 20 min LPG

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After the process, the load is pushed from the furnace into the elevator (above quenching tank) and the load is quenched in oil below the elevator.

3)Hardening

Quenching process is carried out with Quenching oil (savsol 001).

For Pinion, the load is quenched along with the fixture.

4)Washing:

After quenching process, the components (pinion) are sent for washing through water bath along with the fixture.

At Water washing bath, oil and other contaminations from the Pinions will be removed along with the fixture.

5)Tempering

Pinions are sent through tempering furnace along with the fixture – to relive the stress at (150 Deg C for 120 min).

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SHOT BLASTING :

After tempering, the Pinion and Crown wheel are subjected to Shot Blasting to give glossy appearance and to impart strength. Shots are a kind of small steel balls, having hardness of 30 to 35 HRC.

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CHAPTER – III

STORES DEPARTMENT

STORES DEPARTMENT

PROCESS OF PURCHASING & STORING

Purchasing of Raw Materials, spares, equipments, accessories, etc., Is a process of Stores department. The following flow chart will explain the process of purchasing.

Flow Chart of Purchasing, Storing & Issuing

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Requirements

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Purchase Requisition

Quotation

Purchase Order (P.O)

Approval

Material Receiving

Checking &

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Checking &

Material Tagging

Racking

Storing

Coding the Material through SAP

Stock (Material) Issue

ACTIVITIES Raw Materials:

Raw Materials for Production purpose will be stored by Store Department in Stores. The Stores will be having 3 months Stock of Raw Materials for Reserves. The Stores will place order on Raw Materials once in 3 months as a cycle.

Materials Rejection:

Some Raw Materials may be rejected after Checking & Inspection due to damage or low quality. Those rejected materials will be returned to vendors who supplied and payment will not be paid for the rejected materials. Goods Receipt Note (GRN):

GRN is prepared by Stores department for the materials received after Checking & Inspection. This GRN will be forwarded to Finance Department for payment process.

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Stock (Material) Issue

Entering (Posting) Issues in SAP

Material Tagging:

The received material will tagged according to the usage and will be placed according to the respective bin by Racking the material tagged in the racks of the stores. This tagging helps to issue the materials easily and can find the shortages easily. System Analysis and Program Development (SAP):

The Stores department will enter the coding of the materials received in SAP. It also updates the issue of materials in SAP. Stores department will also maintain the entries of delivered finished goods in SAP. The delivered finished goods will be given a code by SAP. SAP is software interlinked with all departments. Storing:

The materials received by the Stores department from Vendors will be stored in Stores and issued for production at the time of need. The Finished Goods will also be packed stored in Stores. The Stores department also stores materials like spares, accessories, new machinery, etc,.

Packing & Delivering:

After Checking & Inspection of Crown Wheel and Pinion (CWP), the Stores department will pack the CWP in a pair as matched by production Department. If CWP is for dispatch for Tractor manufacturing units, 2 pairs of CWP is packed in a plastic box and if CWP is dispatch for Spare

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Parts, 1 pair of CWP is packed in a Card board. These packed boxes will be delivered to necessary place by chartered carrier Tractor manufacturing units or Spare Parts. Delivery Note:

Delivery Note will be prepared by the Stores department as per the delivery of Crown Wheel & Pinion (CWP) to the Tractor manufacturing units or to Spare Parts. The prepared Delivery Note will be forwarded to the Finance department for accounting.

Chart of Packing & delivery of CWP

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Receiving of CWP (Finished Goods) from

Production

Packing & Storing

Delivering to Tractor manufacturing units or

Spare Parts

CHAPTER – IVMAINTANENCE DEPARTMENT

MAINTANENCE DEPARTMENT

Maintenance department is an essential department in this unit which follows the 4 major activities. They are,

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Preventive Maintenance Actual Maintenance Planned Maintenance Special Projects & Developments

ACTIVITIES Preventive Maintenance:

Preventive maintenance can be described as maintenance of equipment or systems before fault occurs. It is also called as Planned maintenance. This Preventive maintenance activity helps the manufacturing unit to function without any disturbances or problems. By predicting the future problems for production and taking necessary steps to overcome and being ready to act on the problem immediately and solve the problem. For example: - Taking necessary steps to overcome the Electricity problems during summer season.

Actual Maintenance:

Actual Maintenance is another major activity of the Maintenance department. In this the Maintenance department will be always ready any time to solve the unexpected problems while running of machines while production. Solving of the unexpected problems on the day to day process of production is called Actual Maintenance.

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For example: - Solving the failures of machinery while production.

Planned Maintenance:

Planned Maintenance is the major activity of the Maintenance department. The Maintenance department will prepare plan and follow the plan to maintain and develop the production process. Planned Maintenance is a regular activity followed by the Maintenance department. For example:- Regular service for machineries, Changing machinery oil periodically, etc,.

Special Projects & Developments:

Special Projects & Developments is the major activity of Maintenance department to support the production process and develop the manufacturing unit. Special Projects & Developments are the activities like installing new machinery, upgrading the existing machinery, making add-ons for the machinery to make the production process easy and fast.

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CHAPTER - V

FINANCE DEPARTMENT

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FINANCE DEPARTMENT

ACTIVITIES

Powers:

Finance department of TAFE Gear Division (TGD) is under control of Finance department of TAFE – Head Office in Anna Salai, Chennai. Finance department of TGD will be reporting to TAFE – Head Office. Finance department of TGD is restricted limited powers.

Impressed amount:

TAFE Gear Division (TGD) is allocated with an Impressed amount (Reserves) minimum of Rs. 30,000 for operations of Finance department for production purpose. Finance department of TGD will maintain this Impressed amount. If the Impressed amount decreases to Rs. 10,000, the Manager of Finance department will make requisition to Head Office for shortage of Impressed amount, immediately Head Office will issue a cheque for the requested amount to Finance department of TGD.

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Funding Operations:

Finance department of TGD is operated with Current A/C in Central Bank of India in Kelambakkam. For withdrawal of Impressed amount or other Sanctioned amount from Head Office for Production purposes and deposits of cash by Finance department of TGD by the Scrap sales is transacted through this bank.

Petty Cash Accounting:

Finance department of TGD follows the Petty Cash Accounting. It follows Petty Cash Accounting because it transacts with only small value of money. Large transactions for TGD production process are made by TAFE – Head Office. Petty Cash Accounting is recorded and filed through System Analysis and Program Development (SAP) by verifying and approving Petty Cash Receipt. This process is called as Real Time Accounting. Real Time Accounting is financial reporting provides financial information on a daily basis.

Credit:

Finance department of TGD avails credit from the government for Excise duty for purchasing Raw Materials and will be adjusted with the Dispatch of Finished Goods to the TAFE Manufacturing unit and to Spare Parts.

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Salary & Wages:

Salary for the Management Staff is paid directly by TAFE – Head Office by crediting the salary to the individual’s bank A/C. The Wages for the Contract Labours are paid by the Finance department of TGD which will be sanctioned and given by TAFE – Head Office.

Tax:

Finance department of TGD will be paying certain taxes like TDS (Tax Deducted at Source) – 2% of Contract Labour Wages, Scrap Sales tax – 1%. These taxes are unavoidable and Finance department of TGD is liable to pay the taxes.

Focus Cost:

Focus Cost means Budget. Focus Cost is prepared by the Finance department for future Production process. Focus Cost will be estimated by Divisional Manager of TGD unit and Manager of Finance department of TGD. This Focus Cost will be sent for approval to TAFE – Head Office by Finance department of TGD. TAFE – Head Office will discuss with Divisional Manager of TGD make some adjustments in Focus Cost if necessary and approve for sanction.

CHART PROCESS OF PURCHASE & PAYMENTS

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Requisition & Quotation

Approval

Delivery of purchase Requisition

Purchase Order (P.O)

Goods Receipt Note (GRN) from Stores

Invoice Verification

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Payment

CHAPTER – VI

HUMAN RESOURCE DEPARTMENT

HUMAN RESOURCE DEPARTMENT (HRD)

ACTIVITIES

Recruitment and Selection:

The candidate will be sent from TAFE – Head Office to Production unit for Selection & Recruitment process. The candidate will be first screened by Personnel officer and Head of the Department, and then screened by Divisional Manager. After Divisional Manager’s screening, the candidate will be interviewed by Senior General Manager in TAFE – Head Office and a final interview by Divisional Manager of HRD in TAFE –

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Head Office. If the candidate passes the above process, the candidate will selected and employment offer will be given.

CHART PROCESS OF RECRUITMENT & SELECTION

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Candidate

Screening by Personnel officer &

Head of the Department in TGD

Screening by Divisional Manager -

TGD

Interview by Sen. Gen. Manager of TAFE –

Head Office

Final Interview by Divisional Manager of HRD – TAFE – Head

Office

Wages & Salary Administration:

Wage Administration for Contract Labour for Production Operations will be under the control of Human Resource Department of TGD.

Salary Administration for Management staffs of TGD will be under the control of Centralized Payroll Department of TAFE – Head Office.

Performance Appraisal:

Performance Appraisal is the major activity of the Human Resource Department. The following is Performance Appraisal Process followed by HRD of TGD.

Performance Appraisal is the activity of HRD of TGD for every Six months.

Performance Appraisal is made by rating every employee of TAFE Gear Division (TGD)

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Candidate is Selected & offered Employment

Performance Appraisal is processed by Performance Appraisal Team which consists of Personnel Officer, Superior of Appraisee & Divisional Manager – TGD. Attendance of employee is also taken for consideration for Performance Appraisal.

Based on the Performance Appraisal employees & labours, Salaries and wages will be increased and promotion is given if necessary.

Employee Welfare:

Many welfare activities are undertaken and followed by Human Resource department of TGD like,

Canteen facility is availed for Management staffs & Contract Labour, where free healthy lunch is provided for them.

Uniform & Shoes are provided to Management Staffs at free of cost.

Safety equipments are provided to Contract Labours for their safety.

Transportation facility is availed for Employees of TGD.

Medical facilities & Allowances are provided for the employees of TGD.

Training & Development:

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Training on new machinery or to new production process is provided for existing employees

Training for new employees is provided. Training calendar is scheduled by Human

Resource Department (HRD) of TAFE – Head Office and followed by HRD of TGD.

Divisional Manager of TGD will give suggestions in framing the training calendar.

Induction & On the Job trainings are 2 types of training provided for new employees of TGD.

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CHAPTER – VII

CONCLUSION

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CONCLUSION

FINDINGS & INTERPRETATION:

TAFE Gear Division (TGD) is a sister concern of Tractors Farms &Equipments (TAFE).TGD is under control of TAFE.

TGD does not have separate department for Marketing activities, because it supplies is produced CWP to TAFE – Tractor Manufacturing units in Madurai (Kallidaipatti), Bangalore (Doddaballapur) and to TAFE – Spare Parts.

TAFE is operating separate divisions like TGD, TAL, etc., to avoid the labour unions, strikes, etc,.

In TGD many innovative production process are made as proto type, tested and implemented.

TGD is fully interlinked with System Analysis and Program Development (SAP).

Labours were employed through Contract Labour Agencies for contract in production unit.

TGD concentrates more on Production Department compared to other department.

TGD strictly follows 5- S principle.

SUGESSTIONS: TGD can sell the CWP to third party also by setting

up Marketing Department to increase the revenue.

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TGD can increase Production by extending the Production Plant. TGD has all facilities to extend its Production Plant.

Separate Packing Cell can be setup for the purpose of Packing Finished Goods.

REFERENCES

http://www.tafe.com/ http://www.tafechannel.com/ http://www.frontpoint.com/tafe/green/htm/

areaoffice.htm http://en.wikipedia.org/wiki/TAFE_Tractors

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