PREFACEIf you know the laws of buoyancy it doesn’t mean that you know how to swim. It is only through jumping in the water that you get the feel of the depth. This is applicable to every aspect of life. Therefore practical training is of utmost importance. The object of undergoing this training was to get familiar with the weary waters of the industry and to learn how to put theory into practice. I have been greatly privileged to have undergone training at PTL. This report contains the extract of things I learned during my training period. HARPREET SINGH ACKNOWLEDGEMENT Any endeavor cannot lead to success unless and until a proper platform is provided for the same. This is the reason I find myself very fortunate to have undergone my industrial training of four weeks at PUNJAB TRACTORS LIMITED. The persons of my department and all other departments have extended a warm and helping hand. I am very fortunate to have had a chance to feel the gravity of what role Mechanical Engineering plays in the industry. It was a golden opportunity for me to get a chance to experience what it feels to be in a company where discipline, quality and hard work are the motto. This training helped me a lot in bridging the gap between the theoretical and the practical aspects of my knowledge. First of all I would like to thank Mr. K.K Sharma for his valuable guidance & encouragement as a teacher and a friend throughout my training period. I am also thankful to MR. J. SINGH for giving me an opportunity to undergo training in such a renowned company. My heartily thanks to Mr.H.S.Baweja who was my project manager & my guide through the project works. They always went out of their way to help me at all times. Their experience & knowledge motivated me to bring out the best in times. I am sure that the knowledge & information that I have gained during this period would be of immense value for my growth in the field of Mechanical Engineering. HARPREET SINGH CONTENTS 1. INDIAN TRACTOR INDUSTRY. 2. BEGINNING OF INDIAN TRACTOR INDUSTRY. 3. MATURING YEARS OF INDIAN TRACTOR INDUSTRY. 4. INDUSTRY STRUCTURE. 5. FUTURE POTENTIAL. 6. COMPANY`S OUTLOOK. 7. INTRODUCTION TO COMPANY 8. SALES SCENARIO OF VARIOUS TRACTOR COMPANIES 9. PRODUCTS MANUFACTURED 10. UNITS OF SWARAJ GROUP 11. MANUFACTURING SYSTEM 12. QUALITY CONTROL INSPECTION 13. MAINTENANCE DEPTT. 14. BIBLIOGHRAPHY INDIAN TRACTOR INDUSTRY Introduction – India being a predominantly agricultural country, where agriculture is the life and blood of the economy, has been a traditional manufacturer of different types of farm machinery and implements. However, the use of advanced agricultural techniques in India started only in early sixties. Modernization and tractor-ization in Indian agriculture is only post independence phenomenon. One of the achievements of green revolution has been that the farmers increasingly realized the advantage of tractor-ization for obtaining the timeliness of operations. This would happen only because of awareness of new farm technology among the farmers, rise in the level of their income and education. The biological source of energy especially bullocks, could not cope with the requirements of the changed situation. Therefore, introduction of tractors got accelerated in several agriculturally advanced states of country like Punjab, Haryana, Maharashtra, etc. Tractors were introduced to Indian agriculture in early twenties. Sh. Joginder Singh was the first farmer to use a tractor, called a steam plough then, on the 12000 acres estate he had inherited in the remote Kheri district of Uttar Pradesh. The demand of tractors rose sharply in last two decades. However, the rate of adaptation of tractors is different in different parts of the country. Punjab occupies number one rank in this regard. Punjab possesses only 1.5% of the geographical area of the country; the density of 85 tractors per hectare in Punjab is the highest as compared to national average of 10.5 tractors per hectare. India is considered the largest tractor market in the world. which is far lower than the global average of above 80 HP. No wonder. That and the highly fragmented land holdings in India have helped our country to become the largest tractor market in the world. India has a tractor density of 10. If that sounds great. we are ranked a distant eighth. . Thus the Indian tractor market. per Se. the small size of land holding in India.5 tractors per thousand hectares of GCA in comparison to the international average of about 28 tractors. the tractor density is very low at about 10.5 tractors per thousand hectares of Gross Cropped Area (GCA) as compared to the international average of close to 30 tractors per thousand GCA. have led to low average power of tractors at 35 Horse Power (HP). let us face hard facts. In terms of penetration. has to be viewed only after considering its position in the world.India is primarily an agrarian nation. In terms of total tractors in use in the country. Also. India’s large gross cropped area (GCA) is next only to the big two — USA and Russia. Despite a phenomenal increase in tractor population in the country. with more than 50 per cent of our GDP being contributed directly or indirectly by agriculture. Figuratively speaking. With the parallel emphasis on industrialization.000. import of tractors into the country was liberalized and over and above the domestic production of 20. with the green revolution. 6 units eventually. established the actual manufacturing facilities. however. 1970: 33. Date of commencement of commercial production and collaboration are given in following table. With the successful introduction and acceptance of the high yielding seeds. the birth of Indian Tractor Industry took place in 1959-60 when the imports were restricted and 5 tractor manufacturing units set up in the private sector.000. A natural consequence of this sharp upsurge and consequent shortage was a heavy premium on the price of tractors. They were as follows: .The Beginning of Indian Tractor Industry The decade of 60’s India saw green revolution resulting in increase in both production and productivity. Total indigenous production of tractors by 1965 was just 6000. all with foreign collaboration.000). 13. The Government’s decision to freely invite new entrepreneurs to manufacture tractor in 1968 and sudden upsurge in demand. led to a scramble of new entrepreneurs for new collaborators. In 1970. Recognizing the situation.000 tractors were imported. there was a sudden upsurge in the demand for tractors after 1967 and the demand started multiplying at an annual rate of approximately 50% (1967:18. At present 44 models tractors are available in India. Today tractors with HP ranging from 12 to 75 are available in India. when a large number of ancillary manufactures had also established them and were in a position to supply a wide variety of components to the tractor industry. In India. listed category-wise as follows: . when low cost import particularly from East European countries had become far more attractive. A fillip to indigenization was also given by the overall industrialization of the country. The sharp liberalization of imports in 1970 had given the nascent Indian Tractor Industry a substantial setback in 1970-73. the variety in land conditions makes it necessary to diversify the availability of tractors.The Maturing Years With the entry of new units in 1970 and increasing Government pressure towards indigenization picked up substantially after 1970 and by 1978 almost all the tractors manufactured were nearly indigenous. Range of Tractors available in India — . it would render the use of tractor uneconomical. there is the running costs angle to it as well. it seems to belie the notion that as the average farm sizes dwindle. Firstly. which used to be 35% in FY 1990—1991 has been pushed to the back seat by the 31 —40 HP segment. the meager shift from 41 — 50 HP to 50 HP levels.Industry Structure The tractor industry is segmented on the power / size of the tractor engine. the drastic shift from less than 30 HP to 31 — 40 HP levels and two. expressed in terms of horse power (HP). The general change in the farmers’ preference for higher HP tractors is significant in more ways than one. Then. The HP-wise composition of tractor industry sales (as shown in the table 6 and the graph showing Indian HP Range Trends) reveals that 31-40 HP tractors still constitute the largest segment with 57% of the total tractor sales in Financial Year (FY) 2002 2003. The shift could be categorized as two — fold. . It can also be seen that demand for less than the 30 HP segments. While the higher HP tractors are more costly in terms of maintenance and running costs. still the fact of the matter is that the sale of the higher HP tractors are increasing. This shows an interesting shift in tractor demand from lower HP to higher HP tractors in recent times. One. exports rose from around 160 tractors in 1990-91 to an estimated 7500 tractors in 1998-99. The density of tractors varies from state to state with Punjab taking the lead at 65 tractors per 1000 hectares of irrigated land.18 lac tractors in the year 2001 . Increasing benefits of mechanization have resulted in an increase in the tractor demand and thereby tractor population over the years. As per reports. With the average number of tractors in India per hectare well below the world average. Company’s Outlook It has been established that there is a close relationship between the growth rate in food grain production and intensity of tractor-ization. The export market. India is the largest market for the below 50 HP tractors in the world.Future potential With a total of 140 million hectares and with the performance of around 2. the average HP of tractors used is around 80 -100 HP. With the total land currently under irrigation being a small fraction of the total irrigation potential of 1134 lac hectares. At present the Indian tractor industry is among the select few in the world that is growing.2002. India today stands as the largest manufacturer of tractors in the world. . a steady demand for tractors in the near future can be anticipated. has been projected to grow at around 10% per annum over the next five years. In international markets. the Indian market is a market with a huge untapped potential. according to industry players. the government of India and financial institutes like Punjab Financial Corporation (PFC) provided significant support. Punjab State Industrial Development Corporation (PSIDC). The Shareholding Pattern chart displays the shareholders in Punjab Tractors Limited and their share proportions.L. which was a major player. industrial department.’s Birth Keeping in mind Punjab’s agrarian economy it was decided by the Punjab government to encourage the growth of industries.P. Punjab being the ex-officio chairman. a public limited company. The public subscribed the remainder. A Board of Directors manages the company with the Secretary. This task was entrusted to Punjab State Industrial Development Corporation (PSIDC). The Vice —Chairman and Managing Directors manage the day-today affairs. With the dual objective of industrial and agriculture growth. which is an important township of Punjab. The factory is located at the Sahibzada Ajit Singh Nagar. . PUNJAB TRACTORS LIMITED was established on 27 June 1970. prompted it. which complement Punjab’s agriculture growth.T. is India’s first largescale project based company with a totally indigenous design. Introduction to the Company Punjab Tractors Limited. know-how and technology. which has played a major role in bringing Punjab to the threshold of the industrial revolution. has not looked back.6 BHP tractors was given the name SWARAJ— 720.T. In all.L. In the first twenty year of its existence its capacity has been increased to 24000 per annum. PTL is considered as a highly reputated and impressive company in India. Ever since then P.7 crores. SWARAJ provides with a host of varied products. which includes: • TRACTORS • HARVESTING COMBINE • FORK LIFTERS • AGRICULTURE IMPLEMENTS • AUTOMOTIVE CASTINGS • LIGHT COMMERCIAL VEHICLES • SHELTER • ENGINES • CASTINGS • ROUGH TERRAIN . its first production of 26. It went into commercial production in the year 1974. It manufactures many products and is helping in to develop India and improving its farming techniques.Growth of PTL Punjab Tractors Limited started with an annual capacity of 5000 tractors and with a capital of Rs. which is a considerable achievement by any standards. 3. The data is collected for the year.L.T. they had entered in international market. Following is the detailed list of sales of leading tractor-producing companies: . So “SWARAJ” was appropriately chosen as its brand name. P. They are also sending their Harvesting Combines to South Korea having first AC cabin Harvesting Combine in India. Sudan.Origin of the word “SWARAJ” The word SWARAJ”. the markets are flooded with tractors of various companies. Since. means “freedom from bondage”. in Hindi. SWARAJ is also an internationally recognized name in the developing world. Kenya. Zambia. Tanzania. SWARAJ are now a well-established brand name in country. Malaysia. etc. Indonesia. Most of the companies provide a range (in terms of power) of tractors to capture the market. SWARAJ GROUP sells its product under this brand name. Earlier. moreover fully based upon Indian technology. SAWRAJ tractors find an important place in developing countries like Ghana. they had also transported the machined rims to Japan. Position of SWARAJ products in market With more than 2 Lac tractors and harvester combines operating in Indian farms. was the first largest tractor project in India. Uganda. a project worth millions of dollars. SALES SCENARIO OF VARIOUS TRACTOR COMPANIES Nowadays. The products of SWARAJ are not only restricted to Indian market but. SWARAJ occupies third position in the market in terms of sales of tractors. Following is the list of the components manufactured by them: • • • • • • • TRACTOR HARVESTOR COMBINES FORK LIFTRES LIGHT COMMERCIAL VEHICLES SHELTERS ENGINES CASTINGS .We see that three-four companies dominate total tractor production in India and around. LIST OF PRODUCTS MANUFACTURED SWARAJ GROUP of industries manufactures a number of products. It was basically designed to harvest wheat and paddy.5 bhp tractor introduced in 1974 a 39 bhp tractor introduced in 1975 a 19. The heart of the FD is a 48 bhp engine supplied by KIRLOSKAR OILS INDIA LIMITED. SWARAJ 720: 5. SWARAJ 834: a 25 bhp tractor introduced in 2003 a 26. . SWARAJ 735: 4. The fork lifter is manufactured by SWARAJ in collaboration with a Japanese firm KOMATSU. Its engine is supplied by ASHOK LEYLAND LIMITED. TRACTOR Following is the list of models of tractors that have been manufactured by this company: 1. FORK LIFT TRUCKS These are also called fork lifters. These can be either battery operated or diesel operated.1. They are used for loading and unloading of heavy equipment and various articles in an industry. SWARAJ 724: 3. 3. It is a six-cylinder engine developing a power of 105 bhp.5 bhp tractor introduced in 1978 a 55 bhp tractor introduced in 2004 2. SWARAJ 722: 2. It has very short turning radius so that it can move easily in limited spaces. HARVESTER COMBINE It was India’s first indigenous built Harvester Combine called H 8100. Also. which are. ENGINES : The engines are required for various models of tractors are supplied by SWARAJ ENGINE LIMITED.Following is the list of fork lifters manufactured a. CASTINGS Castings of differential. used as loading vehicles. castings of various pulleys. gearbox. FD—20 c. and special order vans. Some work of the shelter is done in PUNWIRE also. trumpet SWARAJ FOUNDARY DIVISION produces housing required for the production of tractors. 7. . mini buses. reduction gearbox and gearbox of Harvester Combine are also supplied by Foundry Division. SHELTER SCD manufacturers shelters on order basis. 5. which are made for defence purposes. FD—30 FB—15 FB—20 FB—25 FB—30 4.LIGHT COMMERCIAL VEHICLES: SWARAJ MAZDA manufactures light vehicles. FD—25 d. 6. rear cover. FD—15 b. Following are the five divisions of SWARAJ GROUP: • SWARAJ COMBINE DIVISION • SWARAJ FOUNDARY DIVISION • SWARAJ ENGINE DIVISION • SWARAJ TRACTOR DIVISION SWARAJ COMBINE DIVISION It was set up in 1980 in village Chappercheri. SWARAJ had set up its plant for the production of tractors.6 crores to manufacture self-propelled harvester combines modeled SWARAJ-8100. But with the passage of time. Additionally. with the collaboration of foreign companies like Komatsu. 2. FE-939). it opened its new Division near Chandigarh. company also entered in collaboration with KOMATSU FORKLIFT CO. In year 1990. it diversified into other fields. Ropar. on Landran road near Kharar in Distt. to fulfill the requirements of Indian market. It was started with a capital layout of Rs. of Japan for manufacturing both diesel and electric fork lifters up to 10 tonnes capacity. Mazda etc. . Presently this division is manufacturing around 75 tractors (FE-855. This year target has been set to 30000 tractors annually. indigenous diesel fork FD-20 and FD-25 with a lifting capacity of 2 tonnes. SCD is manufacturing some components for SWARAJ MAZDA DIVISION. In 1985. 2. Later in the year.Units of SWARAJ Group Originally.5 tonnes respectively were brought out. It was India’s first indigenously produced self-propelled harvester combine. the production of tractor was also started here. Engine production in this company has reached level of 15921. Total revenue of this plant has reached up to Rs.4% indigenous components. trumpet housing.S. shop it supply gearbox. mobile radio stations and other similar defense applications. It was setup in the year 1987 for the manufacture of diesel engines.S.6 crores. Shelters are used for various purposes like housing electronic data. It uses about 99.SWARAJ COMBINE DIVISION (SOD) is also producing FIBRE RE ENFORCED PLASTIC (FRP) shelters for Indian army. It was setup in technical and financial collaboration with KIRLOSKAR OIL ENGINE LIMITED. This plant manufactures engines for SWARAJ TRACTORS. . It includes supply of input shafts. differential rear cover. handling systems. It also supplies connecting rods to SWARAJ MAZDA DIVISION. In H. It is situated at a distance of around 22 km from Chandigarh. gear main drive and many other components used in L. SWARAJ ENGINE DIVISION This plant is located in Mohali. a volume growth of 27% as compared to previous year. This division supplies the casting to all other units of SWARAJ GROUP.M. The current capacity of this plant is 800 tonnes of gray iron casting per annum on single shift basis. hub. refrigerated vans. 15 crores.72.M. SWARAJ FOUNDARY DIVISION This plant is located in village Majri near Kurali in Ropar Distt. This plant was set up in the year 1980 with an initial investment of Rs. The installed capacity of this plant was 1500 engines per annum. The Vice-Chairman and the Managing Director manage the day-to-day operations. It manufactures different models of tractors i.e. of different HPs. Govt. It was set up on May 27. Level 1 : Chairman • Ex-officio (Secretary Industries. 1300 crores Hierarchy of the Organization – The Board of Directors with the Secretary Industries.S. of Punjab as its Ex-officio Chairman. Rated capacity : Employee strength: Annual turnover: 40100 tractors per year. This was India’s first large-scale project totally based upon indigenous design and technology of India itself. Around 3000 Rs.A. Department. Nagar. in Punjab. in Ropar District. It was the first SWARAJ DIVISION to be set up. 5 Km from Chandigarh. an important industrial town. Govt. S. 1970 with the dual objective of industrial and agriculture growth.SWARAJ TRACTORS DIVISION (MOHALI) Introduction Swaraj Tractor Division is situated at phase-IV.. manages the company. Presently around 90— 100 tractors are produced in a day in two shifts. of Punjab) Level 2 : Working Director • Vice-Chairman and Managing Director Level 3 : Executive Directors • Finance . • Human Resource and Development • International Business Division • Manufacturing • Material Services • Swaraj Automotive Limited • Swaraj Motors Limited • Senior Vice President (Marketing) Level 4 : Vice President • (3-4 under each Executive Director in level 3) Level 5 Level 6 Level 7 Level 8 Level 9 Level 10 Level 11 Level 12 Level 13 Level 14 Level 15 : : : : : : : Assistant Vice President General Manager Chief Manager Senior Manager Manager Assistant Manager Senior Engineer Engineer Assistant Engineer Junior Engineer Operating Class . Support Services • • • Management systems Finances Purchase . which can be broadly classified into: 1. Product services • • • • • • • • • Tool room Tool control cell (TOO) Industrial engineering Research & Development Production planning & control (PPO) Material Management & control (Stores) Quality Engineering Maintenance Construction 3. Production Light machine shop (LMS) Heavy machine shop (HMS) Assembly shop Heat treatment shop Paint shop 2.Manufacturing System STD operates through a series of departments. The rupees thirty one million plant and machinery of this shop installed in an area of 33. Except the bevel gear generator & gear shaver. drum turret lathe. copying lathe. Gear shaper. and casting. Centering & facing machine. twin chucker. Centre Hole grinding machine. Horizontal Milling Machine. which have been imported from WIv1W & Churchill of West Germany respectively. It has more than 120 machines. . forging and high standard of quality. Honing machine.000 sq. all other machines are from HMT Ltd. TYPES OF MACHINES Cylindrical grinder. Deburring machine. gear hobber. D/E boring machine Gear Shaver GTR machine. boring. Radial drilling machine. Capstan lathe. internal grinder. All transmission components viz. Facilities of this shop include Equipment for blank operation. Vertical Milling machine. Centre lathe. turret lathe. Chuckmatic.LIGHT MACHINE SHOP (LMS) INDRODUCTION: LMS is the largest section in the factory. CNC machine. drilling etc. Power Hacksaw Special purpose drilling machine. Vertical pull broaching machine. ft. Capstan lathe. Bevel Gear Generator. Fay Auto. shafts and gears used in Tractors are manufactured here. drilling of all gears reporting system. • • Quality control and inspection. number of workmen shifts operations Inter relations with other departments • • Tool room : jigs. Production planning and co-ordination: Micro loading of components on a daily basis. bevel gear cutting of all rounds on power hacksaws. • • Assembly: ensuring proper fitment of components.shot blasting operations lab testing.Function of the department Gear manufacture and grinding. machining of bull gears. Gear shaving gear deburring machine. fixtures and cutting tools Maintenance: attending breakdowns and carrying out preventive maintenance of machine tools etc. all type of grinding inner and outer gears. hobbing and broaching machine. . inspection etc. storage and inspection R & D Heat treatment. facing and centering. • Industrial engineering: provision of process charts for machining operations. Finish Turning: Here min. to make the ends flat and smooth& to make the piece of required length. Under Cutting: It is similar to grooving operation but is performed inside a hole. Metal is removed &very little oversize dimensions is left for further machining.Different Manufacturing Operations In LMS Facing: It is the operations of finishing the ends of the work. Broaching: It is a method of metal removal by a tool that has successively higher cutting edges in a fixed path. to remove burs &to protect the work piece from being damaged. Chamfer is provided for better look/to rough turning: in this operations max. Chamfering: It is the operation of beveling the extreme end of the work piece. Knurling: It is a proc of embossing a diamond shaped regular pattern on the surface of the work piece using a special knurling tool. Each tooth removes a fixed amount of material. . Boring: It is a process of enlarging a hole that has already been drilled. metal is removed &very fine finish is obtained on the work surface. Drilling: It is a process of making hole in an object by forcing a rotating tool called drill. Grooving: It is the operation of turning the groove or neck in order to terminate a thread or to provide adequate clearance enable nut to pass freely on threaded work piece. HEAVY MACHINE SHOP INTRODUCTION: All heavy castings of tractors are machined in this shop with the help of variety of special machines (SPM). 76-kg wt. In addition to the machining of castings for the tractor. COMPONENTS MACHINED IN THE SHOP: • Gearbox housing (Material—R-33. for grinding threads. These machines are tailor made by HMT to suit component requirements. About 20 SPM and 30 GPM are installed in a covered area of 47. 2600 tonnes of castings are machined every year on a two-shift basis. ft.In grinding. Casting. the material is removed by a means of a rotating abrasive wheel. The tool used in shaping for teeth cutting is a multipoint cutting tool.Grinding: To grind means to ‘abrade’ to wear away by friction or to ‘sharpen’ . better surface finish etc. 180-230 BHN. at a cost of 20 million.) • Differential Housing • Rear Cover • Trumpet Housing . some jobs are also performed for Swaraj Mazda Limited. Hobbing: It is the process of cutting teeth on gear &shafts & is performed by a rotating tool called hob on the hobbing machine. Shaping: The process of cutting gears on the shaper is known as shaping. It is generally used for sharpening the cutting tool.000 sq. R&D Paint shop . production planning and control. machining of some components for Mazda.FUNCTIONS OF THE DEPARTMENT Machining of heavy castings like differential housing. of workmen.Ensuring proper fitment of components. micro loading of components on day-to-day basis. • • • Quality control & inspection — Storage and inspection. shift operations. fixtures and cutting tools. rear cover. INTER-RELATION WITH OTHER DEPARTMENTS • • Tool room . trumpet housing. machining of tractors parts. ORGANISATION STRUCTURE Hierarchy. Maintenance .Provide process charts for machining operations. reporting system. • Assembly . no. • Industrial engineering . gear box housing.Requirement of jigs.Attending breakdown and carrying out preventive maintenance of machine tools. steering housing of tractors. 733. 744. 834 Sections in Assembly 1.TYPES OF MACHINES • • Radial drilling machine Vertical milling • • • • • • • • Horizontal milling Simplex milling Duplex milling Lathe Double end T/W boring Automatic lathe SPM (special purpose M/c) ASSEMBLY SHOP Function: Assembly of all finished components and bought out components for Swaraj722. . PTO Shaft Assembly 3. 724. 735. Cage Assembly 2. BPS L/R Assembly. Brake Hsg. 17. Coupling Gear Box Assembly with Differential Hsg. 21. 13. 10. Rear Cover Assembly and testing 9. Front and Rear Frame. Assembly. Engine assembly. 6. Mounting of front and rear tire . Coupling Engine Assembly with 13 18. with 17 20. Clutch Pedal Assembly. 12. Assembly.4. Assembly. Assembly other main link items like Levelling Rod. Assembly. and Assembly. Brake Pedal. Trumpet Hsg. Gear Box Assembly. Brake Hsg. Foot Board Assembly. Frame. and Trumpet Hsg. Assembly. to be assembled with 12 14. Steering Assembly. 14 with 16 19. Tie Rod assembly. Stay Bars. Trailor Hook. King Pin Assembly. Greasing all points 22. Battery Mtg. Invasion into painting chamber 23. to be assembled with 11 13. 16. 11. Steering assembly. Differential Assembly and Testing 5. Front Axle Beam Assembly. Differential Hsg. 15. 7.. and testing 8. Front Shield. Oil Filling. Radiator Assembly. 26. Air Cleaner and Exhaust Assembly. the machinist has to drop the final Part on the roller conveyor. 2. Testing The Assembly Shop is the production shop where assembly and sub-assembly I of all the parts take place. Front Grill etc Assembly. 32. The final processed parts from the various parts of production shop such as HMS. Bonnet. Side panel. Gear Box assembly and sub-assembly. with lights and other electrical fitments 25. Rear Shield. and the parts reach the assembly shop after being automatically washed and dried.e. 27. Fuel Tank Assembly. Differential assembly and sub-assembly. shop only after being washed. 30.24. The assembly shop can be divided into various groups depending upon subparts being assembled. These groups are: 1. LMS and Heat Treatment reach the assembly Shop. Battery filling etc. 29. . which takes place when the different parts are on their way to assembly shop. cleansed and dried. 28. 3. The various parts reach the assembly. The above washing process takes place automatically i. Battery fitment 31. Dash Board Assembly and Seat assembly. Fender Assembly. Differential Cover assembly. Planetary Gear Cover. 6. Assembly. making up a complete one unit. and Crown Wheel etc. The DI cover is collected from the conveyor and the various attachments . 7. the oil filter and the brake mechanism Differential Cover Assembly The second stage of Assembly shop is the differential cover assembly shop which incorporates the gear pump assembly. both the BP shafts are fitted with various components such as circular clips. Assembly. This constitutes the assembly of Cross Bar. differential cage etc. The Assembly of Differential Hsg. Steering Gear Box Assembly. And the direction control valve. Assembly of various links.. In the first unit. of engine with Clutch mechanism. Then the differential Cage unit and the BP shaft are assembled. the various sub-assembly. needle bearings etc. Differential Assembly: Before the various differential parts such as BP shaft. to be able to be assembled to the differential Cage. and the Axles are assembled in a different assembly shop and there on the whole unit along with the Bull Gears is assembled to the differential Cage. + Brake assembly. of about parts and integral one are bolted using a pneumatic bolter gun. The various bolts required making the assembly. + Gear Shifting Mechanism Assembly. of parts listed above are performed in the sub units. Foot Board and other accessories.4. 5. are assembled. is complete with the assembly of lay shaft ext. Planetary Gear. After this. The Trumpet Hsg. the differential cage is collected from the conveyor firstly fitted with the necessary bearing races. of 5 and 6 assemblies. The box after being tested for its efficiency is sent to the 5 stages.. DCV Valve etc. the brake assembly is sent to the 1 stage of assembly and the steering gear box and gear box cover assembly is sent to the 3 stage of assembly.such as Power Cylinder. gear shift mechanism on gear cover + the brake mechanism is assembled of these mentioned sub assemblies. clutch shafts. Gear Box Assembly The Gear Box Assembly is the third stage of the assembly unit in which the gear box is assembled. Apart from these sub assembly unit also produces the KPS assembly. Oil Pump. main shaft along with the ball bearings are assembled to the unit. And further sent to the 5 stages of the assembly. and the cover is tested for its efficiency on the testing jig. In this unit the sub assembly of the steering gear box. There is separate sub unit assembling the planetary cage and gears. Firstly. is made. which is then attached to the Gear Box output shaft to obtain the duplex speed ratios of the tractor. Steering Gear Box + Gear Shifting + Brake Assembly: This unit consists of 4 stages of the assembly unit. After which it is sent to the first stage where the whole unit is assembled to the Dc assembly. Piston Assembly. the gearbox cage is collected from the conveyor roller and successively parts such as the counter shafts. . the Gear Box is mantled to the differential Apart from this. nuts etc. the skilled workers are used to accomplish all the stages of assembly. various other accessories such as Foot Board.Assembly of Gear Box Differential Hs and other accessories In the 5 stage of assembly. . Also the whole of the assembly is done on the assembly jigs or stands which is kept moving at a speed of about 7cm/mm. Assembly of Engine with the rest transmission section The assembly of the engine and rest of the transmission is done within the 7 stage. But they are also held by the pneumatic bolt guns and the over head automatic conveyors and the alarm conveyor etc to make their job easy. by mistake is not going to spoil the working space as all these spills gets underneath the working space and as a result the working space remains clean and tidy. Brake Link etc are mantled in this section. In this stage the whole of the chassis is formed as an integral unit. Clutch link. Assembly of Engine + Clutch Mechanism This unit is separate 6 stage of assembly in which the engines are received from the stores and fitted with the clutch mechanism and lay beam along with the counter weights. The various links and mechanism between the engine and the gear box or diff is fastened together and the whole integral unit is checked for its complete accessories etc. Battery Clamp and other links such as Accelerator Pedal Link. In all the above stages of assembly. Also it is to be made in mind that any spill of the sub parts such as bolts. The heat treatment shop at PTL is equipped with several gas carburising furnaces. List of components heat-treated in this shop • • All gears produced in LMS All shafts produced in LMS List of machines in heat treatment shop Following are the machines. The shop is manned by a highly skilled work force. quenching tanks. shafts etc. which are used in the heat treatment shop: • • • • • • • Gas carbursing furnace Induction hardening machine Quenching tank Shot blasting machine Tempering machine Lapping machine Hydraulic press .Heat treatment INTRODUCTION: Heat treatment shop plays a very important role in every industry. these need to be heat treated to impart desired strength and increase the life of components. In automobile industry the important components are gears. induction hardening machines and shot blasting furnaces. Tempering generally follows a carburisation process. Cooling rate after temperature rise also affects the residual stresses.Commonly used terms and operations Carburising Process of adding carbon to the large surface layer of the component is called carburising. It reduces the internal stresses and stabilizes the internal structure of the component. nitrogen to the surface by diffusion from the surrounding medium at high temperature. It is the process of case hardening. These processes consist of heating to marten site state for a scheduled period to an indicated temperature in a range between room temperature and critical temperature. which is the addition of some elements like carbon. The amount of carburising gases depends upon rate of combustion of gases. It converts hard brittle steel into metal of hardness as well as ductility by reducing grain size. which is done to avoid brittleness due to cementite network and to make the surface ductile. . In this case it is necessary to maintain a continuous fresh stream of carburising gases. At PTL gas carburising is carried out in muffle furnace using isopropyl alcohol as a source of carbonaceous gas. The hydrocarbon decomposes at a high temperature thereby releasing atomic carbon. It can be done in three ways: - Gas carburising Liquid carburising Pack carburising The purpose of carburising is to obtain high surface wear resistance and to obtain a hard surface. slower the cooling rate lesser the stresses. Tempering It is the generally the final operation of all the steel components after they have been hardened. followed by cooling. 2.Normalizing Normalizing is a type of heat treatment applicable to ferrous metals only.7 mms. It is metaquench 40 or servo quench 11. High voltage current. At PTL special type of oil is used for quenching purpose. The transfer of heat slows down and hence the internal stresses also come down. is passed through induction coil surrounding the surface to be hardened.2. The yield strength of annealed components is more than that of unannealed one. holding the casting for definite time and then letting it cool in still air. which is transformed into current of low voltage and high ampere. The treatment is same as annealing and it eliminates casting from cooling stresses. When the hot component is dipped in the quench tank it is immediately surrounded by oil vapor envelope. Depth of hardness generally varies from 2. It is then cooled rapidly by spraying water from water jacket.. In this process iron alloy casting is heated to about 50-60 degrees above the critical temperature range. Induction hardness It is employed for increasing the surface hardness of steel. High frequency current is passed. Quenching Heat may be removed or quenching can be done by immersing the hot component into a bath of water or dressed oil. which gradually raises the temperature of the component. To avoid this a motor is run to remove the oil. . The coil induces the current into the component. Gear Z-42.it is done to remove the carbon layer formed on the surface of the bull gear.Shot blasting Bombarding the component with lead fillings does it.it is electrically heated at 910 degree Celsius for 13-14 hours along with liquid feed.it is electrically heated to 910 degree Celsius for 13-14 hours along with liquid feed. Few components on which heat treatment is done are: 1. Bull gear: • Case carburising: . .e. • Quenching: .after quenching bull gear is heated to 220 degree Celsius for 2-3 hours and then gradually cooled in air. • Shot blasting: . drive shaft: • Case carburising: . • Tempering: .it is then cooled at 810-degree Celsius followed by quenching in metaquench oil. • Tempering: . removes scales and material from the component.it is done to remove the carbon layer from the component surface.it is then cooled at 810 degree Celsius followed by quenching in metaquinch oil. and intermediate shaft. input shaft. • Quenching: . • Shot blasting: . The reason for shot blasting is to clean the surface i. A clean uniform and in some cases final finished components is obtained after shot blasting.after quenching it is heated to 180 degree Celsius for 23 hours and gradually cooled in air. PAINT SHOP Operations performed in paint shop are: • Surface Preparation (Pre Treatment Cell)-carried out for sheets and rims. Pre Treatment Cell Various procedures followed here are: • • Degreasing Water Rinsing (part which is degreased is alkaline in nature so rinsed with water due to its being good solvent). Painting Chassis Paint Line: Operations carried out here are: . • Passination (done so as to avoid paint penetrating through certain section of part body’s surface). • • • De Rusting Surface oxidation Phosphating (done so as to form a thin layer of coating on part so that no surface remains unpainted). • • • • Painting Inspection Rejection (Reprocessing)-for sheets and rims. • Primer Painting: A thin layer of primer paint is sprayed on the chassis so that the final paint is strongly fixed on. Various parameters checked are-: • • • Depth of penetration of paint. sheets and rims are first of all cleaned with ordinary cloth. • • • • • Flash Off: This is the distance given so as to allow paint to dry.• Washing: Here chassis is first washed with a chemical cleaner. concentration of which is 5% and auto sprayed in a chamber. Quality Control Inspection If painting in both sheets and rims is satisfactory the piece is selected otherwise rejected. Final Painting Flash off. Baking (at temperature of around 120-130°C) Wet Rubbing and cleaning with tack rag. Sheet and rims Painting: After surface preparation in PTC. Baking: Chassis is allowed to bake for around 30 minutes. There after following operations are carried out: • • • • Primer painting (full primer in addition to single coating of paint) Flash off. • Drying: The chassis is then dried by hot air whose temperature is up to 60 to 70°C. Thickness of paint coating Smoothness . • Uniformity Rejection If piece is rejected it is either again processed whereby is again send to PTC or discarded. it can not be subjected to the production process with the advent of new and modern technology. MATERIAL HANDLING EQUIPMENTS: • • • • • • • Trucks of different types Trolleys Cranes of different types Belt conveyors. maintenance plays vital role. A MORE ABOUT SWARAJ TRACTOR DIVISION IN VERY BRIEF LAYOUT: Layout in the plant is the combination of the line and the batch layouts. Earlier maintenance practices were only confined to the breakdown maintenance. the entire concept of maintenance has changed. Along with production. overhead conveyors Roller conveyors.most common in use Chain conveyors Hoists MAINTENANCE DEPARTMENT INTRODUCTION Many changes have taken place in the maintenance system and practice used in the industries with the progress made by technology. In fact production and maintenance go side by side If a machine is under breakdown. but now different types of maintenance practices are followed like: . need of over time etc. Machine and other facilities should be arranged so that they can be used to their max. capacity. Equipment breakdown leads to inevitable loss of production time. which is prevented by maintenance department. Routine check-up of facilities ensure safe and efficient operation of machinery. • • To keep the plant in proper working condition.1. Maintains optimum production efficiency of machinery 5. Helps in maintaining the operational accuracy and reduces the work content. IMPORTANCE OF MAINTENANCE 1. Preventive maintenance 4. rescheduling of production. 4. needs of sub-contracting work. 3. Break down maintenance 3. Scheduled maintenance 2. • The Maintenance division of the factory ensures the availability of all the facilities necessary for the performance of functions at optimum return of investment. Plant maintenance plays an important role in production management by preventing breakdowns which caves inevitable shortfall of target. . 2. Predictive maintenance The following are the main objectives of maintenance: • To achieve the minimum break down level and to achieve the production target at low cost. 6. Material handling equipment maintenance cell. At present the maintenance deptt. proper utilization of resources . training have also become important now. .cost. to achieve availability performance at the lowest cost and within the safety constants. 7.better spare parts planning. 1. not only predictive and preventive action bus the concept of cost cutting. With rise in the technology.e. This can be made possible to cent percent by systematic maintenance. The function of maintenance is to use these re3 sources to repair. i. In Punjab tractors limited systematic maintenance operations are practiced to improve the plant availability and to achieve the goal at a reasonable cost. production at min. Reduce breakdowns and concerned downtimes thus achieving the target of max. of PTL have five subsections. 5. Engineering machine maintenance cell 3. Engineering utility maintenance Kelley defines maintenance as the operation of a pool of resources like men. replace and adjust or modify the parts of plant to be enabling it to operate the specified availability and performance over a specified time for the specified life. Ensure safety of life and limbs of workers and machine operators. spares and tools directed towards controlling the level of availability and the condition of the plant. 4. Spare part planning and control cell. Electrical maintenance cell 2. ” I received the blend of experience in Private as well as in Govt. It was a good learning time during my training as we were fortunate to be placed in the department related to manufacturing. I also pay my regards to my Lecturers for their guidance during my training and my Academics helped me to do a lot during my training. working with teams and much more. 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.“PUNJAB TRACTORS LTD. In the end I will like to thank all persons who helped me through out my training to enhance my experience.BIBLIOGRAPHY My training was the most versatile experience. HARPREET SINGH . I had the pleasure to do the work with one of the most reputed factory in their field. sector.