End Semester Industrial Training Report

Mahindra & Mahindra Limited – Swaraj Tractors Division

 Step 1 : Identification and definition of the problem

Project 1

Eliminate the rejection/wastage

of the engine oil in engine
assembly due to mixing of water
in all models of tractor

Project completed by the Department of Quality Engineering

and Assurance
Brief Description of the
problem
Engine oil is used in the engine
for lubricating moving parts to
reduce friction between them.
While checking the correct level
of oil in the sump with the help of
dipstick during pre-dispatch
inspection of the tractors, colour
of the engine oil was found
changed due to water mixing.
Engine oil dip-stick

Water Mixing in engine oil

leads to
Water Mixing with the Engine oil
leads to
1 2 3
Rejection of Wastage of Wastage of oil
oil is a man hours in leads to national
monetary replacing loss and
loss to the defective oil environment

4 5 6
Engine paper oil Engine moving Loss of lubricating
filter swells and parts get rusted properties of oil which
has to be may result even in
replaced engine seizure
History of problem
 Step 2 : Observation

1.Observation of the
process
2.Observation of
symptoms
3.Observation of
variation
Observation of the process
Observation of the process
 Observation of symptoms

A Number of Tractors were selected from the yard and

observed. It was found :-
•In certain cases oil level in oil sump is found high and water level
in radiator low.
•In other cases there is no rise in oil level.
•In all the cases engine oil red colour turns whitish ( milky )
 Observation of symptoms
Air Leakage test
Air leakage test is done to find out any points of leakage in the equipment. In the
present situation the air leakage test was performed on the engine assembly to
find out and leakage point from where water was supposedly getting mixed with
the engine oil in the sump.

After the test was performed, following results were observed

•Air leakage observed from breather pipe joint in three cases –2 KOEL engines & 1
SEL engines.
•Air leakage observed oil filler cape in one case - SEL
•Air leakage observed from dipstick one case – ASSEMBLY
Observation of variation
 Step 3: Analysis

1.Possible causes
2.Testing of probable causes
Possible causes
Testing of Probable causes
Testing of Probable causes
Testing of Probable causes
Testing of Hypothesis
Testing of Hypothesis
Testing of Hypothesis
Testing of Probable causes
Testing of Probable causes
Testing of Probable causes

Dipstick
 Root causes identified

1. Sealant not applied properly between

Breather Pipe bush Outer Diameter and
Oil Filler body Inner Diameter
2. Rubber Plug (Bellow) eccentric and not
perpendicular w.r.t. cap. (Oil filler cap).
3. Rubber Plug head Diameter less as per
Design.
4. Steel Washer ineffective in Oil Filler Cap
Assy.
5. Dipstick design not adequate.
6. Flash over Plastic Outer Diameter due
to plastic molding (Dipstick).
Actions taken to eliminate root causes
 Step 1 : Identification and definition of the problem

Project 2

Eliminate Rejection / Wastage of

Diesel due to leakage from fuel
cock Assembly

Project completed by the Department of Quality Engineering

and Assurance
Brief Description of the
problem
Fuel Cock Assembly is connected between
the Fuel Tank Assembly and to the Water
Separator through Fuel Pipe, Fuel Cock
Assembly is used in the diesel circuit to
stop and open the Diesel flow to the feed
pump by gravity. Fuel cock Assembly is
connected to the Fuel Tank with a sealing
Rubber ring between Fuel Cock and Fuel
Tank. A Fuel Pipe is used to carry the
Diesel to Water Separator with a banjo

Fuel cock assembly

The Diesel Leakage through Fuel Cock

Assembly leads to
The Diesel Leakage through Fuel Cock
Assembly leads to
1 2 3
Loss of Entire area Leakage
Diesel, which below the Fuel accumulate on
is monitory tank Assembly the parts showy
loss to the becomes oily shabby looks and
customer and which is major eye sore to the
to company irritation
4 5 6
If the complaint is It also leads to Environment of safety
not attended delay of the finish
immediately, this goods dispatch.
may lead to
engine stop
History of problem
 Step 2 : Observation

1.Observation of the
process
2.Observation of
symptoms
3.Observation of
variation
Observation of the process
 Brief Description

Fuel cock assembly is used in fuel line of the tractor assembly. Its main function is
to cut-off or release the fuel to the fuel line. Fuel cock assembly is consists of main
parts like body, knob, and rubber sealing ring. Fuel cock is fitted to the main tank
with rubber ring . Fuel pipe is fitted with fuel cock with banzo and aluminum
washer.

Fuel Cock
Assy

Upper leakage
point AL
washer

Banjo bolt Bottom

Diesel Off / On
leakage point
Knob leakage
AL washer
point
Brief Description

Interface of Fuel
Cock & Fuel
Tank Assembly

Fixed Torque wrench

 Observation of symptoms

1. Heavy leakage of diesel on tractors in

rework.
2. P.D.I audit (leakage)
3. IQS score

1. I5 cases of Diesel leakage from PDI area & 5 cases from tractor re-work
area were studied. In 15 Cases leakage was observed from bottom face of
banjo bolt ,in 4 case mountings with tank & 1 case from Fuel cock knob.
2. Leakage from the bottom face of the banjo bolts
3. This defect observed in all models of tractors.
4. Torque value of 18 lbsft for banjo bolt tightening was observed under
torque with dial type torque wrench. In other 4 cases leakage found from
interface of Fuel cock Assembly & Fuel Tank Assembly. In one case
leakage was observed from Fuel Cock knob.
 Step 3: Analysis

1.Possible causes
2.Testing of probable causes
Possible causes
Testing of Probable causes
Testing of Probable causes
Testing of Probable causes
Testing of Probable causes
Testing of Probable causes
 Root causes identified

1. Banjo bolt found under torque.

2. Rubber sealing not seated in groove
3. Fuel leakage from fuel cock knob
Actions taken to eliminate root causes
Thank you