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Submitted by:
Harpreet Singh
Roll number: -11235
Registration number: - UCE (P)-05-194
B.Tech. (Mechanical Engineering) – 4th Year
University College of Engineering
Punjabi University
Information
Report submitted by: Harpreet Singh
B.Tech. (Mechanical Engineering)
8th Semester
Roll Number :11235
Registration Number : UCE (P)-05-194
Batch: 2005-2009
University College of Engineering
Punjabi University
Patiala
India
Company Address
where Industrial training was undertaken
Acknowledgement |
Sometimes words fall short to show gratitude, the same happened with me during this
project. The immense help and support received from Reliance Money Limited
overwhelmed me during the project.
It was a great opportunity for me to work with Swaraj Tractor division, pioneers in
the field of farm equipment manufacture, a part of Mahindra and Mahindra Ltd. I am
extremely grateful to the entire team of Swaraj Tractors, SAS Nagar (Mohali) who has
shared their expertise and knowledge with me and without whom the completion of
this project and my industrial training would have been virtually impossible.
My sincere gratitude to Mr. Rajendra Singh (Senior Manager and my mentor,
Swaraj division, Mahindra and Mahindra Ltd. , SAS Nagar(Mohali)) for providing me
with an opportunity to work with them as a trainee who has provided me with the
necessary information and his valuable suggestion and comments on bringing out this
report in the best possible way.
I feel great pleasure to thank Mr.Avtar Singh (In charge-PDI) and all other team
members. I am also very thankful to my friends, partners during the training period and
all the workmen at the Swaraj Division, Plant -1 and who helped me in the completion of
my projects. I am thankful to that power that always inspires me to take right step in the
journey of success my life.
Harpreet Singh
Contents
1. The Indian Tractor Industry Page 1
2 Introduction and Business Description Page 2
Swaraj Tractor Division - Mahindra and
Mahindra Limited
3 Background of the company Page 2
4 Timeline of the company Page 3
5 Company Organization chart Page 5
6 Manufacturing facilities at plant -1 Page 7 -14
1. Light machine shop
2. Heavy machine shop
3. Paint shop
4. Assembly shop
5. Heat treatment shop
6. Quality Engineering
7 Products and specifications Page 15 - 23
8 Project Reports
1. Project – 1 Page 24 - 49
(Elimination / reduction of water-
mixing in the engine oil )
2. Project – 2 Page 49 - 65
(Elimination / reduction of diesel
leakage from fuel cock)
The Indian Tractor Industry |
Page | 1
India is mainly an agricultural country. Agriculture accounts for approximately 25 percent of India’s
GDP. Agriculture in India is the means of livelihood of almost two thirds of the workforce in the
country and employs nearly 62 percent of the population. It accounts for 13 percent of India’s
exports. About 42 percent of India’s geographical area is used for agricultural activities. It is therefore
considered a vital sector of the Indian economy.
The Indian tractor industry is the largest in the world, accounting for one third of global production.
The other major tractor markets in the world are China and the USA. The global spotlight on tractor
manufacture in terms of unit volume seems to be swinging away from the USA, UK and Western and
Eastern Europe towards India and China, where growth in the number of producers and the total
volume of production in recent years has been impressive.
Until 1960, the demand for tractors was met entirely through imports. Indigenous manufacture of
tractors began in 1961, but India continued to import tractors to bridge the total volume needs up to
the late 1970s. The Indian Tractor Industry has come a long way since then. Volume growth in the
past four decades show a compound annual growth rate of 10 percent, despite seasonal variations
that cause natural fluctuations in the demand for tractors, subsequently impacting the industry
volumes.
The Indian tractor market is traditionally a medium-horsepower market consisting of mostly 31-40
hp, which constitutes almost 51 percent to growth in this category. Growth of the Industry is closely
related to growth in this category. In other-size categories, 41-50 hp category achieved the second
highest growth of 34 percent and constitutes 24 percent of the total market share. The rest of the
market share is largely with the 21-30 hp category followed by the category of tractors having more
than 50 hp.
The Indian Tractor Industry has numerous challenges, some of them being:-
1. Reducing the average age of tractor buyers from the age group of above 40 to younger people
2. Development of new products using latest technology and advancements in the field of
electronics and mechatronics and making the tractors more comfortable, stylish and yet
keeping them in range of a farmer.
3. Reduction of emissions in accordance with the new international emission standards
Introduction and Business Description |
Swaraj Tractor Division, Mahindra and Mahindra Limited, is the farm equipment manufacturer
division and the flagship company of the erstwhile Punjab Tractors Limited of which a major share
was acquired by Mahindra and Mahindra Limited in the year 2007. The Company's principal activity Page | 2
is to manufacture, market and servicing of tractors ranging from 25-100 HP. Other products include
self propelled harvester combines, forklifts, tractor drawn agricultural implements, gears, spare
parts, casting and accessories. The Company has manufactured and sold more than 600,000 tractors
over the past 30 years (with 36000 tractors being manufactured and sold in the fiscal year 2008-
2009 alone).The basic credibility of the company is the manufacture of reliable tractors requiring
least maintenance and low cost of ownership. The Company is one of the major share-holder in the
Indian Tractor Industry in a market with rivals like John Deere, Case New Holland, TAFE, etc. The
company has in-house competence in producing engines and transmission systems and has been the
best financially managed company in the Indian Tractor Industry. The reputed Swaraj brand of the
company is sold through 475 exclusive dealers stocking only Swaraj products The manufacturing
plants and the Research and Development centre of the company are located in Mohali, Punjab. The
company exports auto components to the markets of African/SAARC countries.
1. Swaraj Tractor Division (STD) Phase –IV, Industrial Area, SAS Nagar(Mohali)
2. Swaraj Foundry Division (SFD) Mazri, SAS Nagar(Mohali)
3. Swaraj Combine Division (SCD) chapparcheri, SAS Nagar(Mohali)
Punjab Tractors Limited (PTL) was promoted by Punjab State Industrial Development Corporation
(PSIDC) to commercialize the indigenous tractor developed by the Central Mechanical Engineering
Research Institute (CMERI). The Swaraj brand of tractors were India's first indigenously made tractor
suitable for medium land holdings. A number of plants of the company are situated in the S.A.S. Nagar
(Mohali) District, Punjab, India. The construction of the first plant of the company located at phase-IV,
Industrial Area, S.A.S. Nagar (Mohali) started in March 1972 and the first batch of tractors rolled out
on 14th November 1973. The commercial production commenced in the year 1974. Initially, PSIDC
contributed 42% equity capital against the total paid up capital of Rs.140.00 lakhs. The facility was
initially created to manufacture 5000 tractors and the capital cost at that time was Rs.321 lakhs
The company's product line also includes Combine Harvestors and Forklifts. The production capacity
of tractors has increased to 60000 tractors per year from the level of 5000. The company, over the
years, has also promoted two companies, namely, Swaraj Mazda Limited (manufacture of Light
Commercial Vehicles) & Swaraj Engines Ltd. (manufacture of Diesel Engines in collaboration with
Kirloskar limited). Both Kirloskar Oil Engines limited and Swaraj Engines Limited manufacture
tractor engines for the Swaraj Brand of tractors.
Page | 3
Timeline ||
Year Event
1965 Govt. of India's research institute (CMERI) at Durgapur initiates design and
development of SWARAJ tractor based on indigenous know-how.
1970 Punjab Govt. through PSIDC acquires SWARAJ tractor's design from CMERI
and establishes Punjab Tractors Ltd. (PTL) for its commercialization.
1971-73 PTL sets up SWARAJ Project for 5,000 tractors per annum at a capital
outlay of Rs. 37.0 million with an equity base of Rs 11.0 million.
1974 Swaraj 724 (26.5 HP) tractor commercially introduced.
1975 2nd tractor model SWARAJ 735(39 HP) developed by own R&D,
commercially introduced.
1978 3rd Tractor model SWARAJ 720 (19.5 HP) developed by own R&D,
commercially introduced. Maiden equity divided declared.
1980 Guided by social concerns and responsibility, PTL takes over PSIDC's sick
scooters unit - Punjab Scooters Ltd. (subsequently renamed as SWARAJ
Automotives Ltd.)
India's first Self propelled Harvester Combine - SWARAJ 8100 developed
by own R&D, commercially introduced.
SWARAJ Foundry Division set up in Backward area.
1981 Issue of maiden Bonus Shares (2:5), paid-up equity moves to Rs 15.4
million.
1983 4th Tractor Model - SWARAJ 855 (55 HP) developed by own R&D,
commercially introduced.
1995 Setup of tractor Plant II at Village Chappercheri, SAS Nagar with annual
capacity of 12,000 per annum.
1996 3rd issue of Bonus Shares (1:1), paid up equity moves to Rs. 202.5 million.
1998 Commencement of expansion to 60,000 tractors (30,000 at each plant).
Capital outlay of Rs 1000 million, funded mainly through internal accruals.
1999 5th and 6th tractor models - SWARAJ 733 (34 HP) & SWARAJ 744 (48 HP)
developed by own R&D, commercially introduced. FY 1999's divided @
250% was corporate India's highest.
2000 Expansion of annual tractor capacity to 60,000 completed.
4th issue of Bonus Shares (2:1), paid up equity moves to Rs 607.6
million.
2001 PTL won National Championship trophy in competition organized
by All India Management Association (AIMA) for young managers.
Economic times and Boston Consulting Group selects PTL as one of
the India's finest 10 companies out of Economic times top 500
Companies.
2002 Cumulative tractor sales crosses 500,000.
2003 PSIDC's disinvestment of its entire Equity holding (23.49%) in PTL in
favour of CDC Financial Services (Mauritius) Ltd. With this, total holding of
CDC & its associates in PTL stands at 28.48%.
2004 7th & 8th tractor models - Swaraj 939 (41 HP) & Swaraj 834 (34 HP)
developed by own R&D, commercially introduced
2005 PTL disinvested 15,73,000 equity shares of Rs. 10/- each of Swaraj Mazda
Ltd. (constituting approx. 15% of SML's paid up capital) in favour of
Sumitomo Corporation, Japan, a joint venture partner in Swaraj Mazda Ltd.
at a total consideration of Rs. 629.2 million
2007 CDC/Actis Group and Burman Family's disinvestment of their
Equity holding in PTL (43.3%) in favour of Mahindra Group (M&M).
M&M made open offer to shareholders for another 20% equity of
the Company.
Mahindra Group's equity holding in the Company stands at 64.6%
Cumulative Tractor Sales cross 600,000.
Swaraj Track Type Combine designed and developed by in-house
R&D, commercially launched
2008 Swaraj 3 Tonne Battery forklift, designed and developed by in-house R&D,
commercially launched Page | 5
Working Directors
4) Executive Directors:
Finance
Human Resource and Development
Manufacturing International Business Division,
Material Services
Swaraj Automotive Limited
Swaraj Motors Limited
Senior Vice-President (Marketing)
5) Vice Presidents:
each under Executive Director (in previous level)
Page | 6
7) General Manager
9) Senior Manager
10) Manager
13) Engineer
Page | 7
Operating Class
Paint shop ||
Paint Shop is the place where the different sheet metal components are painted. They are
made to pass through various chemicals before they are actually painted. The painting
method opted is that of Spray Painting. The paint shop at the plant is equipped with the
washing and drying facility for the engine and transmission section of the plant as well as
the sheet metal components of the tractor.
Assembly shop ||
The Assembly line at Swaraj Tractor division deals with the assembly of tractor models 722, 724, 733, 735
FE, 735 XM, 744, 834. Assembly is the joining of various constituents to form a final product. The assembly
process is carried out on the main line, which has various sub assemblies along its length.
a) Differential loop.
b) Gearbox loop.
c) Rear cover loop.
d) Engine assembly loop.
Gearbox loop
In the gear box loop, the Gearbox housing mounted on trolley, Drive shaft, input shaft ,output
shaft , Lay shaft, connecting shaft assembly, Shifter rod assembly, Steering assembly are
assembled.
After that the chassis is carried to the next level by the lift where the engine & the 3-point
assembly of the tractor along with the other components are fixed. The parts fitted here are:
Bracket.
Lower link fitted at the left side.
Leveling rod fitted at the right side.
Stabilizer stainer.
Draw bar.
Top link.
Battery frame.
Front frame.
Tie rod attached with the drop arm of the steering system.
Accelerator link.
Delievery pipe.
Engine attachement.
The engine is attached with the chassis system in this level of assembly. The engine is also carried
to this level with the help of the lift crane, which lifts the engine assembly & delievers it to this
level. Shlug is applied at the corneror we can say at rhe circumference of the gearbox where
engine is attached with studs & bolts. Shlugs works as gaskets or seals & avoid the oil leakage and
water mixing in the engine. Then the engine and chassis system, mounted on the coveyor system Page | 10
enter the paint shop area, where it is washed, dried and painted.
The engine and chassis assmbely after the paint shop reach here, and gets fitted with
following parts:
Front axle.
Extension in the front axle used for the setting of the wheels.
K.P.S.A. (King Pin Shaft Axle) with the wheel disc & nuts fitted in there for the fitting of
the wheels.
Drop arms.
Tie rods.
Bucket.
Clutch plates
Alternator.
Self starter.
Fuel pump.
Then the whole assembly is mounted over the conveyor, which takes that piece to different chambers
of washing, drying, primering, baking, painting & again baking.
The chassis
and the
engine going
for washing
and drying
and then it
goes to the
paint shop
After paint area
After painting the conveyor takes the assembled piece to the Dismounting stage where
different parts & components like tyres, radiator, dashboard, sheet metal parts, seating,
steering wheel ,etc are fitted on the tractor & the tractor was completed. After that the
testing of the tractor is done. A tractor has to pass through different tests to claim itself to be Page | 11
worthy to be sold and if there is some problem coming out in this stage, the tractor is send to
the recovery shop, where the problem of the tractor is recovered. After the recovery the
tractor is again tested & after passing the test the tractor finally send to the yard from where
it is dispatched after Pre – dispatch inspection (PDI).
1. Suppliers quality
Suppliers section consists of maintaining the quality of products that are being supplied by
suppliers. It contains inspection of the raw materials being supplied by suppliers. It also
includes discussion regarding delay of raw material and defective parts supplied.
Subsequent actions are taken if the supplied products being supplied are found defective
and inspectors from the industry are sent regularly to avoid such defects. This inspection
is regularly done by the industry so maintain good quality supply and sound relationship
with suppliers.
2. In-House Quality
It is said the prevention is better than cure. To eliminate any problem in the further
stages, In house quality is embedded into every department of the industry. As such there
are six in-house quality check posts:-
Pre-Dispatch Inspection
P.D.I (Pre Dispatch Inspection) is the final quality post which carries a major responsibility of
dispatching the tractors as manufactured by the assembly line of plant-1. This is similar to giving
final touches to the jewellery being sold. This department carries rigorous checks as per the pre-
designed checklist prior to dispatch of machinery.
P.D.I acts as one of the major diagnosing center for every daily to daily outgoing failure and
scrutinizing them and hopefully trying to remove these failures. This way forthcoming problems
reported by dealers are reduced. This helps to maintain a healthy relationship with dealers and
customers.
Measures under PDI
Page | 13
1. TRANSMISSION FLUID LEVEL
2. ENGINE OIL LEVEL
3. FUEL INJECTION PUMP OIL LEVEL
4. WATER LEVEL IN RADIATOR
5. ELECTRICAL FUCTIONING
6. COMPONENT STORAGE
7. CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER
Mahindra and Mahindra limited, manufactures a number of farm equipments under the Swaraj Brand.
Given below is the list of the farm equipment manufactured along with some of its specifications being
manufactured at Plant-1, phase IV, SAS Nagar (Mohali): -
Specifications:
Engine :
HP : 39 S.A.E
Type : 4 Stroke, direct injection, diesel engine.
No. of Cylinders : 3
Bore and Stroke : 100 X 110 mm
Displacement : 2592 cc
Rated Engine Speed : 2000 rev/min.
Air Cleaner : 3 stage Air cleaning system comprising of Cyclonic pre-cleaner, Oil bowl &
Paper element to enhance engine life.
Cooling System : Water cooled with No Loss tank.
TRANSMISSION
Clutch : Heavy duty single dry plate type, 280 mm diameter Page | 16
No. of Gears : 8 forward, 2 reverse speeds with high and low selector lever.
Speed Chart
Gear 1st 2nd 3rd 4th Rev.R
Low 2.3 3.1 4.6 7 2.84.7
High 8.9 12.1 18 27.4 11.2
P.T.O. 21 splines for 1000 rpm
6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)
BRAKES Heavy Duty self energizing, water sealed disc brakes
Parking brake for additional safety, Oil immersed disc brakes (Optional)
STEERING Heavy Duty single drop arm steering for high efficiency and comfortable
drive.
HYDRAULICS 2 lever live hydraulic system having automatic position & draft with mix
control
a) Position control To hold lower links at any desired height.
b) Automatic Draft Control To maintains uniform draft.
c) Mix Control For optimum field output
Hydraulic lift pump Gear type hydraulic pump delivers 17 l/min at rated engine speed.
Specifications:
Engine :
HP : 34 S.A.E.
Type : 4 Stroke, direct injection, diesel engine.
No. of Cylinders : 3
Bore and Stroke : 100 X 105 mm
Displacement : 2474 cc
Rated Engine Speed : 2000 rev/min.
Air Cleaner : 3 Stage Air cleaning system compromising of cycolonic pre-cleaner,
Oil Bowl and Paper element to enhance Engine Life
Cooling System : Water cooled
TRANSMISSION
Clutch : Heavy duty single dry plate type, 280 mm diameter
No. of Gears : 8 forward, 2 reverse speeds with high and low selector lever.
Speed Chart
Gear 1st 2nd 3rd 4th Rev.R
Low 2.1 2,9 4.4 7 2.6
High 8.3 11.3 17.4 27.4 10.4
P.T.O. 21 splines for 1000 rpm
6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)
BRAKES Heavy Duty self energizing, water sealed disc brakes
Parking brake for additional safety, Oil immersed disc brakes
STEERING Heavy Duty single drop arm steering for high efficiency and comfortable
drive.
HYDRAULICS 2 lever live hydraulic system having automatic position & draft with mix
control
a) Position control To hold lower links at any desired height.
b) Automatic Draft Control To maintains uniform draft.
c) Mix Control For simultaneous use of position and draft controls for optimum field
output.
Hydraulic lift pump Gear type hydraulic pump delivers 17 l/min at rated engine speed.
Specifications:
Engine Specifications:
HP : 48 S.A.E.
Type : 4 - Stroke, Direct Injection, Diesel Engine
No. of Cylinders : 3
Bore and Stroke : 110 X 110 mm
Displacement : 3136 cc
Rated Engine Speed : 2000 rev/min
Air Cleaner : 3 Stage Air cleaning system compromising of cycolonic pre-cleaner, Oil Bowl
and Paper element to enhance Engine Life
Cooling System : Water Cooled with Oil Cooler for engine oil.
Transmission:
Clutch : Heavy Duty single dry plate type, 305 mm dia, Dual Clutch, 280 mm
dia. (optional)
No. of Gears : 8 forward, 2 reverse speeds with high and low selector levels.
Gear Speeds (Km/hr)
1 2 3 4 R
Low 3.1 4.2 6.5 8.9 4.3
High 10.2 13.8 21.4 29.2 14.3
P.T.O.
21 Splines for 1000 rpm at rated engine
6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)
Brakes
Heavy Duty Self energizing, water sealed disc brakes with parking brake for additional safety.
Oil immersed disc brakes (optional) Page | 19
Steering
Heavy Duty single drop arm steering for high efficiency and comfortable drive.
Hydraulic and Implement Linkage
2 Lever live hydraulic system having automatic position and draft with mix control.
Position Control: To hold lower links at any desired height
Automatic Draft Maintains uniform draft.
Control:
Mix Control: For simultaneous use of position and draft controls for optimum
field output.
Hydraulic Lift Pump: Gear type hydraulic pump delivers 17 l/min at rated engine speed.
24 l/min for 1500 kg capacity hydraulics.
Linkage
3 point category-I suitable for category-II type implement pins
Lifting Capacity
1000 kgf at Lower Link Ends
1500 kgf at Lower Link ends (Optional)
Electricals
12 Volt, 88 Ah. Battery, starter motor & alternator.
Instruments
Tractor meter with direction indicators, Fuel Gauge, Ammeter, Water Temp. Gauge & Oil
Pressure Gauge.
Tyres:
Front : 6.00 X 16
Rear : 13.6 X 28
Wheel Track:
Front : 1200-1750 mm
Rear : 1350-1900 mm
Deluxe Features
Higher capacity hydraulic (1500 kg.) with improved sensitivity. *
Concealed lockable battery near starter.
Aesthetically designed heavy duty telescopic front axle beam.
Telescopic stabilizers bars for easy adjustment and better implement stability.
Adjustable sliding P.U. seat for operator's comfort.
Centrally located horn switch on steering wheel (like cars) - for operational convenience.
Oil immersed (multi disc) wet brakes. *
(*optional)
Features
Horse Power - 48 SAE
Improved fuel combustion system - lesser diesel consumption.
Most modern oil Cooler - for longer life of engine.
8+2 speed gear box (combination of CM & SM Gears) with suitable speeds for haulage,
field, straw making machine
PTO available in 540/1000 rpm
Dual Clutch for PO driven implements (Optional)
Page | 20
Specifications:
Engine Specifications:
HP : 34 S.A.E.
Type : 4 - Stroke, Direct Injection, Diesel Engine
No. of Cylinders : 2
Bore and Stroke : 100 X 116 mm
Displacement : 2204 cc
Rated Engine Speed : 2000 rev/min
Air Cleaner : 3 Stage Air cleaning system compromising of cycolonic pre-cleaner, Oil Bowl
and Paper element to enhance Engine Life
Cooling System : Water Cooled with Oil Cooler for engine oil
Transmission:
Clutch : Heavy Duty single dry plate type, 280 mm dia
No. of Gears : 8 forward, 2 reverse speeds with high and low selector levels.
Gear Speeds (Km/hr)
1 2 3 4 R
Low 2.1 2.9 4.4 7.0 2.6
High 8.3 11.3 17.4 27.4 10.4
P.T.O.
21 Splines for 1000 rpm at rated engine speed.
6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)
Brakes
Heavy Duty Self energizing, water sealed disc brakes with parking brake for additional
safety.
Steering
Heavy Duty single drop arm steering for high efficiency and comfortable drive.
Hydraulic and Implement Linkage Page | 21
2 Lever live hydraulic system having automatic position and draft with mix control.
Position Control: To hold lower links at any desired height
Automatic Draft Maintains uniform draft.
Control:
Mix Control: For simultaneous use of position and draft controls for optimum
field output.
Hydraulic Lift Pump: Gear type hydraulic pump delivers 17 l/min at rated engine speed.
Linkage
3 point category-I suitable for category-II type implement pins
Lifting Capacity
1000 kgf at Lower Link Ends
Electricals
12 Volt, 75 Ah. Battery, starter motor & alternator.
Instruments
Tractor meter with direction indicators, Fuel Gauge, Ammeter, Water Temp. Gauge & Oil
Pressure Gauge.
Tyres:
Front : 6.00 X 16
Rear : 12.4 X 28
Wheel Track:
Front : 1200 - 1750 mm
Rear : 1350-1900 mm
Deluxe Features
Concealed lockable battery near starter.
Aesthetically designed heavy duty telescopic front axle beam.
Telescopic stabilizers bars for easy adjustment and better implement stability.
Adjustable sliding P.U. seat for operator's comfort.
Centrally located horn switch on steering wheel (like cars) - for operational convenience.
Features
Horse Power - 34 SAE
Most modern air Cooler - for longer life of engine.
8+2 speed gear box (combination of CM & SM Gears) with suitable speeds for all farm
operations.
Live hydraulics.
Alternator - for powerful headlights and longer battery life.
Water separator in fuel line for extra protection of fuel injection pump.
PTO available in 540/1000 rpm.
Low Diesel Consumption
Ideal for all field and haulage operations.
Ideal for paddy cultivation
Shorter turning radius
Page | 22
Specifications:
Engine Specifications:
HP : 26.5 S.A.E.
Type : 4 - Stroke, Direct Injection, Diesel Engine
No. of Cylinders : 2
Bore and Stroke : 100 X 110 mm
Displacement : 1728 cc
Rated Engine Speed : 2000 rev/min
Air Cleaner : 3 Stage Air cleaning system compromising of cycolonic
pre-cleaner, Oil Bowl and Paper element to enhance
Engine Life
Cooling System : Water Cooled
Transmission:
Clutch : Heavy Duty single dry plate type, 254 mm dia
No. of Gears : 8 forward, 2 reverse speeds with high and low
selector levels.
Gear Speeds (Km/hr)
1 2 3 4 R
Low 2.3 4.2 6.3 7.2 3.2
High 8.9 16.4 24.9 28.4 12.5
P.T.O.
21 Splines for 1000 rpm at rated engine speed.
6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)
Brakes
Heavy Duty Self energizing, water sealed disc brakes with parking brake for
additional safety.
Steering
Heavy Duty single drop arm steering for high efficiency and comfortable drive.
Hydraulic and Implement Linkage
2 Lever live hydraulic system having automatic position and draft with mix control.
Position Control: To hold lower links at any desired height
Automatic Draft Maintains uniform draft.
Control:
Mix Control: For simultaneous use of position and draft
controls for optimum field output.
Hydraulic Lift Pump: Gear type hydraulic pump delivers 17 l/min at Page | 23
rated engine speed.
Linkage
3 point category-I suitable for category-II type implement pins
Lifting Capacity
1000 kgf at Lower Link Ends
Electricals
12 Volt, 75 Ah. Battery, starter motor & alternator.
Instruments
Tractor meter with direction indicators, Fuel Gauge, Ammeter, Water Temp. Gauge &
Oil Pressure Gauge.
Tyres:
Front : 6.00 X 16
Rear : 12.4 X 28
Wheel Track:
Front : 1200 - 1750 mm
Rear : 1350-1900 mm
Deluxe Features
Concealed lockable battery near starter.
Aesthetically designed heavy duty telescopic front axle beam.
Telescopic stabilizers bars for easy adjustment and better implement stability.
Adjustable sliding P.U. seat for operator's comfort.
Centrally located horn switch on steering wheel (like cars) - for operational
convenience.
Features
8+2 speed gear box (combination of CM & SM Gears) with suitable speeds for all farm
operations.
Live hydraulics.
Alternator - for powerful headlights and longer battery life.
Water separator in fuel line for extra protection of fuel injection pump.
PTO available in 540/1000 rpm.
Economical in haulage, ploughing, threshing and pump-set operations
Shorter turning radius
Ideal for paddy cultivation
Project 1
Elimination of water
mixing in the engine oil
Project Leader :
Mr. Rajendra Singh
( In House Quality )
Team Member :
Mr. Satpal Parmer
( In house quality –
Assembly )
Mr. Ashwani Kumar
(Supplier quality – SEL)
Mr. R.k jain (Research and
development)
Mr. Avatar Singh (SCPC)
Mr. Brij Lal (Quality)
Project 1: Eliminating / Reducing Water Mix in Engine Oil
History of problem|
Dealer PDI (Pre-dispatch inspection) report and MQN (market quality news) had
given feedback for the water mix in the engine oil of the tractors of all models. This Page | 25
water mixing leads to the loss of value of oil and also affects the life of the engine
components working inside the engine assembly. Based on the feedback from the
PDI area of the plant, same problems were also being faced in the plant also.
Tractors having such problem were taken for investigation and analysis for the
problem identification.
Swaraj 1 3 1 1 10 6 7 6
Engines
Limited
Kirloskar Oil 8 4 4 3 9 2 1 1
Engines
Limited
Page | 26
SEL Engine
with oil filled Engine SEL Engine
Engine
storage on Tractor
coupled
conveyor washed and
KOEL Engine KOEL engine filled with
with Oil filled by
cleaned with
empty chassis
Assembly high pressure
department
Tractor
dismounted
Tractor roller
tested
YES
Tractor R/W. If water Tractor
Oil changed mix R/W Oil
observed changed
YES
No
If water
Dispatched mix PDI
NO observed
Project 1: Eliminating / Reducing Water Mix in Engine Oil
Page | 28
The problematic area – Tractors being washed and washed with high pressure
This washing of
the tractors with
high pressure
takes place on
the assembly line
before the paint
shop, where the
engine assembly
is washed, dried
and then
painted.
||Observation of symptoms
Page | 29
In certain cases oil level in oil sump is found high and water level in radiator low.
In all the cases engine oil red colour turns whitish ( milky ) as shown in the photograph
The water-mix paste turns to a milky colour when it comes in contact with water in the oil
Project 1: Eliminating / Reducing Water Mix in Engine Oil
a. Air leakage observed from breather pipe joint in three cases –KOEl-2 & SEL-1
Page | 30
b. Air leakage observed oil filler cape in one case- SEL
A B
Page | 31
||Observation of variation
48%
52%
Project 1: Eliminating / Reducing Water Mix in Engine Oil
The analysis of the problem lead to the formulation of theories and sub-theories in their logical Page | 32
inter relationship. These came forward after experiments were conducted and brainstorming was
|| Possible causes
i. Excessive clearance between pipe outer diameter and hole in Oil filler body
d. Dipstick assembly if
f. MISC
ii. Leakage in joint between Fuel Injection Pump and Gear Casing
iii. Leakage in joint between Oil Filler Body and Gear Casing
iv. Excessive clearance between pipe outer diameter and hole in Oil Filler Body
|| Cause and effect diagram| the cause and effect diagram gives a systematic overview of the problem
Page | 34
3) Excessive clearance between pipe O/D and hole in Oil Filler Body
16) Leakage in joint between Fuel Injection Pump and Gear Casing
17) Leakage in joint between Oil Filler Body and Gear Casing
Project 1: Eliminating / Reducing Water Mix in Engine Oil
||Testing of hypothesis
All the possible causes were tested after discussion with the team members and marked as a
Page | 36
valid reason or invalid reason accordingly.
Page | 37
i ) Rubber Plug 100 pieces were checked with gauge at the supplier Hypothesis
eccentric and end and 10 pieces were found defective as nut valid
not welding fixture was not there.
perpendicular
w.r.t cap
iii) Rubber Plug 50 Cases were checked for leakage. Seepage was Hypothesis
head Outer observed in 2 cases. valid
Diameter less by
design
9 Oil filler cap Leakage observed in1 out of 5 cases when water was Hypothesis
assembly Design poured at this point. valid.
inadequate.
I)Steel washer
There was metal to metal contact due to steel
11 Dipstick not fully Checked visually. No case was found among Hypothesis
seated. defective and 100 other cases observed. invalid.
I)“O” Ring size & Specification: Diameter 5.0 mm, Thickness 2.0 +/- .08 Hypothesis
thickness not OK invalid.
Observation on failed engine.
ii) Groove Specification Dia. - 4.99 /5.1 mm, Thickness- 1.98/ 2.04 mm Hypothesis
diameter under invalid.
Found OK.
sized
Actual : OK with Plug gauge
14 Flash over plastic Water seepage was observed due to flash over plastic Hypothesis
molding not valid
dressed. Mold. It causes the dipstick tilt to one side thus creating
gap on one side of the “O” ring
I)Die not
reworked In one case of engine oil contamination by water,
Dipstick had conspicuous flash on parting line. This
dipstick was tried on loose Crank Case (as shown in
photograph) by pouring water.
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.
Air leakage observed from breather pipe joint in three cases –2 KOEL engines & 1 SEL
engines.
1. Sealant not applied properly between Breather Pipe bush Outer Diameter and Oil Filler
2. Rubber Plug (Bellow) eccentric and not perpendicular w.r.t. cap. (Oil filler cap).
Page | 42
6. Flash over Plastic Outer Diameter due to plastic molding (Dipstick).
1 Sealant not applied properly (breather pipe bush ) SOP provided and operators
were educated as per SOP at
the suppliers end
2 Rubber plug eccentric and not perpendicular New welding fixture designed
w.r.t. cap (oil filler cap) ( J68080 ). Alternate design
for nut welding provided
(vides drawing no.
V085633/1)
3 Rubber plug head diameter less Diameter changed from
61mm to 63.5 mm
4 Steel washer ineffective in oil filter cap assembly Design changed
1 ) Steel washer replaced with
“O” ring
Page | 43
2200
Target: 1000
2100
PPM PPM
2000 Month Wise Rejection for the
defect - Water mix in Engine oil
1900 ( in PPM)
1800
1700
March WK1 March WK2 March WK3 March Wk4
Page | 44
Following are the areas from where Impact of cost due to failure was reduced
@Return on investment (expected)
Investment- Nil
Cost of mobile Oil (Multi grade) = Rs. 463
Cost of Paper element (P719101) = Rs. 27
Cost of Diesel (3.5 Lts) = Rs. 100
Cost of Labour (Rework) = Rs. 100
Page | 46
Conclusion|
|| Lessons Learnt
|| Horizontal developments
|| Critiquing
The selection of team members was very judicious. It went right up to the completion of the
project. In the beginning, the magnitude of the work involved in the project was not realized.
The pace of the project was rather slow so all members had to over exert in the lateral part of
the project. The work should have been started at war footing from the very outset.
Page | 47
Final report | Submitted to the plant management on the requested pattern
TO resolve PDI and early hour failure (R/1000) in the tractor before and after
OBJECTIVE dispatch.
COMPONENT(S)
Complete engine assembly
UNDER FOCUS
Dealer PDI report and market quality news feed back for the water mix in the
engine oil of tractor. Which leads to loss of value of oil and also effect the life of
engine components working inside the engine assembly.Based on the feed
back, same problem were being faced in the plant also. Tractors having such
problem were taken for the investigation and analysis for the problem
BACKGROUND / identification.
OBSERVATION OF
FIELD DATA Water mixed in engine oil on tractor in the plant and MQN as given below
For finding the root cause of the problem. A reverse Engineering method were
developed and implemented to find the real cause. A dry air test method
design and developed as shown in the fig. test was conducted on the
problematic engine. Air leakage observed through the following points like:
Page | 48
ROOT CAUSE
ANALYSIS Air Leakage Test
SOLUTION
SOP made and implemented for the above said solutions.
VALIDATION
SOLUTION
All the recommended solutions has been implemented.
IMPLEMENTATION
FURTHER ACTION
PLAN - TRACKING Will be monitoring for further, for some time being till the fool proofing not
/ HORIZONTAL done at the supplier end.
DEPLOYMENT Audits and checks are being carried out for the holding gains.
Project 2
Elimination / Reduction of diesel
leakage from fuel cock assembly
Project Leader :
Mr. Rajendra Singh
( In House Quality )
Eliminate Rejection / Wastage of Diesel due to leakage from fuel cock Assembly – High Diesel
leakage from fuel cock assembly. Its average in the last 4 months has been 7408 PPM at present
while the target is to achieve is 500 PPM.
History of problem|
Based on the gate audit of the quality engineering. Reference 10% Audit report.
12000
10000
8000
PPM
6000
4000
2000
Based on the gate audit of the quality engineering. Reference 10% Audit report
Yes
No Roller
Rework Testing
Rework and
PDI at STD before
Correct
Dispatch
OK
Leakage
Dispatch
Project 2: Eliminating / Reducing Diesel Leakage from fuel cock assembly
||Observation of symptoms
1. I5 cases of Diesel leaksge 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.
||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 Page | 55
ring.Fuel pipe is fitted with fuel cock with banzo and aluminium washer.
Fuel Cock
Assy
Upper leakage
point AL washer
||Observation of variation
Observation of leakage from fuel cock Assy and joints on 20 defective tractors. The Following
observations were made:-
Tractors belong to both the shifts. Assembly was done by different persons and at
different times. So there is no variation from
Shift to Shift
Person to Person
Time to time
The analysis of the problem lead to the formulation of theories and sub-theories in their logical
inter relationship. These came forward after experiments were conducted and brainstorming was
|| Possible causes
The analysis of the problem led to the following possible causes
2. Machine
3. Material
|| Cause and effect diagram| the cause and effect diagram gives a systematic overview of the problem
Page | 59
MAN
Torque wrench
METHOD
not used SOP not display
Person not
skilled SOP not made
Assy not as
per SOP
‘O’ Ring
SOP not adequate setting not
ok
No holding
Wrong torque Grease not device used
wrench used applied
FUEL COCK
LEAKAGE
Fuel Tank O/D U/S
Wrong
Sealing mtg.
impact no ‘O’ Ring ‘O’ Ring
torque seat
Face dented
depth Damage/cut Knob ‘O’ ring
Setting excess damage
over Al. washer Material porosity
Torque wrench
Fuel Cock Assy
setting
High M14x1.5 mot ┴
hardness w.r.t to face M5 hole
Butting face not
// to each other through
Setting
Thread
under
Fuel pipe inclined Thread portion length less or more
rejected
Face dent w.r.t face Banjo bolt
Crimping
or defective
not ok
damage
Concentricity of Ø14& M14x1.5
Circular finish
MATERIAL thread portion not ok
MACHINE not ok
Project 2: Eliminating / Reducing Diesel Leakage from fuel cock assembly
||Testing of hypothesis
All the possible causes were tested after discussion with the team members and marked as a
valid reason or invalid reason accordingly.
dented
Page | 61
4 Fuel cock All fuel cock was checked for flatness with the help of calibrated Hypothesis
M16x2 square gauge. All pieces, were qualified the gauge. Invalid
face not
flat
5 Banjo bolt Five banjo bolts removed from the defective tractor and
Ø 14 not checked with concentric gauge (J61405A). All were qualified the Hypothesis
concentric gauge. ┴ =.05 max. invalid.
with
M14x1.5
6 Rubber In four out of 20 defective tractors when dismantled rubber ring Hypothesis
sealing found damage all sealing ring replaced with new ring fitted with valid
ring not tractor not leakage found.
seated in
fuel tank
groove
Project 2: Eliminating / Reducing Diesel Leakage from fuel cock assembly
7 Sealing 15 Sealing ring were checked for diameter & shore hardness. Hypothesis
ring invalid.
(P395208) Diameter-ØO/D Specified = 16.5±.10
diameter Ø O/D Observed = 16.5±.10
undersize Thickness = 1.78±..076
& Shore hardness -
hardness Specified = 65±5
variation Observed= 63-66
8 Fuel Tank Five defective fuel tank were checked for depth & ┴ 0.1 or all Hypothesis
groove were qualified in the gauge No. J61408. invalid.
depth Squareness checking gauge number
excess & Also 100 pieces at random were also checked on line with gauge
M14x1.5 all were qualified.
thread not
┴ or to
the
groove.
9 Fuel pipe All defective pipes checked for parallelism with micro meter. Hypothesis
butting All reading invalid.
not Specified = 0.1mm
parallel to Observed = 0.09mm
each
other
10 Fuel pipe In one case out of 20 , leakage observed from Fuel Cock knob Hypothesis
butting when tested with air pressure at 1.5 kg /cm2 Valid
not
Page | 63
parallel to
each
other
10 tractors with no diesel leakage through fuel cock Assy and their joints were checked. For
verifying the observed possible root cause the following observations were made:-
All the banjo bolts were fully tighten at 18 lbsft torque.
Sealing rings were perfectly ok.
No Fuel leakage from fuel cock knob
|| Development of remedies
2. Rubber sealing ring not Assembly not SOP not followed SOP not made
seated in fuel tank done properly
groove. To find out
3. Diesel leakage from fuel Air leakage leakage point
cock knob performed
|| Final remedies
Final report |
The final report, testing and checking of this project is still underway. The project is still under
process