Mech Training Report (Swaraj Engines)

Six Months Industrial Training Report
PUNJAB TRACTORS LIMITED
P.T.U
JALANDHAR
SIX MONTHS TRAINING
REPORT
Training Implemented at
SWARAJ TRACTOR DIVISION(MOHALI)

A MAHINDRA & MAHINDRA SUBSIDARY
SUBMITTED TO:
SUBMITTED BY:
Er.GAUTAM KOCHAR
(H.O.D OF MECHANICAL
DEPTT.)
PARIKSHAT WADHERA
B.TECH(7th SEMESTER)
UNIVERSITY ROLL NO:
5831112569
DEPARTMENT OF MECHANICAL ENGINEERING.

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www.final-yearproject.com | www.finalyearthesis.com
R.I.E.T
PHAGWARA.
R.I.E.T PHAGWARA
THIS IS TO CERTIFY THAT THE SIX MONTHS

INDUSTRIAL TRAINING IMPLEMENTED AT
SWARAJ TRACTOR DIVISION
A MAHINDRA & MAHINDRA SUBSIDARY
(MOHALI)
SUBMITTED BY:
PARIKSHAT WADHERA
B.TECH(7th SEMESTER)
COLLEGE ROLL NO:19/ME/05
IS COMPLETED AS BY THE REQUIREMNT

OF P.T.U JALANDHAR IN THE PARTIAL
FULFILMENT OF THE DEGREE OF BTECH(MECH.) FOR THE ACADEMIC YEAR
2008-09.
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HEAD OF DEPT.
PRINCIPAL
Order of the pages:
1.
2.
3.
4.
5.
Front Page
Acknowledgement
Preface to SWARAJ
Contents:
Company Profile
Various companies of SWARAJ group
Introduction to SWARAJ GROUP
Introduction to SWARAJ TRACTOR DIVISON,
Mohali
Departments
Analysis of individual module
Projects Undertaken
Conclusion
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4
ACKNOWLEDGEMENT
It is a great pleasure for me to attend my training in this esteem organization.
At the very outset, I would like to express my deep gratitude to SWARAJ
GROUP for giving me an opportunity to work upon and do my training in
this reputed organization. I express gratitude and pay my whole regards to
all the people at Punjab Tractors Limited, Tractor division who helped me
& made my training a success. I feel I have been part of the Swaraj family
though only for a short time and shared the work culture which inspired me
to adapt a goal oriented approach. I owe my success to many people who
guided me and shared with me their valuable time & suggestions so that I
could develop. I would like to take this opportunity to thanks
Mr. Ashok Jain

Mr. H.S Baweja
Mr. Achhar Singh
Mr. Umesh Malhotra
Mr. Navjot Singh
Under whose guidance and rich pool of experience I have completed my

training. I am thankful to
Supervisors of all the other departments
Mr.J.Singh
All the operators of the shop & also the Apprentice
For introducing me to the members of Swaraj family and for guiding me
throughout the training period. And for giving me time from their busy
schedule to ask my queries.
I would be failing in my duty if I dont spell my thanks to the
employees of Punjab Tractors Limited for giving shape to my ideas and
thinking. They were more than encouraging and helpful, by giving me time
from their schedule to ask my queries.
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Parikshat Wadhera
PREFACE
Punjab, the bread basket of India, the land of 50376 sq.km is
situated in Northern part of India. It is agriculturally Indias most
advanced and most prosperous state. Till late 60`s agriculture was
done with old crude methods. To industrialize the agricultural sector,
Punjab Tractors Limited was promoted by PSIDC as one of its
projects in 1970 for manufacturing of agricultural tractors with
indigenous know how. Since, this gave independence to country
from import of tractors, so the brand name SWARAJ, total
independence was given.
Swaraj tractors conceived in 1965 by a tem of dedicated

engineers and scientists working at Central Mechanical Research
Institute, Durgapur with a firm belief
that Indian Technology could be brought at par with the best
in the world. The first model developed was Swaraj-724 developed
over a period of 5 years. Independent commercial production started
in the year 1974 and after this company grew by leaps and bounds.
Today it is one of the leading tractor manufacturing companies.
In the month of July,2003 the 23% stake held by the PSIDC
has been disinvested to COMMONWEALTH DEVELOPMENT
CORPORATION, a UK based firm.
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ORIGIN OF THE WORD SWARAJ

In Hindi, the word SWARAJ means Freedom from Bondage. Since P.T.L.
was the only first largest tractor project in India, moreover fully based upon Indian
technology. So SWARAJ was appropriately chosen as its brand name. SWARAJ
GROUP sells its product under this brand name.
POSITION OF SWARAJ PRODUCTS IN MARKET
With more than 2 lacs of tractors & harvester combines operating in Indian farms,
SWARAJ are now a well-established brand name in country. SWARAJ is now an
internationally recognized name in the developing world.
The products of SWARAJ are not only restricted to Indian market but they had
entered in international market. SWARAJ tractors find an important place in developing
countries like Ghana, Tanzania, Zambia, Kenya, Sudan, Uganda, Indonesia & Malaysia,
etc. they are also sending their combines to South Korea having first A.C. cabin combine
in India. Long way back, they had also transported the machined rims to Japan, a project
millions of dollars.
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SWARAJ HISTORY
The Indian Tractor Industries, as it is now, is a major segment of its engineering industry.
However till 1974, Indian firms assembling semi knocked down (SKD) kits in
collaboration with foreign manufactures met the tractor requirements of the country
largely through imports & partly. Though the first Tractor Company was set up in India in
1960, but the growth in real terms started from 1974, when the government banned the
import of tractors. Today India is the largest tractor producing and consuming country. In
an effort to reduce imports & develop indigenous technology, the government, permitted
setting up of the major manufacturing companies.
1.
Eicher Good Earth
1960
2.
TAFE
1964
3.
International Tractors
1965
4.
Escorts Tractors
1966
5.
Ford Tractors
1971
6.
HMT
1973
7.
Punjab Tractors
1974
8.
Kirloskar
1974
9.
Harsha
1975
10.
Auto Tractors
1981
11.
Universal Tractor
1982
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INDIAN TRACTOR INDUSTRY MARKET

DIMENSION
9
GEOGRAPHICALLY
TERRITORY
%age of Domestic Sales
North (Punjab, Haryana & Uttar Pradesh)

Central (Madhya Pradesh & Rajasthan)
East (Bihar, West Bengal, Orissa & Assam)
32%
26%
10%
West (Gujarat & Maharashtra)

South (Andhra Pradesh, Tamil Nadu,
Karnataka & Kerala)
12%
20%
SEGMENTWISE
HP Range
%age of Total Sale
Up to 30 HP
19%
31-40 HP
51%
Above 40 HP
30%
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PTLS BIRTH
Keeping in mind Punjab agrarian economy it was decided by Punjab Govt. to
encourage the growth of industries which complements Punjabs agricultural growth.
This task was entrusted to P.S.I.D.C. that was played a major role in bringing Punjab to
threshold of industrial revolution. With the dual objective of industrial & agricultural
growth, P.T.L. was established on 27th June 1974.
LOCATION
The factory is located at S.A.S. Nagar, the important industrial town of Punjab, 5
kms. from Chandigarh. This factory was among the first to be set up in this industrial
town. The company is managed by board of Directors, while the day to day operations
are managed by Vice Chairman & M.D. of the company.
GROWTH OF PTL
PUNJAB TRACTOR LIMITED started with an annual capacity of five thousand

tractors & with a capital of Rs. 3.7 crores. It went into commercial production in the year
1974; its first production was 26.6 BHP tractors given the name SWARAJ-720. Ever
since then P.T.L. has not looked back. In the first twenty years of existence its capacity
has been increased to 24,000 per annum, which is a considerable achievement by any
standards. Besides tractors, it has added a host of other products to its range, which
includes:
Harvesting Combine.
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Fork Lifters.
Agriculture implements.
Automotive casting.
Punjab Tractors Ltd (PTL) is one of the leading manufacturers of tractors in India.
PTL has been known as the industry out performer since inception. Even when the
industry grew at a CAGR of 6.1% during 1991-2000, PTL grew at the CAGR of 11.9%.
In terms of market share, PTL is the second largest player after M & M in FY2001 with a
market share of 18.1%. PTL tractors are sold under the Swaraj brand name. PTL has
strong market share of around 20% in the northern region with the highest share in
Punjab and Haryana and 16% in the western regions and southern regions of India. In the
east the company accounts for 11% market share. The tractor sales accounted for 83.3%
of PTL's turnover in FY2001 whereas the harvester-combines, forklifts and spare parts
accounted for the balance. Industry basics The Indian tractor market is dominated by
low price, rugged, versatile and low to medium powered tractors; the main reason being
the inability of farmers to invest in farm mechanization. Tractors are categorized on the
basis of horse power (HP) of the engine. In India, the popular range of tractors is 20-40
HP compared to 60 HP in Europe and 90 HP in the USA. Though large tractors were
economically unviable in India, there has been an increasing demand for high-powered
tractors due to soil conditions, particularly in states of MP, Gujarat and Maharashtra. But
more recently, higher-powered tractors are also being sold in states like Punjab where it is
considered as a status symbol. Tractors available in India are 1/4th of the prices of similar
powered tractors internationally or in developed countries. Availability of credit is the
most crucial factor impacting tractor demand, as in India 90% of the tractors are financed
by bank credit at concessional rates. Increased use of irrigation facilities, shift towards
multi-cropping, consolidation of lands holdings, promotion of co-operatives and higher
investment in agriculture also contributes to higher tractor demand. The tractor segment
comprises players like Eicher, Escorts, HMT, Punjab Tractors, M&M, TAFE, Sonalika,
which control about 98% market share. India is the worlds largest market in tractors
since 1996. A few international players like Case New Holland, John Deere and Steyr
have also set up facilities in India. But these players have entered the higher-powered
category and, thus, pose little threat to the existing players who enjoy advantages of
established distribution/service network and strong brand equity. Punjab Tractors is
promoted mainly by Punjab State Industrial Development Corporation Limited and has
acquired the second highest market share in the tractor segment from 9.1% in 1975. In
1970, PTL had major competition from other companies like Eicher, Tractors and Farm
Equipment (TAFE), Mahindra & Mahindra (M&M), Escorts and HMT. PTL is one of the
leaders in its business and has put up a heady performance in contrast to other private
sector players. As against other players, which report a ROCE of 15% on an average,
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PTL has consistently remained at about 50% in the last few years though the industry is
capital-intensive. Punjab Tractor is the only major tractor company, which entered this
business without any foreign collaboration. The company has beefed up its R&D
capabilities in the last two to three years. PTLs Swaraj-735 is in a class of its own and
has been benchmarked by its competitors to which 16 new features have been added. PTL
has single mindedly focused on increasing its market share in tractors. Current
Scenario During the first half of 2001-02 PTL increased its market share from 18.5% to
21.4%. With the total industry volumes plummeting by 16.6% the sales of PTL fell only a
trifle 3.1%. Under these circumstances, though the revenue has fallen by a 0.38% the
operating profitability has risen by 1.03%. PTL garnered the operating margins of 19.4%
in the first half of FY2001-02, while the lead players like M&M Escorts and Eicher have
reported operating margins of 4.4%, 0.7% and 2.9% respectively. The Net Profit has
increased by 1.4% to Rs.564 million and the contribution of 40-50HP tractors has
increased by 30%, which indicates higher margins from bigger tractors due to a strong
foothold in Punjab and Haryana markets.
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SWARAJS YEARLY PROGRESS

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.
1983: 4th Tractor Model - SWARAJ 855 (55 HP) developed by own R&D,
commercially introduced. Expansion of annual capacity to 12,000 tractors per annum at
Plant 1.
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1984: SWARAJ MAZDA Ltd. promoted in technical and financial collaboration with
Mazda Motor Corps. & Sumitomo Corpn. Japan for manufacture of Light Commercial
Vehicles. PTL's equity participation is Rs. 30.4 million (29%) and that of Mazda and
Sumitomo's Rs. 27.0 million (26%).
1985: SWARAJ Industrial Forklift Trucks developed by own R&D, commercially

introduced.
1986: SWARAJ ENGINES Ltd. promoted in technical and financial collaboration with
Kirloskar Oil Engines Ltd.(KOEL) for manufacture of diesel engines. PTL's equity
participation is Rs. 6.9 million (33%) and that of KOEL's Rs 3.6 million (17%).
1995: Setup of tractor Plant II at Village Chappercheri with annual capacity of 12,000
per annum.
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.
2000: Expansion of annual tractor capacity to 60,000 completed.

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 5,00,000.
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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) & Swarj 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
Punjab Tractors Ltd. (PTL) has commercially launched another model - Swaraj 939
FE at a function in Indore.101 units of this new generation tractor were delivered to
farmers from all over Madhya Pradesh and Chhattisgarh, by Mr. R.Gopalan, Managing
Director, State Bank of Indore in the presence of PTL's Mr. Yash Mahajan (VC & MD)
and Mr. A.M. Sawhney (SVP-Mktg).
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Powered by a future ready, fuel - efficient 41 HP SAE, three-cylinder water-cooled diesel
engine, Swaraj 939 FE has a constant mesh gear box, diaphragm clutch and neutral safety
switch. Upgraded variants of this model can also be supplied as per customer
needs/requirements.
INTERNATIONAL AND NATIONAL COLLABORATION

OF SWARAJ GROUP
Swaraj group has entered into technical and financial collaborations with various
national and international companies.
Swaraj Mazda Limited was set with technical and financial collaborations with
Mazda Motors Corporation of Japan.
Swaraj Combine Division was entered into with Komatsu Forklift Company of
Japan for manufacturing fork lifters.
Swaraj Engines Limited was set up in technical and financial collaboration with
Kirloskar Oil Engines Limited, Pune for manufacturing diesel engines.
EXPORT PERFORMANCE OF SWARAJ GROUP

Having established Swaraj in the national market, the group made a determined start in
the 1980s it to get a foothold in the international market. Over the years a large number
of Swaraj Tractors and other implements have been exported to many African countries
such as Zambia, Kenya, Tanzania and Nigeria and also in the middle east and south east
Asia. Recently it has exported same engines to U.S.A.
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RESEARCH AND DEVELOPMENT IN SWARAJ GROUP

Research and development is an integral and sustaining department of any organization,
which want to sustain its place in the ever-developing industrial environment. The
emphasis on research and development in the Swaraj Group is proved by a long list of
new products that have been introduced and established in the years ever since the
establishment of Swaraj Group. There is a separate research and development unit of the
group located at phase 7 of S.A.S. Nagar (MOHALI). Research work is carried out in this
unit and design work is accomplished presently, the research and development is going
on with various new products.
VARIOUS DIVISIONS OF SWARAJ GROUP:Swaraj consists of SIX divisions:

1. Swaraj Tractors Division.
2. Swaraj combine Ltd.
3. Swaraj automotive Ltd.
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4. Swaraj foundry division
5. Swaraj Engines Ltd.
SWARAJ TRACTORS DIVISION

It is located in Phase-IV, SAS Nagar. The construction work of PTL was started in March
1972 and the first batch rolled out on 14 th November 1973. It started with an annual
capacity of 5000 tractors with a capital of Rs. 37 million. In 1974 it went into commercial
production with Swaraj 724 26.5 BHP tractors as its first model. During its 22 year of
production, it has not only expanded its manufacturing capacity to more than 24000
tractors per annum but adds more products into its manufacturing range. Its product range
includes the following.
TRACTORS:Swaraj 724
26.5 BHP
1974
Swaraj 735
39.0 BHP
1975
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UNMATCHED PULLING POWER
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Specifications:
Engine :
Model :
RV-3 TR ; Kirloskar
HP :
39 S.A.E
Type :
4 Stroke, direct injection, diesel engine.
No. of Cylinders :
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 dia.
No. of Gears :
8 forward, 2 reverse speeds with high and low selector lever.
SPEED CHART
Gear
1st
2nd
3rd
4th4
Rev.R
Low
2.3
3.1
4.6
2.84.7
High
8.9
12.1
18
27.431.6
11.215.5
P.T.O.
21 splines for 1000 rpm

6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)
BRAKES
Heavy Duty self energising, water sealed disc brakes

Parking brake for additional safety
Oil immersed disc brakes (Optional)
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STEERING
Heavy Duty single drop arm steering fo rhigh 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.
3 POINT LINKAGE
Category-I suitable for category-II type implement pins.
LIFTING CAPACITY
1000 kgf at lower link ends.
ELECTRICALS
'12 volt, 88 Ah. Battery

Starter motor & alternator
Head light with parking lamps
INSTRUMENTS
Engine rpm cum hour meter, Fuel gauge, Water Temp. gauge, Oil pressure gauge,
Ammeter, Hi beam indicator, Trailer light indicator.
TYRES
Front 6.00 x 16
Rear 12.4 x 28
WHEEL TRACK
Front 1200 - 1750 mm

Rear 1350 - 1900 mm
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DIMENSIONS
O.A.Length
3420 mm
O.A.Width
1675 mm
O.A.Height
2270 mm
Wheel Base
1960 mm
Min.ground Clearance
390 mm
Weight of Tractor
1925 kg
Swaraj 722
19.5 BHP
1978
Swaraj 855
55.0 BHP
1983
Swaraj 922
22.0 BHP
1995
Swaraj 744
44.0 BHP
1999
23
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Specifications:
Engine Specifications:
Model :
RB-30 TR KIRLOSKAR
HP :
48 S.A.E.
Type :
4 - Stroke, Direct Injection, Diesel Engine
No. of Cylinders :
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
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
Brakes
Heavy Duty Self energizing, water sealed disc brakes with parking brake for additional safety.
Oil immersed disc brakes (optional)
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Swaraj 978
78.0 BHP
2007
Swaraj 939
26
27

Specifications:
Engine Specifications:
Model :
RV - 30 TR ; KIRLOSKAR
HP :
34 S.A.E.
Type :
4 - Stroke, Direct Injection, Diesel Engine
No. of Cylinders :
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 dia
No. of Gears :
8 forward, 2 reverse speeds with high and low selector levels.
Gear Speeds (Km/hr)

1
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.
Brakes
Heavy Duty Self energizing, water sealed disc brakes with parking brake for additional safety.
28

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 Control:
Maintains uniform draft.
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:
Rear
6.00 X 16
12.4 X 28
Wheel Track:
Front
Rear
1200-1750 mm
1350-1900 mm
29
Dimensions:
O.A. Length :
3440 mm
O.A. Width :
1675 mm
O.A. Height :
2270 mm
Wheel Base :
1930 mm
Min. Ground Clearance : 390 mm

Weight of Tractor :
1875 kg
Deluxe Features
Aesthetically designed heavy duty telescopic front Axle Bearn.
Concealed lockable battery near starter.
Telescopic stabiliser 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
34 HP SAE , 3 Cylinder, 2.5 litre engine conforms to Bharat Trem II emission norms.
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.
30
SWARAJ ENGINES LIMITED
Swaraj engines limited are a part of Swaraj enterprise. Swaraj Engines Ltd., situated at
phase 9, Industrial Area, Mohali. This plant was established in technical and financial
31

collaboration with Kirloskar oil engines Ltd. For manufacturing diesel engines for Swaraj
Tractor Division. The Governor of Punjab S.S. Ray paid the foundation stone of the
factory on 29th Dec. 1987. It started production from 28th Dec. 1988.
This plant produces engines in the range of 20hp to 50hp. This plant had produced
18000 engines in the first year of his production. But now it is producing 50 engines
averagely every day. There are 300,000 tractors working successfully in the fields which
are having engines of Swaraj engines limited .This plant is a boon for agricultural
automotive industry.
The various engine models being produced at SEL are:1.
RV2
-----------
two cylinders
24 B.H.P.
2.
RV3
-----------
three cylinders
39.5 B.H.P.
3.
S15
-----------
Single cylinder
4.
RB33
-----------
three cylinders
55 B.H.P.
5.
RB30
-----------
three cylinders
44 B.H.P.
25 B.H.P.
These engines are sent to the Swaraj tractor division where these are fitted on various
model tractors. The S-15 engines are manufactured in the Swaraj combine division and
are fitted on Swaraj 722 model tractors.
VARIOUS DEPARTMENTS IN SWARAJ TRACTOR

DIVISION
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INTRODUCTION
The manufacturing of Tractor is performed in various steps. It is manufactured
after passing through various processes in various shops. Firstly, various operations on
33

various parts are performed in the L.M.S. (Light Machine Section) and H.M.S. (Heavy
Machine Section). In H.M.S. generally there are four major heavy parts that are given
proper machining operations. These include Gear Box Casing, Differential Housing,
Trumpet Housing and Rear Cover. Similarly, in L.M.S. the light parts are given proper
machining. These include various parts such as Gears, Shafts, Cage Assembly casing etc.
In Heat Treatment Shop, the light parts such gears, shafts etc are given the heat
treatment to ensure their strength. Firstly the part after passing through various operations
in L.M.S. is taken to the Heat Treatment Shop. Here the part is kept in the furnace for
suitable time period up to certain high temperature. Then it is taken to the Quenching
tank where it is dipped in the oil tank. After that it is taken to washing tank for washing of
dirt and oil etc. Then it is taken to the Assembly line.
In Assembly line various parts are being assembled into a single unit termed
Tractor. During assembling the various parts are being fitted according to the stage.
This would includes the assembly of important parts such as Rear Cover, Gear Box,
Differential Housing and trumpet Housing. Firstly the Various sub-parts of the Rear
Cover are being fitted. Then the various parts such as gears, shafts, bearing, oil rings,
clutch actuator and circlip etc are fitted into the Gear Box. After that both the Rear Cover
and the Gear Box are taken to the line where Gear Box if fitted ahead of the Differential
Housing whereas the Rear Cover on the Top. Then various things such as Brakes, P.T.O.
Shaft, Cage Assembly, Trumpet Housing etc are fitted to the Differential Housing. Then
this whole assembly is fitted with the engine against the Gear Box.
After whole assembly is fitted with the Engine, this assembly is taken to the
Chassis Paint Area where it is washed and dry followed by Paint on the chassis.
Then the tractor reaches to the Final stage where certain electrical and other
accessories such as Battery with Battery cover, Steering Wheel, radiator etc are fitted.
Proper level of Engine oil is also filled into the Differential and Gear Box. Greasing of
34

various parts is also performed with Grease Gun. After that the Tractor is taken out of the
line after taken it out from the hooks. This stage is termed as Dismounting Stage.
Then the Testing of the Tractor is performed which include the checking for
vibrations, noise, brakes, oil level and other factors that effects the performance of tractor.
LIGHT MACHINE SHOP

Introduction:
L M S is the largest section of the factory. All transmission
components like shafts and gears used in tractors are manufactured here. L.M.S
comprises of 117 machines. Except the bevel gear generator & gear shaver, which have
been imported from W M W & Churchill of Germany respectively, all other machines are
from HMT Ltd. 160 highly experienced operators and inspectors manned this shop.
Types of machines:
S.No.
Bull
1.
2.
3.
4.
5.
Bull
6.
7.
M/C
Description
Job
Operations
ECO-5 CNC
Broaching machine
Gear hobbing
machine
Deburring machine
Shaving machine
Bull Gear
Bull Gear
Bull Gear
Turning
Cutting Internal Spline
Cutting Outer Spline
Bull gear
Bull Gear
For removing rough edges

Shaving or finishing
Pinion Shaft
Center Facing
machine
Line
BP shaft
Facing, Centering
Femco Turning
BP shaft
Gear Line
Rough, Finish turning

(first 4 steps)
35

8.
Femco WNCL-30
BP shaft
9.
10.
11.
COOPER
HMT H400
Shaving machine
BP shaft
BP shaft
BP shaft
Cage
Assembly
12.
VMC-40
13.
Boring machine
Cylindrical
Grinding machine
14.
15.
Other
16.
17.
18.
19.
20.
Rough, Finish turning (next 6

steps)
Spline cutting
Gear cutting
Shaving
Right cage
Drilling, Chamfering,
Grooving, Tapping, Facing
Cage assembly
Boring (both sides)
Cage assembly
Grinding
HMT HMC-320
Cage assembly
Cross drilling
Machines
Lichberr (HMT)
Hobbing
Gear cutting
Cooper
Gear idle cluster
Cutting
Parisuda AHG 80
CNC
HMT Radial drill
Intermediate shaft
Grinding
GCI 300 CNC
Bevel Gear
drilling
Grinding
21.
VMC-500 vertical
milling machine
Milling, Drilling
22.
WIDMA drilling
machine
Drilling
SPILOTE
Copy turning Lathe
23.
24.
PS-180
Gear shaper(not
bevel)
Spline cutting
36
DIFFERENT MANUFACTURING OPERATIONS IN L M S:
Facing: It is the operation of finishing the ends of the work to make the ends
flat and smooth and to make the piece of required length.
Under cutting: It is similar to grooving operation but is performed inside a

hole.
Chamfering: It is operation of beveling the extreme end of the work pieces,

chamfer is provided for better look.
Rough turning: In this operation max Metal is removed and very little over
size dimensions are left for further machining.
Finish turning: Here minimum metal is removed and very fine finish is
obtained on the work surface.
Grooving: It is 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 to remove burs and to protect the work piece from being damaged.
Knurling: It is the process of embossing a diamond shaped regular pattern on

the surface of the work piece using a special knurling tool.
Broaching: It is the method of metal removal by a tool that has successively

higher cutting edges in a fixed path. Each tooth removes a fixed amount of
material.
Drilling: It is the process of making hole in an object by forcing a drill.
Boring: It is the process of enlarging a hole that has already been drilled.
Grinding: It is generally used for sharpening the cutting tool, grinding threads
and better surface finish etc.
Shaping: The process of cutting gears on the shaper is known as Shaping. The
tool used in shaping for teeths cutting is a multi-point cutting tool.
Hobbing:
37

Hob: - Hob is a cutting tool used for cutting gears or similar form gears by the
generating principle.
A Hob resembles a worm in appearance its cutting teeth on the outside of a
cylindrical body following a helical path corresponding to the thread of a worm. It
is useful to think of a hob as a cylinder with a series of racks being parallel to the
hob axis or nearly so and each one slightly displaced axially with respect to the
preceding racks. As the hob rotates in fixed rotation with the blank each row of
teeth successively cuts the next portion of the gear tooth spaces.
Hobs can be broadly classified as
Single start
Double start
Triple start.
Hob material
1.
High speed steel (HSS) - M2
2.
HSS with 8% cobalt (M35)
3.
Power metallurgy (ASP 30)
4.
Carbide.
5.
Tool steel.
Gear shaving: Gear shaving is a metal cutting operation for finishing the gear
cutting process.
Shaving is a low pressure, free cutting, finishing operation applied to a hobbed gear to
achieve the following:1. Correct eccentricity and errors in index, helix angle and tooth profile.
2. Improve tooth surface finishing.
3. Maintain tooth size.
4. Eliminate tooth-bearing conditions by producing a crowned tooth form.
38
HEAVY MACHINE SHOP (H. M. S.)

All heavy casting of tractors is machined in this shop with the help of variety of
special machine (SPM). These machines are tailors made by IIMT to suit component
requirements. In addition, facilities of this shop include general-purpose turning, drilling
and milling machines. About 20 SPM and 30 GPM are installed in a covered area of
47,000 sq. Ft. At a cost of 20 million, 2600 tones of castings are machined every year on
a two-shift basis. In addition to the machining of casting for the tractor, some jobs are
also performed for Swaraj Mazda Limited.
COMPONENTS MACHINED IN THE SHOP
Gearbox housing (Material R-33, Casting, 180-230 BHN, 76-Kg wt.).
Differential housing.
39
Rear cover.
Trumpet housing
Brake housing
40
DIFFERENT MANUFACTURING OPERATIONS IN HMS:
Milling- It is a process of smoothing a surface by a rotating tool called milling

cutter.
Drilling- It is a process of making holes in workpiece by a tool called drill.
Boring- It is a process of enlarging a drilled hole.
Tapping- It is a process of putting thread on internal side of drilled hole. This is

done by a tool called tap. Different taps are available for different pitch angles.
Chamfering- It is a process of making a seat on a drilled hole. Seat is made either

to place head of bolt or for tapping purposes.
Turning- It is a process of making cuts on a rotating workpiece in lathe machine.
Grooving- It is a process of making an internal cut in a hole.
Side Milling
Facing
CONCEPT OF DOWELLING
41
The main aim or purpose of doweling is to act as a guide to the work piece setting
proposes prior to machining. Use of this process helps in reducing the setting time
considerably during machining of heavy components. It is very difficult to set the work
piece in required position prior to machining, this process is very time consuming, hence
when initially the cast piece is brought dowel holes are drilled which act as the pivot
around which the whole machining takes place. Dowel hole act as the reference point for
machining of all the other holes on the work piece all the operation to be performed on
the work piece are taken in reference to the dowel holes thus the hole act as the reference
to all the operations.
PROCESS OF SETTING PRIOR TO DOWEL

Before the dowelling the cast piece is clamped manually, there are three points to be
touched. It follows the phenomena of 3-2-1, which means that we have to restrict the
motion in three directions i.e. x, y, z direction, two to restrict horizontal and vertical
motion and one act as reference point, this process is known as butt and clamp. By
dowelling it is all about locate and clamp hence there is lot of saving of time.
REFERENCING
Dowel act as reference, all the dimension of the work piece i.e. all the machining
operations are from the reference of Dowel hole.
Types of machines
42
Sr.No.
M/C Description
Gear
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Trumpet
12.
13.
14.
Operations
Box Housing
HMC (multipurpose machine), HDC
Milling, Drilling, Dowel

holes
Duplex milling machine (cutter 500

mm, total length made 490 mm, 26
inserts 1 viper (inserts for rough cut,
viper for finish)
Milling
HMC 500
Internal milling, drilling CD

hole (39 mm for outer, 24.2
for inner),
Boring machine
Rough Boring
Boring machine
Finish Boring
Turning Lathe
Turning
Cross hole
Drilling
HMT HDC-S
Drilling (4 holes for

connecting rod 2 inner 2
outside)
HMT HMC 500 S
Drilling, Spot facing
Turning
Finish turning
Radial drilling machine
Drilling, Reaming, Tapping,

Chamfering
Assembly
Two way boring machine
Rough Boring
RAYAUTO (7 tools work at a time)
Rough turning, Facing
Boring machine
Finish Boring
43
15.
16.
17.
Rear
18.
19.
20
21.
22.
HMT SBCNC 35
Finishing (outer face)
SPM
Drilling, Tapping
TICO multipurpose machine
Milling, Drilling, Tapping
Cover Assembly
Free Spindle SPM
Milling(1 Vertical,2
horizontal)
CNC milling machine
Milling
Horizontal HC 630 CNC
Drilling, Boring, Milling
VA 50
Drilling, Milling, Tapping
XLO
Boring (one way)
HEAT TREATMENT SHOP

Heat treatment shop plays a very important role in every industry. In automobile industry
all the gear and shafts need to be heat treated to impart desired strength and increase life
of the component. The H.T. shop at PTL is equipped with several gas carbonizing
furnaces, quenching tanks, induction hardening machines and shot blasting furnaces.
Heat Treatment is an operation or combination of operations involving heating and
cooling of metals and alloys in the solid state to produce certain desired properties. All
the heat treatment processes may be considered to consist of three main parts:
1. The heating of the metal to pre-determined temperature.
2. The soaking of the metal at that temperature until the structure becomes uniform
throughout the mass.
3. The cooling of the metal at some pre-determined rate to cause the formation of
desirable structures within the metal/alloy for the desired purposes.
44
PURPOSES OF THE HEAT TREATMENT

Changes in properties result from the micro-structural changes in the material produced
by heat treatment operation. However, these serve one or more of the following purposes:
1. Improve machinability.
2. Relieve internal stresses.
3. Improve mechanical properties such as ductility, strength, hardness, toughness etc.
4. Change in grain size.
5. Increase resistance to heat and corrosion.
METHODS OF HEAT TREATMENT

Various methods depending upon the nature of job .i.e. it material, use etc are employed
for giving then Heat Treatment. These methods used are:
Annealing
Normalizing
Hardening
Quenching
Tempering
Case Hardening
a)carburizing
45

b)Cyaniding
Induction Heating.
ANNEALING
Annealing means softening of the material by heating and cooling process. The cooling
stage may be performed by regulating the fall of the temperature in the furnace or by
buried the article in sand or lime, and quenching in oil or water, according to the material
being treated.
NORMALISING
In this process the material is heated steadily through out its mass to just beyond the
critical temperature, and then withdrawn from the furnace and allowed to cool in still air.
With the normalizing process there is not soaking period, for the work is held at the
desired temperature for a period only sufficient to give uniformity through out the mass.
HARDENING
The operation of hardening is applied to all the tools and some important machine parts
intended for especially heavy duty service, as well as to all machine parts made of alloy
steel. Hardening of steels is done to increase the strength and wear properties.
QUENCHING
Quenching is the act of rapidly cooling the hot steel to harden the steel. Oil is used when
a slower cooling rate is desired. Oil quenching results in fumes, spills, and sometimes a
fire hazard.
TEMPERING
46

It is an operation to reduce the internal stress and brittleness. With plain carbon steel,
tempering operation consist in slowly heating the hardened material from room
temperature up to maximum of about 600oC and then quenching in water or oil, the
temperature and length of soaking period being dependent in service requirement. Thus if
plain carbon steel is to be hard without any appreciable ductility, a temperature of about
150oC will be required.
CASE HARDENING (CARBURISING)

It is method of producing hard surface on steel. The steel used for this purpose is usually
a low carbon steel of about 0.15% carbon, which does not respond appreciable to heat
treatment. In course of the process, the outer layer is converted into high carbon steel
with a carbon content ranging from 0.9% to 1.2% carbon.
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.
NEED FOR PAINTING

Long life
Rust resistance
Better look (more appealing)
47

The various operations performed in paint shop are:
Surface Preparation (Pre Treatment Cell) - carried out for sheets and rims.
Painting JOST 1(dash board, rear frame, front shield, top bonnet), JOST 2(fenders,
side panel), CHASIS BOOTH (washing, primer, washing zones), FINAL TOUCH UP.
Inspection
Rejection (Reprocessing)-for sheets and rims.
PAINTING
The process (sheet and rim painting) includes

Full Primer + one coat of paint (30-40 microns)
Flash off (This is the distance given so as to allow paint to dry)
Baking (120-130 degree centigrade)
Rubbing
Cleaning with tag rag
Final painting
Flash off
Baking
CHASIS PAINTING
Washing
Drying
Primer painting
48

Flash off
Final painting
Flash off
Baking
After painting inspection is carried out inspection is carried out and the
product is passed or rejected.
Various parameters checked are:
Depth of penetration of paint
Thickness of paint coating
Smoothness
Uniformity
INDUSTRIAL ENGG DEPARTMENT

The department allocated to me was Manufacturing Engineering (M.E). This department
is commonly known as Industrial Engg. department. This department is backbone of the
industrial unit. All shops come under this department. It deals with the activities related to
industrial engg.
About the Industrial Engg department

Introduction
49

The Manufacturing Engg. department (M.E.) plays a vital role in efficient and smooth
working of the manufacturing and developing programs of the company.
The American Institute of Industrial Engg. (AIIE) has defined this special field as:
Concerned with design, improvement and installation of integrated system of people,
materials, equipment and energy.
Industrial Engineering is engineering approach to the detailed analysis of the use and the
cost of the resources of an organization. The main resources are men, money, material,
equipment and machinery. The Industrial Engineer carries out such analysis in order to
achieve the objective and policies of an organization. It is not associated with meeting
cost factors, but with organization structure, administration, technology and human
problems etc.
Earlier it was mainly employed to manufacturing industries for improving methods of
production, to develop production work standards and to formulate production contract
and wage policies. But with the advancement of technologies and industries, I.E also
spread to non-manufacturing like construction, transportation etc.
It is the most important and result oriented department in terms of production, planning,
designing, optimization of methods etc. Some functions involve planning of layouts of all
the shops to get maximum benefits of available space, setting workers time standards to
perform a certain job by motion study and implementing standards laid. Other function of
this department also includes selection of tooling, fixture etc.
In PTL the I.E. department is further divided into three sections: Process planning
Plant and machinery
Work- study
Job responsibilities of I.E.
To set up production norms for all production departments i.e. to set up time
standard for the entire job.
To design / improve work place arrangement to improve productivity and to
create good working conditions and environment for work place.
To design / improve material handling system to make its use and optimize its
cost.
50
To design material storage system for optimizing utilization and minimizing cost.
To calculate efficiencies of shops and thereby incentives.
To set up new machines and to make process plan.
Design formats for management reports like rejection of manpower facilities,
production target v/s production efficiency.
Plant layouts: best optimum utilization of space can be achieved by optimum
layout.
Installation of new machines and conveying systems. Another important function
of I.E. is to get the new machinery installed according to the proposed layout.
Functions of I.E. department
Receiving components and drawings from R&D.

Prepare and release of process sheet.
Assessment of direct labour requirements.
To make decisions for required equipments.
To make decision for purchasing new machines.
Installation of new machines at proper places.
Releasing of jigs, tools and fixture drawings.
Preparation of release of operating conditions of machines.
To study the machining time.
To make operation research.
Miscellaneous and advisory functions.
Applications of I.E.
Earlier it was mainly applied to manufacturing industries for improving methods

of production, to develop work standards or to formulate production control and
wage policies.
Later on, the use of I.E. also spreaded to non-manufacturing activities such as
construction and transportation, farm and air-line operations and maintenance,
public utilities, government and military operations.
But today it finds its major application in manufacturing plants and industries.
In an industry besides the production, other departments utilization I.E. concept
is marketing, finance, purchasing and industrial revolution etc.
51
Process planning
The process planning system deals with LMS, HMS, Assembly, Paint Shop and Heat
Treatment Shop. In this, first I.E get drawings of components to be manufactured in the
plant from R&D. Then I.E lay down the sequence of operation to be performed on the
material. After this workstation is decided, on which the respective operation is to be
performed. Through work-study, I.E standardize the time for setting, tooling and
operation. After getting all the information, I.E prepare the summary of the operation
sheet comprising the operation no., operation work center, time, weight, quantity,
material used etc.
After this I.E prepare a detailed operation as for each operation, comprising operation
details, part no., machining condition, rpm, feed, depth of cut, workstation, quantity,
description of standard tooling and special tooling, jigs, fixtures, which are prepared in
plant, according to the requirements.
Operation sheets also have space for drawing of the corresponding component showing
the position of clamping, resting, flatness, surface finish and there is column for
amendment.
Work Study
Under this section comes incentive scheme and time study. This section is mainly
concerned with incentive scheme, as they have already worked on time study and
prepared the charts referring the time taken by different operations on respective
machines in respective shops and departments. Time study is generally done when a new
machine is being installed, some new aid is being given to the workers on the machine
for easy working or some new method is being used for increasing the productivity.
QUALITY ENGINEERING
QUALITY IMPROVEMENT SYSTEMS
1. COMPONENT DRAWINGS.
2. PROCESS SHEET WITH SUMMERY SHEET. (REF. SCD PROCESS SHEETS).
3. FIRST PC. SETTING OK RECORD
52

4. RUN CHART FILLING BY OPERATOR & AUDIT BY QE ON RUN CHART.
5. CHECKLIST ON FRONT SIDE & PDI ON THE BACKSIDE OF THE SHEET.
6. IN PLANT REJECTION & THERE DEFECT ANALYSIS.
7. PERIODIC INSPECTION AND MAINTENANCE OF TOOLS/GAUGES &
MACHINES.
8. MASTER SAMPLE SHOULD BE AVAILABLE FOR EACH SHEET.
9. MATERIAL SHOULD BE PROPERLY STACKED IN BINS .(NO MATERIAL
SHOULD BE ON SHOP FLOOR)
10. TOOLS & GAUGES SHOULD BE KEPT PROPERLY AT THEIR ENMARKED
PLACE.
11. WORKSTATION SHOULD BE ACCORDING TO LAYOUT PLAN.
12. MATERIAL SHOULD BE TRANSPORTED TO PTL IN BINS & ARRANGEMENT
SHOULD BE AVAILABLE FOR LODING BINS INTO LCVs.
13. THE RESPONSIBILITY OF IMPLEMENTING AND MAINTAINING THE
VERIOUS RECORDS SHOULD BE CLEARLY DEFINED AND THE NAME OF THE
PERSON TO BE INTIMATED TO VDC AND BUY.
14. SUBMISSION OF SELF-APPRAISAL FORM.
ASSEMBLY SHOP
The Assembly at SWARAJ TRACTOR DIVISION deals with the assembly of
tractor models 722, 724, 733, 735, 744, and 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. Assembly shop can be divided in two
main areas: 53

1)
2)
Before paint area

After paint area.
BEFORE PAINT AREA

The area before painting can further be divided into sub assemblies/ loops namely
Differential loop.
Gearbox loop.
Rear cover loop.
Engine assembly loop.
DIFFERENTIAL LOOP
Differential casting mounted on trolley after washing.
Bull pinion Shaft left and right fitted.
Cage assembly fitted. It consists of:
1. Crown wheel.
2. Tail pinion assembly.
3. Roller bearing.
4. Bevel wheels.
5. PTO shaft fitted.
6. Rear axle/trumpet is fitted.
7. PTO shifter assembly fitted.
8. Gearbox assembly is lifted.
9. Rear cover assembly fitted.
10. Brakes are fitted.
11.Parking brake.
54

12.Suction pipe
13.PTO cover
14. Trailer hook is fitted.
15. Angle bracket is fitted.
16. Rocket link is fitted.
17. Footboard is fitted.
18. Clutch pedal is fitted.
GEAR BOX LOOP
Gearbox housing mounted on trolley.
Drive shaft & input shaft assembly.
Output shaft assembly.
Lay shaft and connecting shaft assembly.
Shifter rod assembly.
Steering assembly.
REAR COVER LOOP
Rear cover mounted on trolley.
Control valve and response valve assembly.
Ram assembly. (This consists of cylinder, piston and piston rods.)
Testing of hydraulic lift.
ENGINE ASSEMBLY LOOP
Engine mounted on trolley
Dynamo is fitted.
55
Self-motor is fitted.
Oil pump is fitted.
Front axle beam and bracket is fitted.
Clutch plate is fitted.
After that the chassis is carried to the next level by the lift where the engine & the 3point assembly of the tractor along with the other components are fixed. The parts fitted
here are:
3-point linkage which contains the following parts:
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
56

as gaskets or seals & avoid the oil leakage & water mixing in the engine. the engine,
which is suplied to this level of assemble where the engine is attached contain the
following parts attached on it:
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.
The above parts are already fitted with the engine when it comes to the engine
chassis assembly. The make of the engine is KIRLOSKOR or SWARAJ KIRLOSKOR
depending upon the model as 3-cylinder, 2-cylinder or 1-cylinder. The engine was
imported from this company from Pune. SWARAJ also has its own engine plant where
the engines are assembled. After assembling the chassis & engine arrangement, the
fitments are checked by the workmen appointed there at this level & if there is some part
missing, it is attached here. Then the whole assembly is mounted over the conveyor,
which takes that piece to different chambers of washing, drying, primering, baking,
painting & again baking.
After painting the conveyor takes the assembled piece to the DISMOUNTING
STAGE where different parts & components are fitted on the tractor & the tractor was
completed. After that the testing of the tractor is done. A tractor has to pass through
57

different tests to claim itselfs to be as perfect & 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 send to the R & D Complex for further tests.
Now we shall discuss the DIFFERENTIAL, GEAR BOX, REAR COVER AND
DISMOUNTING STAGE in detail.
58
GEAR BOX
The power, which the engine develops, is transmitted to the wheels of the tractor
by certain essential parts. The application of engine power to the driving wheels through
these parts is called POWER TRANSMISSION. These parts are clutching, gear box,
differential and rear axles.
To start a tractor from rest, the inertia of its whole weight must be overcome.
Diesel engine does not develop its full power at low speed. It has to run at fairly high
speed before it develops maximum power and torque.
Since much power is needed in starting, climbing uneven land and in pulling
varying loads, a provision must be made to permit the engine to run at high speed while
the wheels run at lower speed. This is achieved by a system called GEAR BOX.
With the help of gearbox we can achieve this and pulling power of the tractor can
be increased or decreased by varying the speed of tractor. For these tractors gearbox used
is of the type of SLIDING MESH GEAR type.
59
FUNCTIONS
To convert the power of the engine running at high speed into low speed at high
torque, this is required for starting.
To exchange the forward motion into reverse motion of the vehicle.
To disconnect the engine from the rear wheels by putting the gearbox into the
neutral position.
TYPES OF GEAR BOX
Selective gearbox.
a. Sliding mesh type
b. Constant mesh type.
c. Synchronous type.
Planetary gear transmission.
Automatic gearbox.
GEAR BOX SUB-ASSEMBLY

It consist of following sub-assemblies:1. Input Shaft:
This shaft transfer the power from the engine to the gear box. One end of the shaft
is splined which is connected to the engine and second end is the integral constant
mesh pinion which transfers the power to the constant mesh gear splined on the
lay shaft.
60
2. Lay Shaft:Gears are in the fixed position provided by the spacers. Gears on the lay shaft can
only rotate but can not move axially. It consists of one constant mesh (CM) gear
and three straight teeth gear. CM gear of lay shaft is in mesh with the CM gear of
the input shaft, due to which lay shaft moves with the constant speed. All the gear
on the lay shaft moves with the constant speed. Lay shaft also gives drive to the
PTO shaft.
3. Intermediate shaft:It is the splined shaft consist of three gear which are axially movable on the shaft.
All the gears are provided with the collar, so that forks are fitted in these collars
and help the gears to move axially. These gears are meshed with the gears on the
lay shaft to have the correct gear pair with required gear ratio. Only one pair is in
mesh at one time so to avoid double engaging.
4. Three forks:
One fork is used for:

(a) Engaging reverse gear with the help of idler cluster.
(b) Engaging 1st gear
Second fork used for engaging 2nd gear
Third fork used for engaging 3rd and 4th gear.
5. Epicyclic gear train:It is used to have high speed ratio between input shaft and output or intermediate
shaft. This is done by engaging hi-low gear. This gear train consist of following
sub-assemblies:
Internal gear.
61
Planet gears (3 in number).
Sun gear, which is the splines of the intermediate shaft itself.
Planet carrier.
Hi-low sleave.
Hi-low shaft.
Different views of assembled Gear Box
WORKING IN GEAR BOX

The Constant Mesh (CM) gear is rigidly fixed to the input shaft or clutch shaft. It remains
always connected to the drive gear (also CM gear) of the lay shaft. Three other gears are
also rigidly fixed to the layshaft. They are the second speed gear, first speed gear and
reverse speed gear. Two gears are mounted on the splined main shaft or output shaft (also
known as intermediate shaft) which can be slided by the shifter fork when the shaft
lever is operated. These gears are the second speed gear and first and reverse speed gear.
They can be connected to the corresponding gears of the layshaft and always remains
connected to the reverse gear of the layshaft.
Gears in neutral: When the engine is running and clutch is engaged, the CM gear
drives the layshaft gears. The layshaft rotates opposite in direction of the clutch shaft.
Note that in neutral position, only the CM gear is connected to the CM gear of the
62

layshaft. Other gears are free, and hence the transmission intermediate shaft is not
turning. The vehicle is stationary.
First or low speed gear: By operating the gear shift lever, the larger gear on the
intermediate shaft is moved along the shaft to mesh in the first gear of the layshaft.
The intermediate shaft turns in the same direction as the input shaft. Since the smaller
layshaft gear is engaged with the larger intermediate shaft gear, a gear reduction of
approximately 3:1 if obtained. That is, the input shaft turns three times for each
revolution of the input shaft. Further gear reduction in the differential at the rear
wheels produces a still higher gear ratio, approximately 12:1, between the engine
crankshaft and the wheels.
Second speed gear: By operating the gearshift lever, the larger gear of the
intermediate shaft is demeshed from the first gear of the layshaft and then the smaller
gear of the input shaft is meshed with the second gear of the layshaft. The
intermediate shaft turns in the same direction as the input shaft. A gear reduction of
approximately 2:1 is obtained. The differential gear reduction increases this gear ratio
to approximately 8:1.
Third, top or high speed gear: By operating the gear shaft lever, the second gear of
the intermediate shaft and layshaft are demeshed, and then the second and top gear of
the input shaft is forced axially against the CM gear of the input shaft. External teeth
on the input shaft gear mesh with the internal teeth in the second and top gear. The
intermediate shaft turns with the input shaft and the gear ratio of 1:1 is obtained. The
differential reduction reduces a gear ratio of about 4:1 between the engine crankshaft
and the wheels.
Reverse gear: by operating the gear shaft lever, the larger gear of the intermediate
shaft is meshed with the lever idler gear. The reverse idler gear is always in mesh with
the layshaft reverse gear. Interposing the idler gear between the layshaft reverse gear
63

and intermediate shaft bigger gear, the intermediate shaft turns in the direction
opposite to that of the input shaft. This reverses the rotation of the wheels so that the
vehicle backs.
High/Low Gear: High/low gear shifter enables to achieve either high torque-low
speed or low torque-high speed with the help of planet gear & carrier assembly.
HIGH GEAR: Low torque-high speed is achieved when hi-lo shifter is shifted in
high gear position. Coupling intermediate shaft and output shaft with the help of
sleeve transmits the power.
LOW GEAR: High torque-low speed is achieved when hi-lo shifter is shifted in low
gear position. The power is transmitted to output shaft from intermediate shaft, planet
gear and carrier assembly and sleeve. The planet gear & carrier assembly reduces the
high speed and subsequently torque is increased.
LAY and INTERMEDIATE Shafts with required GEARS
64
DIFFERENTIAL SYSTEM
If the car travels in a straight line, the two rear wheels turn on the road exactly at the
same speed. There is no relative movement between the two rear wheels. The propeller
shaft may be geared rigidly, in the case, with the rear axle to rotate the rear wheel
together. But when the car takes the turn, the outer wheel travels on the longer radius than
the inner wheels. The outer wheel turns faster than the inner wheel, i.e., there is the
relative movement between the two rear wheels. If the two rear wheels are rigidly fixed
to a rear axle, the inner wheel will slip which will cause:
Rapid tyre wear.
Steering difficulties.
Poor road holding.
Therefore, there must be some devices to provide relative movement to the two
rear wheels when the car takes a turn. And here comes the purpose of differential.
65
The differential is a device that splits the engine torque two ways, allowing each output to
spin at a different speed.
The differential is found on all modern cars and trucks, and also in many all-wheel-drive
(full-time four-wheel-drive) vehicles. These all-wheel-drive vehicles need a differential
between each set of drive wheels, and they need one between the front and the back
wheels as well, because the front wheels travel a different distance through a turn than the
rear wheels.
Part-time four-wheel-drive systems don't have a differential between the front and rear
wheels; instead, they are locked together so that the front and rear wheels have to turn at
the same average speed. This is why these vehicles are hard to turn on concrete when the
four-wheel-drive system is engaged.
The differential has three jobs
To aim the engine power at the wheels
To act as the final gear reduction in the vehicle, slowing the rotational
speed of the transmission one final time before it hits the wheels
To transmit the power to the wheels while allowing them to rotate at

different speeds (This is the one that earned the differential its name.)
66
PICTURES OF ASSEMBLED DIFFERENTIAL
67
DIFFERENTIAL ASSEMBLY
It consists of following sub-assemblies:-
1. Cage Assembly:
a. Left Cage: It consists of following parts:
Four planet gears which are bevel pinion.
One cross (or spider) housing the planet gear.
Two bevel gears with internal splines.
b. Right cage: It consist of :
Crown Wheel having spiral teeth
2. Tail Assembly: It consists of following sub-assembly:

a. Tail Pinion Carrier.
b. Tail Pinion.
c. Taper roller bearing.
Tail Pinion is integral with Tail Pinion Shaft. Other end having splines to
take power from the Gear Box.
68
3. Left Bull Pinion Shaft (LBPS):

It consist of two taper bearing. It has a bore on its right side which
provide place for the entry of the RBPS so to support it with eccentricity.
So LBPS is also known as female type of shaft.
4. Right Bull Pinion Shaft (RBPS):

It also consist of two taper bearing. It is the male type of shaft of which
very few part enters into the bore of the LBPS to have eccentricity.
5. PTO Shaft:
Both ends of this shaft are splined. One end is connected to the lay shaft
of the gear box, while the other end (only the splined part) is outside the
differential housing. PTO shaft transfers the torque from the gear box to
other agricultural equipments like Reaper, generator, etc.
6. Two Bull Gear:

These gears transfers torque from the Bull Pinion Shaft(BPS) to the rear
axle through trumpet assembly.
7. Differential Housing:
It is the casting that houses all the above Sub-Assemblies.
69
REAR COVER ASSEMBLY

Rear cover is mounted on the differential assembly. It is used to cover the differential
assembly. It performs various other operations also.
The different components are as follows:
Hydraulic cylinder.
Control valve.
Operating sector components.
Response valve.
Sensor tube.
FUNCTIONS OF DIFFERENT COMPONENTS
HYDRAULIC CYLINDER: This hydraulic cylinder completes lift arm

mechanism.
CONTROL VALVE: It is used to control the position of the lift arm.
OPERATING SECTOR COMPONENTS: Position lever is required for

positioning of the lift arm. Draft lever is used to give the maximum and
minimum position to the lift arm.
RESPONSE VALVE: This is used to give response to the lift arm.
SENSOR TUBE: Its function is to operate the lift arm on uneven surface. It
automatically lifts the arm when any hard surface is hit.
Different views of assembled rear cover
AFTER PAINT AREA:- This
stage is also called the DISMOUNTING
STAGE of the tractor.
DISMOUNTING STAGE
INTRODUCTION
DISMOUNTING means the removing of the complete assembled tractor piece from
the conveyor. The conveyor is a long rail like carrier system, which carries the tractor
chassis & engine assembly through the different chambers of washing, drying,
primering, baking & then to the dismounting stage.
After the attachment of the complete assemblies of differential housing, gearbox &
engine fitting, the assembled piece is mounted on the conveyor which takes the
assembled piece to the different chambers of washing, drying, primering, baking &
then further to the dismounting stage. First of all the chassis & engine part is washed in
the washing chamber. After washing the assemble piece is dried with the blowers in
the drying chamber. After that the assembled piece is coated with the primer in the
primering chamber. A primer makes a thin layer on the assembled piece, which helps
the paint to be attached to the assembled piece. After the primering the assembled
piece is dried out. Then the assembled piece travels to the painting chamber & paint is
sprayed on the assembled piece of the tractor containing the chassis & the engine.
After the paint section, the assembled piece travel to the baking chamber. In this the
paint dried out & fixed on the assembled piece. Then at last the assembled pieces
reaches to the dismounting stage. In this stage the wiring, sheet metal work attachment
& other parts of the tractors like radiator, steering, fuel tank, etc. is fitted. When the
fitting of the parts of the tractor is complete the tractor piece is removed from the
conveyor called the DISMOUNTING of the tractor. Then the further test like road
testing, rig test, engine test, etc. is done.
After the dismounting stage, we get the complete tractor but without testing. So testing
of the tractor is done after dismounting & after passing the tests, the tractor is sent to
the yard from where it is supplied to R & D COMPLEX. Here further testing of the
tractors is done on the engine & other parts like lifting, etc. & improvement or
development is done in the tractor for better performance. After all this procedures of
testing etc., the tractor is ready to be supplied to the market.
DISMOUNTING STAGE:
After the processes of washing, drying, painting, baking, the assembled piece is finally
arrived to the DISMOUNTING STAGE through conveyor. This dismounting stage is
further divided into different small stages & in each stage, 2 persons works at a time,
on an assembled piece of chassis & engine. The work is divided between these 2 men
at the different stages. The dismounting stage is divided into 5 different stages in
which the parts of the tractor are fitted on the assembled piece of chassis & engine &
in every 6 minutes, we got a complete tractor, which is removed from the conveyor of
the dismounting stage.
STAGE 1:
Alternator connection
Horn
Brake rod
Brake switch connection
Fan belt
STAGE 2:
Speedometer wire
Rear frame
Fuel tank
Overflow pipes
Felt pads
STAGE 3:
Fan
Radiator
Hose pipes
Dash board (it mainly has instrumental panel which contains engine oil
meter, fuel gauge, ampere meter, temperature gauge, speedometer)
Dash board cover
Number plate
STAGE 4:
Battery
Steering wheel
Head lights
Clutch connection
Hooks and side panel
Knobs and covers
Sealings
STAGE 5:
Seat
Sheet metal covers (side panel covers, side shield, bonnet, front grill)
Fenders
Tyres fixing
Batter cover
Torque checking
Engine oil pouring and greasing
Charts and stickers
After completing all the above stages the tractor reaches the point where it is
removed from the conveyor, which is known as the DISMOUNTING STAGE
of the tractor. A platform is there & when the tractor reaches the platform the
conveyor is removed & the tractor is free. After that the tractor slides down the
platform & reaches the stage, which is the final stage after the dismounting of
the tractor. This stage comes before the testing of the tractor. In this following
functions & equipments are fitted on the tractor:
Air cleaner
Exhaust
Front tyres distance check and adjust
JOB-ASSIGNED
I was working under the guidance of Mr. Navjot Singh (Officer Heavy
Machine Shop) during the training period. The main areas of interest which my job
includes are as follows:1. To study the FANUC operating system which is widely used uin HMS.
2. To study the LAYOUT plan of all the lines
3. To note down any problem/fault occurred during the shift.
4. MAINLY TO DO ALL THE TPM WORK ON M/C No. 488.01,491.03,491.04
INTRODUCTION
Efficiency Is-the term associated with every business, resulting in profit
making, it is defined as the ratio of output to the input, it is necessary that stress
have to be laid on maximizing the output with keeping input to the lowest
possible level, to increase the profit. II is also important that at the same time
quality and reliability has also to be ensured. Today industry demands faster
production in harder and tougher material to unprecedented tolerances.
Conventional machines either manual or automatic cannot meet these demands.
Automation in production process may be achieved by one of the following
strategies.
a) Industrial Process Control
b) Computer Aided Data Processing
c) Special Purpose Manufacturing Machines
d) Numerical Control
CNC Computer Numerical Control

CNC is a mini computer used to control the machine tool functions
from stored information, it is defined as given below:The numerical control system where a dedicated, stored program
computer is used to perform some or all of the basic numerical control
functions in accordance with control programs stored in memory of the
computer.
TOOLING FOR CNC MACHINE

Design Features: The following points to-be considered before selecting the CNC tooling;1.
Rigidity of tooling against higher cutting forces
2.
To give high accuracy
3.
Variety of operations to be done
4.
To keep the down time minimum by having provision for quick changing
of tools or jobs in minimum possible time
5.
Interchangeably to produce same accuracy on all the jobs.
FUNCTIONS OF CNC
1.
The functions of CNC are:Machine tool control
2.
In-process Compensation
3.
Improved programming and operating Features
4.
Diagnostics
ADVANTAGES OF CNC MACHINES OVER NC MACHINES

1. More Flexibility
2. Reduced Data Reading Error
3. On line Editing of Program
4. Diagnostics
5. Conversion of Units
DISADVANTAGES OF CNC
1.
High Initial Cost
2.
High Maintenance Cost
3.
Skilled CNC Personnel
4.
Not suitable for long run applications
PARTS SUITABLE FOR CNC MACHINES

a) Where the set up and operations are very large or costly.
b) For small to medium batch quantity

c) When the part geometry is so complex that the quantity production of it, involves
possibility of human error.
d)
e)
f)
g)
h)
i)
The operations to be performed are very complex.

For parts subjected to regularly design changes
Where close and repetitive operations are required on the work parts.
Where the tooling cost, forms significant part of unit cost.
Where tool storage is a problem.
When the inspection is required 100% and the inspection cost is a major portion
of total cost.
j) Where very much metal needs to be removed.
k) When the machining time is very less.
Factors affecting the tooling for CNC machines

1.
2.
3.
4.
5.
6.
Type of component to be made

Material to be machined
Production schedule
Complexity of operation
Operator's skill and training
Programming of job
CNC PROGRAMMING
Program: It is a set of instructions to perform the operations on the
component. This program is fed in the computer interfaced with the CNC
machine which performs the required operation as per the instructions.
Operation: It refers to the metal cutting process the machine performs in

accordance with the given program.
STEPS IN DEVELOPING A CNC PROGRAM

1. Preparing of the AC co-ordinate drawing : This is done according to the type
of dimensioning system of the NC machine- absolute or incremental
2. Process Planning: This is to determine or plan the sequence of operations to
be followed for preparing a workpiece.
3. Part programming and its manuscripts: This contains all the machining
instructions like feed rate spindle speed etc..
4. The program is fed to the machine using a suitable media and is checked for
accuracy.
OPERATING MODES:1. Automatic operation (CRT display: AUTOMATIC)
To process a part program in this operating mode, the control colls the blocks
in sequence and elevates them. The evaluation takes all offsets into account that
are referenced by the program. The blocks prepared in this way are processed
in sequence.
The part program can be entered into the control via the universal interface
(e.g. via punched tape or via the keyboard). While one part program is
being processed, another part program can be entered simultaneously.
2. Jog (CRT display: JOG)
With the direction keys and the preset feed rate value "F", you can traverse
the tool at random. After a program interruption, you can see the distance to the
point of interruption displayed in the "REPOS offset"
3. Manual data input/ Automatic (CRT display: MDI

AUTOMATIC)
In this operating mode, you can input part program blocks into the buffer
memory of the control. The control processes the input block, and then
clears the buffer memory ready for new data
PART PROGRAMMING:-
The part program is a sequence of instructions, which describe the work,

which has to be done on a part in the form required by a computer under the
control of a NC computer program.
O - Program number (Used for program identification)
N - Sequence number (Used for line identification)
G - Preparatory function
X - X axis designation
Y - Y axis designation
Z - Z axis designation
R - Radius designation
F - Feed rate designation
S - Spindle speed designation
H - Tool length offset designation
D - Tool radius offset designation
T - Tool Designation
M - Miscellaneous function
As you can see, many of the letter addresses are chosen in a rather logical
manner (T for tool, S for spindle, F for feed rate, etc.)- A few require
memorizing.
There are two letter addresses (G and M) which allow special functions to
be designated. The preparatory function (G) specifies is commonly used to set
modes. We already introduced absolute mode, specified by G90 and incremental
mode, specified by G91. These are but two of the preparatory functions used.
You must reference your control manufacturer's manual to find the list of
preparatory functions for your particular machine.
Like preparatory functions, miscellaneous functions (M words) allow a
variety of special functions. Miscellaneous functions are typically used as
programmable switches (like spindle on/off, coolant on/off, and so on). They are
also used to allow programming of many other programmable functions of the
CNC machine tool.
To a beginner, all of this may seem like CNC programming requires a great
deal of memorization. But rest assured that there are only about 30-40 different
words used with CNC programming. If you can think of learning CNC manual
programming as like learning a foreign language that has only 40 words, it
shouldn't seem too difficult.
G-CODES
CODE
DESCRIPTION
GOO
G01
Rapid positioning
Linear
interpolation
Circular Interpolation(clockwise)
G02
G03
G04
G10
G1l
G12
G13
G17
G18
G19
G33
G36
G37/G38
G40
G41
G42
G43
G44
G53
G54
G55
G56
G57
G59
G60
G62
G63
Circular Interpolation(Counter
Clockwise)
Dwell Time(Time Delay)
Polar co-ordinate programming rapid
Polar co-ordinate programming feed
Circular interpolation clockwise
(Polar)
Circular interpolation counter
clockwise (Polar)
Plane selection x, y
Plane selection x, z
Plane selection y, z
Thread cutting
Cancel transmit co-ordinate
transformation
Transmit co-ordinate transformation
Diameter compensation cancel
Diameter compensation left(cutter left of the
job)
Diameter compensation right(cutter right of
the job)
Tool length offset positive
Tool length offset negative
Canceling Zero Offset
Settable Zero Offset no.l
Zero Offset no.2
Zero Offset no.3
Zero Offset no.4
Programmable zero offset
Exact stop
Contour machining(round of block)
Tapping with a floating tap holder
CORRESPONDING
CHARACTER
G64
G70
G71
G74
G75
G76
G80
G81
G82
G83
G84
G85
G86
G87
G88
G89
G90
G91
G92
G94
G95
G96
G98
Continuous path control

Inch Input System
Metric Input System.
Quadrant circle programming
Full circle programming absolute centre
co-ordinates
Full circle programming incremental
centre co-ordinate
Fixed cycle cancel
Drill cycle
Drill cycle with dwell
Deep drill cycle with wood packing
Taping cycle Reaming cycle (modified as per requirement)
Boring cycle with spindle stop and dwell
Boring cycle with key lock (for top and bottom
chef)
Boring cycle with key lock and dwell
Reaming cycle with dwell
Absolute Programming
Incremental Programming
Cylinder interpolation
Feed Rate in mm/minute
F(F40,50in length)
Feed Rate in mm/revolution
F(F)0.1,0.2perre.
Constant surface speed (c.s.s)
S
Insert absolute preset
LEARN TO OPERATE THE MACHINE

LEARN THE OPERATING SYSTEM (FANUC SERIES)
LOADING, CLAMPING, DE-CLAMPING, UNLOADING

After loading the component proper care must be taken to properly place the
component i.e. the dowel pin must be inserted in the dowel holes & the piece
should be properly clamped.
After all the operations have been completed on the component the component
should be properly de-located (dowel pin removed) & then the unclamped before
unloading.
TO START THE M/C

1.
2.
3.
4.
5.
6.
7.
Switch ON the MAINS

Switch ON the AC UNIT
Switch ON the Stabilizer
Check the POWER INDICATOR on the M/C.
Press the POWER ON button on the CRT PANNEL.
Check Emergency Stop position
Check Block Skip is ON
HOMING OF THE M/C (REFERENCE)

1. Turn the MODE SELECTION knob to HANDLE or JOG & make slight
changes in the position of all the three/four axis.
2. Now turn the mode selection knob to ZRN & press the X, Y, Z axis buttons
for Auto Reference.
3. Turn the selection knob to EDIT& enter the programme no. for the R/C
model for pallet A & B(to read the offsets)
4. Load the piece.
5. Turn the knob to auto & press Cycle Start.
While making the first piece of the shifts do check the TOOLING of both the pallets.
If same model is to be made as in earlier shift:
Switch on the M/c.

turn the mode selection knob to EDIT
Press restart.
Give the command for pallet change i.e. O02
Press the button.
Turn the knob to auto
Press cycle start.
If a different model is to be made:
Switch on the M/c.

Turn the knob to MDI
Press DGNOS PROG button
Press PARAM button.
SETTING 1 page opens press
SETTING 2page opens. Press 1 to enable.

Press DGNOS PROG
Enter the programme no. for pallet A in 450 & for pallet B in 452
Come to setting 2.press 0 to disable
Do the homing of the machine.
To change the tools used in the m/c(worn out or damaged)
Turn the knob to jog

Remove tool from spindle
Turn knob to MDI
Press OFFSET
Enter the offset of the new tool against the tool no.
Turn knob to Jog
Place the tool in spindle
Then do the Homing.
To stop the ongoing operation on the m/c press SINGLE BLOCK,

To resume the operation after SINGLE BLOCK again press single block and then
press CYCLE START.
TRUMPET LINE
178.01
487.02
487.03
178.03
167.01
476.01
477.01
50.04
REAR COVER LINE

494.01
487.01
494.02
285.01
498.01
49A.01
437.27
437.26
GEAR BOX LINE

491.05
120.02
287.05
491.07
486.03
489.01
492.01
120.03
491.01
491.04
437.28
121.01
491.02
437.22
491.06
491.03
DIFFERENTIAL LINE
480.02
480.03
494.04
494.03
287.04
288.01
437.08
437.05
488.01
48A.01
497.01
50.05
437.18
478.01
479.01
475.01
BRAKE HSG LINE

192.01
49E.01
492.10
437.25
What is Total Productive Maintenance (TPM)?

It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is
a maintenance program which involves a newly defined concept for maintaining plants and
equipment. The goal of the TPM program is to markedly increase production while, at the same
time, increasing employee morale and job satisfaction.
TPM brings maintenance into focus as a necessary and vitally important part of the business. It is
no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of
the manufacturing day and, in some cases, as an integral part of the manufacturing process. The
goal is to hold emergency and unscheduled maintenance to a minimum.
Why TPM?
TPM was introduced to achieve the following objectives. The important ones are listed below.
Avoid wastage in a quickly changing economic environment.
Producing goods without reducing product quality.
Reduce cost.
Produce a low batch quantity at the earliest possible time.
Goods send to the customers must be non defective.
Similarities and differences between TQM and TPM:

The TPM program closely resembles the popular Total Quality Management (TQM) program.
Many of the tools such as employee empowerment, benchmarking, documentation, etc. used in
TQM are used to implement and optimize TPM.Following are the similarities between the two.
1. Total commitment to the program by upper level management is required in both
programmers
2. Employees must be empowered to initiate corrective action, and
3. A long range outlook must be accepted as TPM may take a year or more to implement
and is an on-going process. Changes in employee mind-set toward their job
responsibilities must take place as well.
The differences between TQM and TPM is summarized below.
Category
TQM
TPM
Object
Quality ( Output and effects )
Equipment ( Input and cause )
Mains of attaining goal
Systematize the management. It is

software oriented
Employees participation and it is

hardware oriented
Target
Quality for PPM
Elimination of losses and wastes.
Types of maintenance:
1. Breakdown maintenance:
It means that people waits until equipment fails and repair it. Such a thing could be used when
the equipment failure does not significantly affect the operation or production or generate any
significant loss other than repair cost.
2. Preventive maintenance (1951):

It is a daily maintenance (cleaning, inspection, oiling and re-tightening ), design to retain the
healthy condition of equipment and prevent failure through the prevention of deterioration,
periodic inspection or equipment condition diagnosis, to measure deterioration. It is further
divided into periodic maintenance and predictive maintenance. Just like human life is extended
by preventive medicine, the equipment service life can be prolonged by doing preventive
maintenance.
2a. Periodic maintenance (Time based maintenance - TBM):

Time based maintenance consists of periodically inspecting, servicing and cleaning equipment
and replacing parts to prevent sudden failure and process problems.
2b. Predictive maintenance :

This is a method in which the service life of important part is predicted based on inspection or
diagnosis, in order to use the parts to the limit of their service life. Compared to periodic
maintenance, predictive maintenance is condition based maintenance. It manages trend values,
by measuring and analyzing data about deterioration and employs a surveillance system,
designed to monitor conditions through an on-line system.
3. Corrective maintenance ( 1957 ) :

It improves equipment and its components so that preventive maintenance can be carried out
reliably. Equipment with design weakness must be redesigned to improve reliability or
improving maintainability
4. Maintenance prevention ( 1960 ):

It indicates the design of a new equipment. Weakness of current machines are sufficiently studied
( on site information leading to failure prevention, easier maintenance and prevents of defects,
safety and ease of manufacturing ) and are incorporated before commissioning a new equipment.
TPM - History:
TPM is an innovative Japanese concept. The origin of TPM can be traced back to 1951 when
preventive maintenance was introduced in Japan. However the concept of preventive
maintenance was taken from USA. Nippondenso was the first company to introduce plant wide
preventive maintenance in 1960. Preventive maintenance is the concept wherein, operators
produced goods using machines and the maintenance group was dedicated with work of
maintaining those machines, however with the automation of Nippondenso, maintenance became
a problem as more maintenance personnel were required. So the management decided that the
routine maintenance of equipment would be carried out by the operators. (This is Autonomous
maintenance, one of the features of TPM). Maintenance group took up only essential
maintenance works.
Thus Nippondenso which already followed preventive maintenance also added Autonomous
maintenance done by production operators. The maintenance crew went in the equipment
modification for improving reliability. The modifications were made or incorporated in new
equipment. This lead to maintenance prevention. Thus preventive maintenance along with
Maintenance prevention and Maintainability Improvement gave birth to Productive
maintenance. The aim of productive maintenance was to maximize plant and equipment
effectiveness to achieve optimum life cycle cost of production equipment.
By then Nippon Denso had made quality circles, involving the employees participation. Thus all
employees took part in implementing Productive maintenance. Based on these developments
Nippondenso was awarded the distinguished plant prize for developing and implementing TPM,
by the Japanese Institute of Plant Engineers (JIPE). Thus Nippondenso of the Toyota group
became the first company to obtain the TPM certification.
TPM Targets:
P
Obtain Minimum 80% OPE.
Obtain Minimum 90% OEE ( Overall Equipment Effectiveness )
Run the machines even during lunch. ( Lunch is for operators and not for machines ! )
Q
Operate in a manner, so that there are no customer complaints.
C
Reduce the manufacturing cost by 30%.
D
Achieve 100% success in delivering the goods as required by the customer.
S
Maintain a accident free environment.
M
Increase the suggestions by 3 times. Develop Multi-skilled and flexible workers.
Motives of TPM
1.
2.
3.
Uniqueness of TPM
TPM Objectives
Direct benefits of TPM
Indirect benefits of TPM
Adoption of life cycle approach for improving the overall performance of

production equipment.
Improving productivity by highly motivated workers which is achieved by job
enlargement.
The use of voluntary small group activities for identifying the cause of failure,
possible plant and equipment modifications.
The major difference between TPM and other concepts is that the operators are
also made to involve in the maintenance process. The concept of "I ( Production
operators ) Operate, You ( Maintenance department ) fix" is not followed.
1.
2.
Achieve Zero Defects, Zero Breakdown and Zero accidents in all functional areas
of the organization.
Involve people in all levels of organization.
3.
Form different teams to reduce defects and Self Maintenance.
1.
2.
3.
4.
5.
Increase productivity and OPE ( Overall Plant Efficiency ) by 1.5 or 2 times.

Rectify customer complaints.
Reducethe manufacturing cost by 30%.
Satisfy the customers needs by 100 % ( Delivering the right quantity at the right
time, in the required quality. )
Reduce accidents.
6.
Follow pollution control measures.
1.
2.
3.
4.
5.
6.
Higher confidence level among the employees.

Keep the work place clean, neat and attractive.
Favorablechange in the attitude of the operators.
Achieve goals by working as team.
Horizontaldeployment of a new concept in all areas of the organization.
Share knowledge and experience.
7.
The workers get a feeling of owning the machine.
Steps in introduction of TPM in a organization :

Step A - PREPARATORY STAGE :
STEP 1 - Announcement by Management to all about TPM introduction in the

organization :
Proper understanding, commitment and active involvement of the top management in needed for
this step. Senior management should have awareness programmes, after which announcement is
made to all. Publish it in the house magazine and put it in the notice board. Send a letter to all
concerned individuals if required.
STEP 2 - Initial education and propaganda for TPM :

Training is to be done based on the need. Some need intensive training and some just an
awareness. Take people who matters to places where TPM already successfully implemented.
STEP 3 - Setting up TPM and departmental committees :

TPM includes improvement, autonomous maintenance, quality maintenance etc., as part of it.
When committees are set up it should take care of all those needs.
STEP 4 - Establishing the TPM working system and target :

Now each area is benchmarked and fix up a target for achievement.
STEP 5 - A master plan for institutionalizing :

Next step is implementation leading to institutionalizing wherein TPM becomes an
organizational culture. Achieving PM award is the proof of reaching a satisfactory level.
STEP B - INTRODUCTION STAGE

This is a ceremony and we should invite all. Suppliers as they should know that we want quality
supply from them. Related companies and affiliated companies who can be our customers, sisters
concerns etc. Some may learn from us and some can help us and customers will get the
communication from us that we care for quality output.
STAGE C - IMPLEMENTATION
In this stage eight activities are carried which are called eight pillars in the development of TPM
activity.
Of these four activities are for establishing the system for production efficiency, one for initial
control system of new products and equipment, one for improving the efficiency of
administration and are for control of safety, sanitation as working environment.
STAGE D - INSTITUTIONALISING STAGE

By all there activities one would has reached maturity stage. Now is the time for applying for PM
award. Also think of challenging level to which you can take this movement.
Organization Structure for TPM Implementation:
Pillars of TPM
PILLAR 1 - 5S:
TPM starts with 5S. Problems cannot be clearly seen when the work place is unorganized.
Cleaning and organizing the workplace helps the team to uncover problems. Making problems
visible is the first step of improvement.
Japanese Term
English Translation Equivalent 'S' term
Seiri
Organization
Sort
Seiton
Tidiness
Systematize
Seiso
Cleaning
Sweep
Seiketsu
Standardization
Standardize
Shitsuke
Discipline
Self - Discipline
SEIRI - Sort out:

This means sorting and organizing the items as critical, important, frequently used items, useless,
or items that are not need as of now. Unwanted items can be salvaged. Critical items should be
kept for use nearby and items that are not be used in near future, should be stored in some place.
For this step, the worth of the item should be decided based on utility and not cost. As a result of
this step, the search time is reduced.
Priority
Frequency of Use
How to use
Low
Less than once per year, Once per

year<
Throw away, Store away from the

workplace
Average
At least 2/6 months, Once per month,

Once per week
Store together but offline
High
Once Per Day
Locate at the workplace
SEITON - Organize :
The concept here is that "Each item has a place and only one place". The items should be placed
back after usage at the same place. To identify items easily, name plates and colored tags has to
be used. Vertical racks can be used for this purpose, and heavy items occupy the bottom position
in the racks.
SEISO - Shine the workplace:
This involves cleaning the work place free of burrs, grease, oil, waste, scrap etc. No loosely
hanging wires or oil leakage from machines.
SEIKETSU - Standardization:
Employees have to discuss together and decide on standards for keeping the work place /
Machines / pathways neat and clean. These standards are implemented for whole organization
and are tested / inspected randomly.
SHITSUKE - Self discipline:
Considering 5S as a way of life and bring about self-discipline among the employees of the
organization. This includes wearing badges, following work procedures, punctuality, dedication
to the organization etc.
PILLAR 2 - JISHU HOZEN ( Autonomous maintenance ) :

This pillar is geared towards developing operators to be able to take care of small maintenance
tasks, thus freeing up the skilled maintenance people to spend time on more value added activity
and technical repairs. The operators are responsible for upkeep of their equipment to prevent it
from deteriorating.
Policy :
1.
Uninterrupted operation of equipments.
2.
3.
Flexible operators to operate and maintain other equipments.

Eliminating the defects at source through active employee participation.
4.
Stepwise implementation of JH activities.
JISHU HOZEN Targets:

1.
Prevent the occurrence of 1A / 1B because of JH.
2.
3.
4.
Reduce oil consumption by 50%

Reduce process time by 50%
Increase use of JH by 50%
Steps in JISHU HOZEN :

1.
Preparation of employees.
2.
3.
4.
5.
6.
7.
8.
Initial cleanup of machines.

Take counter measures
Fix tentative JH standards
General inspection
Autonomous inspection
Standardization and
Autonomous management.
Each of the above mentioned steps is discussed in detail below.

1.
Train the Employees : Educate the employees about TPM, Its advantages, JH advantages and Steps in JH.
Educate the employees about abnormalities in equipments.
2.
Initial cleanup of machines :

o Supervisor and technician should discuss and set a date for implementing step1
o Arrange all items needed for cleaning
o On the arranged date, employees should clean the equipment completely with the help of
maintenance department.
o Dust, stains, oils and grease has to be removed.
o Following are the things that has to be taken care while cleaning. They are Oil leakage, loose
wires, unfastened nits and bolts and worn out parts.
o After clean up problems are categorized and suitably tagged. White tags is place where problems
can be solved by operators. Pink tag is placed where the aid of maintenance department is
needed.
o Contents of tag is transferred to a register.
o Make note of area which were inaccessible.
o Finally close the open parts of the machine and run the machine.
Counter Measures :
3.
Inaccessible regions had to be reached easily. E.g. If there are many screw to open
a fly wheel door, hinge door can be used. Instead of opening a door for inspecting
the machine, acrylic sheets can be used.
o To prevent work out of machine parts necessary action must be taken.
o Machine parts should be modified to prevent accumulation of dirt and dust.
4. Tentative Standard :
o JH schedule has to be made and followed strictly.
o Schedule should be made regarding cleaning, inspection and lubrication and it
also should include details like when, what and how.
5. General Inspection :
o The employees are trained in disciplines like Pneumatics, electrical, hydraulics,
lubricant and coolant, drives, bolts, nuts and Safety.
o
This is necessary to improve the technical skills of employees and to use

inspection manuals correctly.
o After acquiring this new knowledge the employees should share this with others.
o By acquiring this new technical knowledge, the operators are now well aware of
machine parts.
6. Autonomous Inspection :
o New methods of cleaning and lubricating are used.
o Each employee prepares his own autonomous chart / schedule in consultation
with supervisor.
o Parts which have never given any problem or part which don't need any
inspection are removed from list permanently based on experience.
o Including good quality machine parts. This avoid defects due to poor JH.
o Inspection that is made in preventive maintenance is included in JH.
o The frequency of cleanup and inspection is reduced based on experience.
7. Standardization :
o Up to the previous stem only the machinery / equipment was the concentration.
However in this step the surroundings of machinery are organized. Necessary
items should be organized, such that there is no searching and searching time is
reduced.
o Work environment is modified such that there is no difficulty in getting any item.
o Everybody should follow the work instructions strictly.
o Necessary spares for equipments is planned and procured.
8. Autonomous Management :
o OEE and OPE and other TPM targets must be achieved by continuous improve
through Kaizen.
o PDCA (Plan, Do, Check and Act) cycle must be implemented for Kaizen.
o
PILLAR 3 - KAIZEN :
"Kai" means change, and "Zen" means good ( for the better ). Basically kaizen is for small
improvements, but carried out on a continual basis and involve all people in the organization.
Kaizen is opposite to big spectacular innovations. Kaizen requires no or little investment. The
principle behind is that "a very large number of small improvements are move effective in an
organizational environment than a few improvements of large value. This pillar is aimed at
reducing losses in the workplace that affect our efficiencies. By using a detailed and thorough
procedure we eliminate losses in a systematic method using various Kaizen tools. These
activities are not limited to production areas and can be implemented in administrative areas as
well.
Kaizen Policy :
1. Practice concepts of zero losses in every sphere of activity.
2.
3.
4.
5.
relentless pursuit to achieve cost reduction targets in all resources

Relentless pursuit to improve over all plant equipment effectiveness.
Extensive use of PM analysis as a tool for eliminating losses.
Focus of easy handling of operators.
Kaizen Target :
Achieve and sustain zero loses with respect to minor stops, measurement and adjustments,
defects and unavoidable downtimes. It also aims to achieve 30% manufacturing cost reduction.
Tools used in Kaizen :

1. PM analysis
2.
3.
4.
5.
Why - Why analysis

Summary of losses
Kaizen register
Kaizen summary sheet.
The objective of TPM is maximization of equipment effectiveness. TPM aims at maximization of

machine utilization and not merely machine availability maximization. As one of the pillars of
TPM activities, Kaizen pursues efficient equipment, operator and material and energy utilization,
that is extremes of productivity and aims at achieving substantial effects. Kaizen activities try to
thoroughly eliminate 16 major losses.
16 Major losses in a organization:
Loss
1.
2.
3.
4.
5.
6.
Failure losses - Breakdown loss

Setup / adjustment losses
Cutting blade loss
Start up loss
Minor stoppage / Idling loss.
Speed loss - operating at low
speeds.
7. Defect / rework loss
Category
Losses that impede equipment efficiency
8. Scheduled downtime loss

9. Management loss
10. Operating motion loss
11. Line organization loss
12. Logistic loss
Loses that impede human work efficiency
13. Measurement and adjustment loss

14. Energy loss
Loses that impede effective use of production

resources
15. Die, jig and tool breakage loss

16. Yield loss.
Classification of losses:
Aspect
Sporadic Loss
Chronic Loss
Causes for this failure can be

easily traced. Cause-effect
relationship is simple to trace.
This loss cannot be easily

identified and solved. Even if
various counter measures are
applied
Easy to establish a remedial

measure
This type of losses are caused

because of hidden defects in
machine, equipment and
methods.
A single loss can be costly
A single cause is rare - a

combination of causes trends to
be a rule
Frequency of
occurrence
The frequency of occurrence is

low and occasional.
The frequency of loss is more.
Corrective action
Specialists in process
Usually the line personnel in the
engineering, quality assurance
production can attend to this
and maintenance people are
problem.
required.
Causation
Remedy
Impact / Loss
PILLAR 4 - PLANNED MAINTENANCE :

It is aimed to have trouble free machines and equipments producing defect free products for total
customer satisfaction. This breaks maintenance down into 4 "families" or groups which was
defined earlier.
1. Preventive Maintenance
2. Breakdown Maintenance
3. Corrective Maintenance
4. Maintenance Prevention
With Planned Maintenance we evolve our efforts from a reactive to a proactive method and use
trained maintenance staff to help train the operators to better maintain their equipment.
Policy :
1.
Achieve and sustain availability of machines
2.
Optimum maintenance cost.

Reduces spares inventory.
Improve reliability and maintainability of machines.
3.
4.
Target :
1. Zero equipment failure and break down.
2. Improve reliability and maintainability by 50 %
3. Reduce maintenance cost by 20 %
4. Ensure availability of spares all the time.
Six steps in Planned maintenance :

1. Equipment evaluation and recoding present status.
2. Restore deterioration and improve weakness.
3. Building up information management system.
4. Prepare time based information system, select equipment, parts and members and map
out plan.
5. Prepare predictive maintenance system by introducing equipment diagnostic techniques
and
6. Evaluation of planned maintenance.
PILLAR 5 - QUALITY MAINTENANCE :

It is aimed towards customer delight through highest quality through defect free manufacturing.
Focus is on eliminating non-conformances in a systematic manner, much like Focused
Improvement. We gain understanding of what parts of the equipment affect product quality and
begin to eliminate current quality concerns, then move to potential quality concerns. Transition is
from reactive to proactive (Quality Control to Quality Assurance).
QM activities is to set equipment conditions that preclude quality defects, based on the basic
concept of maintaining perfect equipment to maintain perfect quality of products. The condition
are checked and measure in time series to very that measure values are within standard values to
prevent defects. The transition of measured values is watched to predict possibilities of defects
occurring and to take counter measures before hand.
Policy :
1.
Defect free conditions and control of equipments.
2.
QM activities to support quality assurance.

Focus of prevention of defects at source
Focus on poka-yoke. ( fool proof system )
In-line detection and segregation of defects.
Effective implementation of operator quality assurance.
3.
4.
5.
6.
Target :
1. Achieve and sustain customer complaints at zero
2. Reduce in-process defects by 50 %
3. Reduce cost of quality by 50 %.
Data requirements :
Quality defects are classified as customer end defects and in house defects. For customer-end
data, we have to get data on
1. Customer end line rejection
2. Field complaints.
In-house, data include data related to products and data related to process
Data related to product :

1. Product wise defects
2.
3.
4.
5.
Severity of the defect and its contribution - major/minor

Location of the defect with reference to the layout
Magnitude and frequency of its occurrence at each stage of measurement
Occurrence trend in beginning and the end of each production/process/changes. (Like
pattern change, ladle/furnace lining etc.)
6. Occurrence trend with respect to restoration of breakdown/modifications/periodical
replacement of quality components.
Data related to processes:

1. The operating condition for individual sub-process related to men, method, material and
machine.
2. The standard settings/conditions of the sub-process
3. The actual record of the settings/conditions during the defect occurrence.
PILLAR 6 - TRAINING :
It is aimed to have multi-skilled revitalized employees whose morale is high and who has eager
to come to work and perform all required functions effectively and independently. Education is
given to operators to upgrade their skill. It is not sufficient know only "Know-How" by they
should also learn "Know-why". By experience they gain, "Know-How" to overcome a problem
what to be done. This they do without knowing the root cause of the problem and why they are
doing so. Hence it become necessary to train them on knowing "Know-why". The employees
should be trained to achieve the four phases of skill. The goal is to create a factory full of
experts. The different phase of skills are
Phase 1 : Do not know.
Phase 2 : Know the theory but cannot do.
Phase 3 : Can do but cannot teach
Phase 4 : Can do and also teach.
Policy :
1.
Focus on improvement of knowledge, skills and techniques.
2.
3.
4.
Creating a training environment for self learning based on felt needs.

Training curriculum / tools /assessment etc conductive to employee revitalization
Training to remove employee fatigue and make work enjoyable.
Target :
1.
Achieve and sustain downtime due to want men at zero on critical machines.
2.
3.
Achieve and sustain zero losses due to lack of knowledge / skills / techniques
Aim for 100 % participation in suggestion scheme.
Steps in Educating and training activities :

1.
Setting policies and priorities and checking present status of education and training.
2.
3.
4.
5.
6.
Establish of training system for operation and maintenance skill up gradation.

Training the employees for upgrading the operation and maintenance skills.
Preparation of training calendar.
Kick-off of the system for training.
Evaluation of activities and study of future approach.
PILLAR 7 - OFFICE TPM :

Office TPM should be started after activating four other pillars of TPM (JH, KK, QM, PM).
Office TPM must be followed to improve productivity, efficiency in the administrative functions
and identify and eliminate losses. This includes analyzing processes and procedures towards
increased office automation. Office TPM addresses twelve major losses. They are
1. Processing loss
2. Cost loss including in areas such as procurement, accounts, marketing, sales leading to
high inventories
3. Communication loss
4. Idle loss
5. Set-up loss
6. Accuracy loss
7. Office equipment breakdown
8. Communication channel breakdown, telephone and fax lines
9. Time spent on retrieval of information
10. Non availability of correct on line stock status
11. Customer complaints due to logistics
12. Expenses on emergency dispatches/purchases
How to start office TPM ?

A senior person from one of the support functions e.g. Head of Finance, MIS, Purchase etc
should be heading the sub-committee. Members representing all support functions and people
from Production & Quality should be included in sub committee. TPM co-ordinate plans and
guides the sub committee.
1.
Providing awareness about office TPM to all support departments
2.
Helping them to identify P, Q, C, D, S, M in each function in relation to plant

performance
Identify the scope for improvement in each function
Collect relevant data
Help them to solve problems in their circles
Make up an activity board where progress is monitored on both sides - results and actions
along with Kaizens.
Fan out to cover all employees and circles in all functions.
3.
4.
5.
6.
7.
Kobetsu Kaizen topics for Office TPM :
Inventory reduction
Lead time reduction of critical processes

Motion & space losses
Retrieval time reduction.
Equalizing the work load
Improving the office efficiency by eliminating the time loss on retrieval of information,
by achieving zero breakdown of office equipment like telephone and fax lines.
Office TPM and its Benefits :

1. Involvement of all people in support functions for focusing on better plant performance
2. Better utilized work area
3. Reduce repetitive work
4. Reduced inventory levels in all parts of the supply chain

5. Reduced administrative costs
6. Reduced inventory carrying cost
7. Reduction in number of files
8. Reduction of overhead costs (to include cost of non-production/non capital equipment)
9. Productivity of people in support functions
10. Reduction in breakdown of office equipment
11. Reduction of customer complaints due to logistics
12. Reduction in expenses due to emergency dispatches/purchases
13. Reduced manpower
14. Clean and pleasant work environment.
P Q C D S M in Office TPM :
P - Production output lost due to want of material, Manpower productivity, Production output
lost due to want of tools.
Q - Mistakes in preparation of cheques, bills, invoices, payroll, Customer returns/warranty
attributable to BOPs, Rejection/rework in BOP's/job work, Office area rework.
C - Buying cost/unit produced, Cost of logistics - inbound/outbound, Cost of carrying inventory,
Cost of communication, Demurrage costs.
D - Logistics losses (Delay in loading/unloading)
Delay in delivery due to any of the support functions
Delay in payments to suppliers

Delay in information
S - Safety in material handling/stores/logistics, Safety of soft and hard data.

M - Number of kaizens in office areas.
How office TPM supports plant TPM :
Office TPM supports the plant, initially in doing Jishu Hozen of the machines (after getting
training of Jishu Hozen), as in Jishu Hozen at the
1. Initial stages machines are more and manpower is less, so the help of commercial
departments can be taken, for this
2. Office TPM can eliminate the lodes on line for no material and logistics.
Extension of office TPM to suppliers and distributors :

This is essential, but only after we have done as much as possible internally. With suppliers it
will lead to on-time delivery, improved 'in-coming' quality and cost reduction. With distributors
it will lead to accurate demand generation, improved secondary distribution and reduction in
damages during storage and handling. In any case we will have to teach them based on our
experience and practice and highlight gaps in the system which affect both sides. In case of some
of the larger companies, they have started to support clusters of suppliers.
PILLAR 8 - SAFETY, HEALTH AND ENVIRONMENT :
Target :
1. Zero accident,
2. Zero health damage
3. Zero fires.
In this area focus is on to create a safe workplace and a surrounding area that is not damaged by
our process or procedures. This pillar will play an active role in each of the other pillars on a
regular basis.
A committee is constituted for this pillar which comprises representative of officers as well as
workers. The committee is headed by Senior vice President ( Technical ). Utmost importance to
Safety is given in the plant. Manager (Safety) is looking after functions related to safety. To
create awareness among employees various competitions like safety slogans, Quiz, Drama,
Posters, etc. related to safety can be organized at regular intervals.
For the TPM a total of 40 M/c s were selected from the whole plant & out of these 7 were from
HMS.
From these m/cs I did the TPM on m/c no.
491.03
491.04
488.01
Process of TPM
TAGGING: Red & white tags are put on the machines according to the
abnormalities.
Red Tags are those which show the abnormalities to be removed by the other
departments
White Tags are those which have to be removed by the own Deptt (in this case
HMS).These are basically dirtiness tags.
After the tags have been put the main stress is given to the removal of tags.
During cleaning CLITA are identified
C-Hard to clean
L-Hard to lubricate
I-Hard to inspect
T-Hard to tighten
A-Hard to adjust
After the identification of CLITA counter measures are done to remove them.
For these Kaizens and OPLs are done.
KAIZENS DONE ON THE MACHINE:
OPLs MADE.
CONCLUSION
The real spirit of achieving a goal is through the way of excellence and strict discipline. We
would have never succeeded in completing our task without the co-operation, encouragement
and help provided to us by various personalities.
As per the schedule of PTU we have completed the six months industrial training at
SWARAJ TRACTOR DIVISION(MOHALI) from 1st JULY to 31st DECEMBER. As
requirements of mechanical engineers students to tie over the practical work the industrial
training is beneficial for them. I have done training work with a full of interest given by industry.
I have done work at industry as per my capabilities and guidance of engineers of SWARAJ
GROUP to tie over the projects given by the industry.
The technical guidance and constant encouragement made it possible to tie over the
numerous problems, which so ever came up during the study without which, this training period
would not have been fruitful.

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Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

SWARAJ TRACTOR DIVISION(MOHALI)

DEPARTMENT OF MECHANICAL ENGINEERING.

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

THIS IS TO CERTIFY THAT THE SIX MONTHS

IS COMPLETED AS BY THE REQUIREMNT

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

Order of the pages:

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

Mr. Ashok Jain

Under whose guidance and rich pool of experience I have completed my

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

Swaraj tractors conceived in 1965 by a tem of dedicated

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

ORIGIN OF THE WORD SWARAJ

POSITION OF SWARAJ PRODUCTS IN MARKET

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

Eicher Good Earth

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

INDIAN TRACTOR INDUSTRY MARKET

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

%age of Domestic Sales

North (Punjab, Haryana & Uttar Pradesh)

West (Gujarat & Maharashtra)

%age of Total Sale

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

PUNJAB TRACTOR LIMITED started with an annual capacity of five thousand

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

SWARAJS YEARLY PROGRESS

1974: Swaraj 724 (26.5 HP) tractor commercially introduced.

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

1985: SWARAJ Industrial Forklift Trucks developed by own R&D, commercially

1998: Commencement of expansion to 60,000 tractors (30,000 at each plant). Capital

2000: Expansion of annual tractor capacity to 60,000 completed.

2002: Cumulative tractor sales crosses 5,00,000.

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

INTERNATIONAL AND NATIONAL COLLABORATION

EXPORT PERFORMANCE OF SWARAJ GROUP

Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

RESEARCH AND DEVELOPMENT IN SWARAJ GROUP

VARIOUS DIVISIONS OF SWARAJ GROUP:Swaraj consists of SIX divisions: