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KURUKSHETRA
(Institute of National Importance)
Sumit Saini
Company Profile
PTL`S birth
Introduction:
Punjab Tractors Limited, a public limited company, is India's first
large—scale project based company with e totally indigenous
design, know—how and technology. Punjab State Industrial
Development Corporation {PSIDC},which was a major player,
prompted it; the government of India and financial institutes like
Punjab Financial Corporation {PFC} provided significant support. The
public subscribed the remainder.
The factory is located at s.a.s.nagar which is important township of
Punjab. A board of directors manages the company with the
secretary,industrial department,Punjab being the ex-offical
chairman. The vice-chairman and managing director manages the
day to day affairs.
Growth of PTL:
Punjab Tractors limited started with an annual tractors of 5000 units
and with an inventory of rs.3.7 crores. It went into commercial
production in the year 1974; its first production of 26.6 BHP tractors
was given the name SWARAJ-720, ever since the PTL has not look
back. In first 20 years of its existence its capacity has increased to
24000 tractors annually, which is a considerable achievement.
In all, SWARAJ provides a variety of products, which includes:
Tractors
Harvesting Combine
Fork Lifters
Agriculture Implements
Automotive Castings
Light Commercial Vehicles
Shelter
Engines
Castings
Rough
Terrain
Origin of SWARAJ
The word `SWARAJ` means Bondage from Freedom.
Since PTL was the first largest tractor project in India, moreover fully
based upon Indian technology. So `SWARAJ` was appropriately
choosen as its brand name.
SWARAJ GROUP sells its products under this brand name.
SWARAJ in Market
With more than 2 lacs tractors and harvesters combines operating in
Indian farms , SWARAJ is now a well established brand name in
Indian market and also a well recognized international name in
developing countries.
The products of SWARAJ are not only restricted to Indian
market , but they had entered into the international market.
SWARAJ tractors find an important place in developing countries like
Ghana , Tanzania , Zambia , Kenya , Sudan , Uganda , Indonesia ,
Mayamar etc.
They also send harvesting combines to South Korea having first A.C.
cabin hsrvesting combines in India.
They also send various machined parts to Japan worth millions of
dollars.
INDIAN TRACTOR MARTKET SALES SCENARIO
Gear manufacturing
Machining of Bull Gears
Bevel Gears cutting of all rounds on power hacksaws
Facing and Centering
All type of grinding i.e. inner and outer gears both
Hobbing and Broaching
Gears shaving
TYPES OF MACHINES:
MANUFACTURING OPERATIONS:
Facing
Undercutting
Chamfering
Finish turning
Grooving
Knurling
Broaching
Drilling
Boring
Grinding
Hobbing
Shaping
All heavy castings of tractors are machined in this shop with help of
variety of special machines(SPM).
Facilities of this shop includes general purpose turning, boring,
drilling and milling machines.
About 20 SPM and 30 GPM are installed in a covered area of about
47,000 sq.ft.
WHY?
Improve mach inability
Relieve internal stresses
Improve mechanical properties such as ductility, strength,
hardness, toughness etc.
Change in grain size
Increase resistance to Heat and Corrosion
Carbonizing
Quenching
Tempering
Hardness testing
Shot blasting
Penning
ASSEMBLY LINE
In this shop, the different machined parts, housing and other
components which are finished or machined in other departments of
industry and other components which are purchased from the
vendors are assembled here. The different parts are assembled in
different shops and joined to each other. The heavy parts are lifted
by overhead chain rotating conveyor. It is supported from ceiling and
has a fixed path to travel which saves valuable floor space
Following are the main phases of assembly line:
Hub
Stub-axle
Pivot pin
Hydraulic cylinder
Steering arms
Hub is the part of assembly that holds the wheel. It is fitted in stub
axle by hydraulic machine. This is then fitted to front beam axle.
There is a hole for putting pivot pin in front axle. It is a hole to put
hydraulic cylinder also. Hydraulic cylinders are absent in manual
steering. Left and right steering arms are put on lower side on both
sides. The steering arms are joined by a rod, called tie rod so that
both the wheels can turn in same side. In power steering, oil is given
by pump at engine to hydraulic cylinder by pipes. The flow is
channelized and controlled by steering wheel.
Front wheel axle
Tie rod
FINAL ASSEMBLY (DISMOUNTING STAGE):
Before sending to pre-delivery inspection, the tractor goes through
final assembly. Here some important parts like fender, installing fuel
tank, electrical assembly, radiator assembly, and other parts.
Radiator
Fuel tank
QUALITY DEPARTMENT
There are 5 quality assurances at Swaraj division in the quality
department which manage the overall product and service quality.
SQA:
It works with the quality of the material coming from the venders.
Here the vender’s service and his quality is assured and inspected.
RQA:
PQA:
CQA:
In CQA tasks like checking and solving customer complaints are done.
There are 4 QP’s at the swaraj division plant 1 at the different stages
of the product manufacturing.
QP1: this comes before the all assembled chassis is sent to the paint
shop. A person inspects the chassis overall to see if any of the bolts
are loose or any of the holes are kept open before the paint job and
all this. After the chassis is marked pass at the QP1 it is headed to the
paint shop for paint job.
(QUALITY POST-1)
QP3: at this quality post the road and roller test of the tractor is
done.
Also, the testing of hydraulic lift takes place here. They check all the
functions of the lift mechanism correctly and then the product is
headed to the final inspection.
QP4: this is the final inspection of the product.
AUDITS-
TORQUE AUDIT-
Poka-yoke AUDIT-
In this how a fitment should be done and how the parts should
be handled and carried comes. For every part there are some
standards that how it should be carried to the assembly line
and how it should be fitted. The worker has to follow this
standard made for every product.
MILIPORE AUDIT-
PROBLEM STATEMENT-
PAINT FLOW-
LESS PAINT-
This defect occurs when any area of the surface is not painted
properly.
Its cause can be that the defected area maybe hard to reach or
a blind spot that do not come under the eye of the painter. Also
there are some tackle points on the tractor chassis on which
less paint defect can be seen because at the tackle point the
paint cannot be applied properly.
ORANGE PEEL-
The term orange peel refers to a bumpy coating surface that
resembles the surface of an orange. Orange peel normally is due to
poor flow-out and leveling of spray droplets, but occasionally is
caused by surface tension driven flow (sometimes called sinks and
bumps) in the oven. Orange peel rarely affects gloss, but the bumpy
surface really reduces the quality and finish of the paint job.
(ORANGE PEEL)
In this defect the paint on the surface starts chipping off. It can be
very small but it can not be ignored because it can damage the whole
paint job. This defect occurs mainly because of poor paint job done
at the surface or maybe any kind of rusting or dusting on the surface.
PAINT DUST-
this defect occurs because the surface was not properly cleaned
before the painting process, the dust particle on the surface are
responsible for this defects as they create small edgy bumps on the
surface on a quite large scale so this defect damages the paint job.
(PAINT DUST)
PIN HOLES-
In this defect small holes takes place on the surface they are very
small in size but can be large in number. These can be caused by
moisture in the spray guns or unclean surfaces.
So here from the list of defects occurred in the month of June we can
see that the most occurring defects were the fender edge paint
damage, trailer hook paint flow and draw bar paint damage and
paint dust on CRE plate.
4. For the defect of less paint if the workers can give a little bit
more attention at the rear side of chassis while
painting(without taking much time) in paint shop then we
can minimize the less paint and some other defects on parts
like trailer hook, angle brackets and rocker link which are
mostly seen at the QP-4 and the time taken to fix them is
more at the quality post as compared to if we already
correctly spray paint on them in the paint shop.
5. And for the fender edge paint damage, we should ensure the
proper cleaning of fenders before painting also the paint
booth, because most of the time the paint damage at the
edges was due to dusting and in some cases it was paint
flow, so we suggested our ideas to the paint shop and they
accepted them. Also for the better protection of the fender
edges the coverings used for the fenders can be a little large
in size. Because they only cover the upper part of the fender
but if they also covers the edges it would be much better.
PROJECT WORK-
Problem Statement:
In case of tractors,its engine is stopped with help of fuel cut off valve
which is controlled by help of a rod connected to it & extended
towards operator position.
Sometimes, when we pull this rod it gets very sticky & jammed
abruptly , so therefore it took some time to off the engine and in
rare cases we are no longer be able to switch of the engine.
So, our task is how to overcome this problem.
I do received previous 6 month data about this problem, which is as
follow:-
Month & Year No. of tractors having this defect
per 1000 tractors
December 2018 42
January 2019 41
February 2019 39
March 2019 41
April 2019 41
May 2019 39
SUMIT SAINI