Harpreet Singh | Roll Number: 11235 |4th Year |Mechanical Engineering | Group M2

Intra Semester Training Report

2009
Report: Report contains an overview of the Quality Engineering Department at Swaraj Tractors Division, Mahindra and Mahindra, Phase IV, Mohali, Punjab. It gives detailed information of the tests performed at Pre-Dispatch Inspection check post and problems faced by the warranty section, pooled in from all the dealers of Swaraj Tractors from all over India.

Swaraj Tractor Division Mahindra and Mahindra Limited, Mohali, Punjab

Quality Engineering Department Trainee number: T-055 I have been doing training under Mr. Rajendra Singh, Senior Manager (In House quality).

QUALITY ENGINEERING DEPARTMENTMENT Discipline that deals with the analysis of a manufacturing system at all stages, to improve the quality of the production process and of its output. Quality engineering receipt (formally known as Quality Engineering Department) is divided into two fields at Swaraj division of Mahindra and Mahindra Ltd. 1. Suppliers Quality 2. In-House Quality SUPPLIERS QUALITY Suppliers section consists of maintaining the quality of products that are being supplied by suppliers. It contains inspection of the raw materials being supplied by suppliers. It also includes discussion regarding delay of raw material and defective parts supplied. Subsequent actions are taken if the supplied products being supplied are found defective and inspectors from the industry are sent regularly to avoid such defects. This inspection is regularly done by the industry so maintain good quality supply and sound relationship with suppliers.

IN HOUSE QUALITY In house quality is embedded into every department of the industry. As such there are five dept. that are: Q.E.L.M.S (Light Machine Shop) Q.E.H.M.S (Heavy Machine Shop ) Q.E.H.T (Heat Treatment) Q.E.P.M (Plant maintenance) Q.E.A (Assembly)

Quality Engineering Assembly Quality Engineering Assembly consists of five quality posts. Each Quality Posts are situated at every intervals of the assembly line. Each Quality post has a certain responsibility of maintaining the quality of the Product being manufactured in the industry. And the final quality post is known as P.D.I (Pre Dispatch Inspection).

P.D.I. (Pre Dispatch Inspection) P.D.I (Pre Dispatch Inspection) is the final quality post which carries a major responsibility of dispatching the tractors as manufactured by the assembly line of phase IV. This is similar to giving final touches to the jewellery being sold. This department carries rigorous checks as per the pre-designed checklist prior to dispatch of machinery. HOW DOES IT HOLDS GOOD? P.D.I acts as one of the major diagnosing center for every daily to daily outgoing failure and scrutinizing them and hopefully trying to remove these failures. This way forthcoming problems reported by dealers are reduced. This helps to maintain a healthy relationship with dealers and customers. MEASURES UNDER P.D.I 1. 2. 3. 4. 5. 6. 7. 8. 9. TRANSMISSION FLUID LEVEL ENGINE OIL LEVEL F.I.P OIL LEVEL WATER LEVEL IN RADIATOR ELECTRICAL FUCTIONING COMPONENT STORAGE CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER PAINT DEFECTS AND OTHER VISUAL INSPECTIONS WATER MIX IN ENGINE AND TRANSMISSION FLUID

TRANSMISSION FLUID LEVEL To check the transmission fluid level, the dipstick from tractor is removed using D/E spanner (24*27). The oil level is checked by using the gauge. If the oil is over or under the required quantity, oil is added or drained respectively to adjust the oil level and it is brought up to the required level.

ENGINE OIL LEVEL To check the engine oil level, a pull out dipstick is used which is pulled out from the eng ine block by hand. To check the oil level correctly, the oil is wiped off the dip-stick with a clean cloth. The dip-stick is reinserted and then again taken out. The oil level is again checked using the mark built on the dip-stick. If the oil is above or below the required level, it is added or drained respectively. F.I.P OIL LEVEL To check the oil level of the Fuel Injection Pump oil level, we loosen the inspection screw by D/E spanner (14*17) and check the oil in the F.I.P(Fuel Injection Pump). Oil is added in case the oil is not coming out.

WATER LEVEL IN RADIATOR The water level in the radiator has a very essential role. Without the water the radiator cannot work efficiently. Before the tractors are dispatched, the water/coolant level is checked and filled if the level is not upto the full mark. To check it, radiator cap is opened and so is the cap of the water/ reservoir tank. The level of water/coolant in the reservoir tank can be checked by visual inspection. To check the water levels in the radiator, finger is immersed inside it after removing the cap. If the water level is not fine it is filled up to the required level. This test also checks the seals on the radiator cap.

Level of water in the Reservoir tank

The open lid of the radiator

ELECTRICAL FUCTIONING 1) Operation of Brake Switch Brake switch is a small, brake pedal operated spring loaded switch used to light up the rear stop light (red light) on the application of the brakes. It can have very serious affects if the tra ctor is on a heavy traffic road. To check if its working properly or not, the electrical switch of the

battery is put on the on level and then the brakes are applied. If the stop lights, light up , then the switch is working fine otherwise it is replaced. 2) Battery The battery of the tractor is a very costly and an essential part. The customer should not get a de-charged battery. The battery of the Swaraj 735 FE and above models have a battery with a magic eye. The magic eye has a colour indicator for the indication of the condition of the battery. If the battery is OK - then the colour shows Green If the battery needs charging then it shows a white indicator If distilled water needs to be added to the battery It shows a red indicator 3) Fuse box The fuse box of the tractor is also checked before it is rolled out. To check if any fuse has been broken, the tractor is started and all the electrical functions like the head and the rear lamps, the turn-indicators and the horn is checked. If any component does not seem to work, the first check is to check the fuse connections in the fuse box. COMPONENT STORAGE Visually inspect the tractor is done. All the nuts and bolts are checked, the logos and stickers are observed and checked so that they are correctly placed and are appropriate to the product. If the components are missing, deteriorated or wrongly fitted, the needful is done. For example, all the 4 tyres of the tractor are required to be of the same brand. This helps in the proper control of the tractor while in motion. CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER The air intake by the engine is done through the air filter. If the air does not goes through the air filter the engine will choke destroying the piston linings and hence causing a massive damage to the engine. The intake of air through the air filter is even more important in case of tractors as they work in dusty environments full of sand and other materials. The air filter is located above the level of the engine on the left side, as seen by the driver. To check if there is any air leakage in the suction tube, the air filter cap is removed and the tractor is started. Hand is placed on top of the air inlet pipe, properly covering it. If the engine stops on doing this, the tractor passes the test.

When the hand is placed and the entry of the air is blocked, the engine stops

The air enters through this air filter

PAINT DEFECTS AND OTHER VISUAL INSPECTIONS A variety of paint defects occur while the tractor is being assembled. These defects are inspected at the IQS (Internal quality study). The IQS area at Swaraj tractors plant has been set up by Mahindra and Mahindra Limited. It involves a thorough check on tractors finish i.e. Buff marks, etc. It involves a very thorough check in very good illumination from each side. They select five random tractors from the assembly line and inspect them thoroughly. Various paint defects that are found at IQS are: 1. 2. 3. 4. 5. 6. 7. 8. 9. Dust in paint Excessive buff marks Metal scratches Paint scratches Paint run-down Poor touch up/ overspray Dent / ding Paint chip off Pettling marks over the engine

10. Improper sticker application 11. Engine (pettling marks / seapage ) 12. Others, etc
WATER MIX IN ENGINE AND TRANSMISSION FLUID Due to various leakage points, water seepage occurs and water seeps into the engine oil and transmission fluid compartments. The water mix levels of engine oil and transmission fluid is checked by two methods:

1. Visual inspection of the Dip-sticks of both the engine oil and the transmission fluid compartments can easily tell if water is present or not. If water is not mixed , both the engine oil and the transmission fluid are transparent. If water is present in the engine oil compartment, the drop of the oil which comes out with the dip-stick will be hazy. The same is the case of transmission fluid. If water is present it will turn translucent. 2. Water mix paste is used to check if water is present in the engine oil or transmission fluid. The Water mix paste ( green in colour ) is put on the tip of the dip-stick and inserted back into the respective compartments. If water is present, it reacts with the green coloured water mix paste and turns it pink in colour. This gives a proof of the presence of water.
Various others tests are performed before the tractors are finally dispatched, which are performed as the need arises.

Tests Performed and Performance data

A number of tractors are dispatched daily and all have to pass through all the above and many other tests at the PDI check post before they are finally allowed to move out. No tractor is allowed to move out of the premises with the PDI OK sticker. Although we perform all those tests and carry out research on other warranty related issues, we were called upon to record and submit few reports regarding some tests by inspecting a number of tractors in dispatch. Here I like to present few reports: 1st report containing the Chassis Number, Details about water mix in Engine oil, transmission fluid, radiator coolant level and the colour of the magic eye
Sr. No. 1 2 3 4 5 Chassis No. of the tractor 8819 10709 10740 21589 21703 Engine oil purity Not ok ok ok Not ok not ok Transmission Fluid purity not ok Ok not ok Ok Ok Radiator coolant level ok ok ok ok ok Battery Magic Eye Green Green Green Green Green

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

21736 78595 78935 78944 79095 79268 79406 79528 79529 79530 79533 79535 79537 79538 79665 79722 79725 79742 79753 79760 79769 79822 79823 79831 79837 79842 79906 79907 79908 79918 79919 79924 80009 80010 80023 80024 80025 80029 80033 80038 80044 80054 80088 80089 80090

ok ok ok ok ok Not ok ok ok Not ok Not ok Not ok ok ok Not ok ok ok Not ok Not ok Not ok Not ok ok ok ok ok Not ok ok ok Not ok Not ok ok Not ok Not ok ok Not ok ok ok ok Not ok ok ok Not ok ok ok ok not ok

Ok Ok Ok Ok Ok Ok Ok not ok Ok not ok Ok Ok Ok Ok Ok Ok Ok Ok Ok Ok Ok Ok Ok ok ok ok ok ok ok ok ok ok ok not ok ok ok ok ok ok ok ok ok not ok ok ok

ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok not ok not ok not ok ok ok ok ok ok ok ok ok ok ok ok not ok not ok ok ok not ok ok ok ok ok ok

Green Green White Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green White White White Green Green Green Green Green

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95

80097 80101 80104 80105 80111 80127 80129 80130 80131 80133 80135 80137 80138 80142 80143 80145 80146 80150 80151 80154 80164 80166 80169 80177 80179 80182 80191 80192 80193 80202 80205 80235 80259 80263 84842 84846 85976 85978 85980 85981 85982 85983 85985 85990 86003

ok Not ok Not ok ok not ok ok ok ok ok ok Not ok ok ok ok ok ok ok ok ok Not ok ok ok ok ok ok ok ok ok ok not ok ok ok ok ok Not ok Not ok ok ok ok ok ok ok ok ok ok

low level ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok not ok ok ok ok not ok ok ok ok ok ok ok ok ok ok ok ok ok not ok ok ok ok ok ok ok ok ok

ok ok ok not ok ok not ok not ok not ok not ok not ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok not ok ok not ok not ok ok ok ok ok ok not ok ok ok ok not ok not ok not ok not ok not ok not ok not ok not ok

Green Green Green Green White White Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green White Green Green Green Green Green Green Green Green White White White Green Green Green Green Green Green Green Green

96 97 98 99 100 101

86018 86021 86024 86030 86033 96035

ok ok ok ok Not ok ok

ok not ok ok ok ok ok

ok ok not ok not ok ok ok

White White Green Green White White

Checked by Harpreet Singh ok not ok means that the inspected parameter is found ok means that the value of the inspected parameter is either found doubtful or is not ok

2nd report:
Swaraj Tractors Evaluation Sheet Situation of Battery Magic Eye Colour horn GREEN OK GREEN OK WHITE OK GREEN OK GREEN OK GREEN OK GREEN OK GREEN OK WHITE OK GREEN OK WHITE OK GREEN OK GREEN OK GREEN OK GREEN OK WHITE OK GREEN OK GREEN OK GREEN OK GREEN OK GREEN OK GREEN OK GREEN NOT OK GREEN OK GREEN OK GREEN OK GREEN OK

Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Chassis Number QUTA22705010542 QUTA30405078926 QUTA30405078933 QUTA30405078934 QUTA30405078936 QUTA30405079456 QUTA30605078941 QUTA30605078943 QUTA30705079597 QUTA30705079636 QUTA30705079649 QUTA30705079680 QUTB22705010647 QUTB22705010717 QUTB30705079666 QUTB30705079681 QUTB30705079683 QUTB30705079967 QUTB30705079999 QUTB30705080002 QUTB30705080003 QUTB30705080004 QUTB30705080008 QUTB30705085951 QUTB30705085952 QUTB30705085954 QUTB30705179745

Model Number 834 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 834 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE 735 FE

28 29

QUTB30705179747 QUTB31619079903

735 FE 735 FE

GREEN GREEN

OK OK

3rd report The third report was for the leakage of the air-filters
Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Chassis Number 80131 80133 80135 80137 80138 80142 80143 80145 80146 80177 80179 80182 80191 80192 80193 Air filter check ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok

These reports were submitted to Mr. Rajendra Singh, Senior Manager (In House Quality )