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CHAPTER ² I INTRODUCTION

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REPORT ON ORGANISATION STUDY AT TAFE ² GEAR DIVISION
CHAPTER ² I - INTRODUCTION
ABOUT THE COMPANY
Tractors and Farm Equipment Limited (TAFE) is an Indian manufacturer of tractors and other farm equipment with its corporate headquarters in Chennai. The company was established in 1960 and has reported annual revenue of $ 1 billion and a sales volume of over 100,000 tractors annually. Tractors and Farm Equipment Limited (TAFE) is a member of the $1.6 billion Amalgamations Group. TAFE has collaboration with Massey Ferguson (now owned by AGCO Corporation, USA). TAFE is a renowned manufacturer of tractors and a variety of farm equipment under the TAFE Massey Ferguson and Eicher brands. TAFE acquired Eicher tractors in 2005 through a special purpose vehicle, TAFE Motors and Tractors Limited. It is a unit company of the Amalgamations Group, which is a wholly owned subsidiary. It has major presence in a number of Indian states like Rajasthan, Gujarat, Andhra Pradesh, Karnataka, Madhya pradesh and Uttar pradesh. It is one of India's largest Light Engineering Groups with diverse interests in Diesel Engines , Automobile components , Tractors and related farm machinery, lubricants, panel instruments, hydraulic pumps, Engineering Tools, Storage Batteries, Paints , Engineering Plastics , Automobile franchises and Printing apart from interests in Agribusiness , book selling and publishing. The group's leadership technology, built on foreign know how has been nurtured through indigenous efforts.

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TAFE was established in 1961 in collaboration with Massey Ferguson, UK to manufacture and market a range of tractors and related farm equipment in India. One of the largest tractor manufactures of tractors in India, TAFE's vision is to be the first choice of customers in India and to also move towards a growing presence in the international markets. With a network of more than 500 dealers, branches, service outlets as well as its own sales offices and depots covering the entire width and breadth of India, TAFE is committed to providing complete farming solutions to its customers and empowering them to work towards increased farm productivity, prosperity and profits. TAFE started its production of the popular tractor model, Massey Ferguson 1035 in 1961. Now they manufacture tractors under three brand names, TAFE, Eicher and Massey Ferguson. TAFE has a five decade old collaboration with Massey Ferguson (now a part of AGCO Corporation, USA), which is one of the leading manufacturer of tractors in the world. The company is currently investing in a Greenfield project at Manisa Industrial Estate in Turkey with a capacity to manufacture about 15000 tractors. TAFE has been a pioneer in the mechanization of the Indian farms. Beginning with the popularizing of tractors in agriculture in the early 60s, TAFE has many firsts to its credit. TAFE was the first company to market a total package of Tractors and farm equipment to not only provides farm power but also interfaces to transform the farm power to increased farm productivity. TAFE was also the first to introduce the Direct Injection technology in India, thereby intiating considerable fuel saving and the resulting economies in tractor operations cost to its customers. TAFE was also the first Indian manufacturer to launch a 75 HP tractor to cater to the emerging needs of very large farms and agri-businesses. With four manufacturing locations at Chennai(Sembiam), Madurai (Kallidaipatti),
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Bangalore(Doddaballapur), and Mandidheep (Bhopal), TAFE has a large manufacturing base. Its Madurai plant, the latest and possibly the largest such plant in the country is specially tailored to take on short run production batches to the exacting standards demanded by advanced countries. TAFE is also involved in making diesel engines, gears, panel instruments, engineering plastics, hydraulic pumps, plantations and passenger car distribution through other divisions and wholly owned subsidiaries. TAFE Motors and Tractors Limited has, apart from the tractor manufacturing plant at Mandideep mentioned above, a Diesel Engine plant at Alwar, Rajasthan producing a range of air cooled and water cooled diesel engines upto 80 HP with plans are on to increase the product range up to 125 KVA. The Transmissions Division located at Parwanoo in Himachal Pradesh produces a range of transmission components both for captive use as well as for sale to OE manufacture and marketing of farm implements, trailers and accessories, distribution of passenger cars, manufacture of hydraulic pumps and panel instruments to discerning customers both in India and overseas. All its plants and sales offices are linked by VSAT links providing fast and efficient communications and data linkage another first of its kind in India. Apart from its core business of manufacturing and marketing tractors, TAFE is also involved in the following related and unrelated areas. As a natural sequel to producing tractors, TAFE has developed a range of matching trailers, implements and accessories. These are marketed through TAFE's dealer network by a totally owned subsidiary, TAFE Access Limited (TAL). As a natural corollary, TAFE, through TAL is also involved in the marketing and distribution of lubricants and greases for tractors through its dealer network.

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A related facility for the manufacture of panel instruments.. TAFE therefore has in-house facilities for the manufacture of hydraulic pumps and also gears for tractors.TAFE is also involved in the packaged power industry through its Power Source Division. AMCO Batteries Limited. TAFE has also diversified into Engineering plastics and production of tools and dies for this industry. it produces a range of automobile batteries. Its commercial tool room produces tools and dies to international specifications demanded by discerning buyers. not only for captive use but also for sale to the growing automobile industry in India is an integral part of the company. As well as for sale directly through a dedicated distribution channel under the brand name of ´Speedµ. under the AMCO brand name. The tractor's hydraulics is an important part in the transformation of power into farm productivity and the hydraulic pump is a critical component of any tractor. This approach to quality as being inherent to its existence has obtained for TAFE certification under ISO 9002. The transmission of power developed in the tractor's engine to the ground is also a major part of the total design of the tractor. TAFE's vision of being the customer's first choice on offering to the customer·s quality products engineered to perfection using technology that is contemporary and relevant to the market it serves. the 5|Pa g e . near Chennai. IT. Its Doddaballpur plant has clamp capacities ranging upto 1300 tons and is a major supplier of the needs for precision plastic components of the white goods. The batteries are marketed through another unit of the Amalgamations group viz. automobile industries. which find wide OE application in the new generation two and four wheelers manufactured in India as well as in the replacement market. At its fully automated modern plant at Maraimalai Nagar.

TGD has total area of 2. Gears division is a supplier machine shop which manufactures Crown wheel and Pinion used in transmission system. Sunday is holiday. In all that it does.quality movement permeates throughout the organization and is apparent from the various laurels won by quality circles from the company in national and international arenas. COMPANY LOGO: 6|Pa g e . built up over the past four decades. "To us in TAFE. Parts manufactured in this division are supplied to the assembling units in Kallidaipatti (Madurai). TGD functions for 3 shifts in 24 hours.µ TAFE ² Gears Division (TGD) was established in 1996 which is located in Pudupakkam 5 kms from Kelambakkam district. Doddabalbur (Bangalore) and for spare parts. input or inspect into our products. TAFE pursues excellence. That this is not a cliche is reflected in the words of TAFE's chairman. excellence is not something that we engineer. TAFE's vision is not just wishful thinking but based on recognized engineering. It is an innate desire that inspires our hearts at work and at home and ripples out into the world around us.83 hectares and the plant is built in 1500 sqmts. marketing and financial strengths.

They are checked thoroughly for high spots because this ensures premature failure and noise-free operation. In all front engines. rearwheel drive cars with the engine mounted longitudinally.e. which reduce the rotational speed of the gearbox output shaft to that supplied to the wheels ² sometimes abbreviated as CWP. A crown wheel is a wheel with cogs or teeth set at right angles to its plane and the pinion is a small cogwheel that meshes with the crown wheel. from fore aft to transverse. Tooth contact of a crown pinion is insected on a Gleason machine at regular intervals of time for uniform and adequate case depth.PRODUCT PROFILE Crown Wheel & Pinion (CWP)  Product Portfolio : y 6T x 37T CWP y 7T x 39T CWP y 11T x 38T CWP The above mentioned are the 3 versions of Crown Wheel & Pinion (CWP) manufactured in this TAFE Gear Division INTRODUCTION TO CROWN WHEEL AND PINION The final drive components. the crown wheel and the pinion rotates the drive through 90 deg i. The reduction ratio (commonly called the final drive ratio) lies in most common automobile applications between 3:1 and 5:1. 7|Pa g e . The pinion thread is specially made on the thread gringer to ensure proper fitting.

They are one of the most stress prone parts of a vehicle. when any torque is applied to the drive unit. 8|Pa g e . APPLICATION Crown wheel and pinion are used widely in automotive industries. To maintain forward motion both output drive shaft sides covers are removed and the pinion and crown wheel are swapped completely with differential.FEATURES Crown wheel and pinion usually have the following features:  Excellent heat distortion control  High strength  Wear resistance property and  Noiseless and vibration free operation. the tendency is for the crown wheel and pinion to be forced into or out of mesh by the sliding contact. They are used in automobiles to maintain forward motion. In a machine.

TAFE Power Source Division 9|Pa g e . ED .ORGANISATION CHART Tractors and Farm Equipment Limited (TAFE) Senior management Team MANAGING DIRECTOR & CHAIRMAN ED ² TAFE Motors and Tractors Ltd.TAFE Hydraulic Pump Division ED .

TAL Precision Parts ED .ED ² TAFE Gears Division ED . ED .TAFE Reach Ltd. 10 | P a g e .AMCO Batteries Ltd.TAFE Access Ltd Instrument Division ED .TAFE Engineering Plastics Division ED .

General Manager 11 | P a g e .Chart of TAFE .Gear division ² (TGD) ED ² TAFE Gear Division (TGD) Directors President Vice President Sr.

Manager Asst. Manager Supervisors Supervisors Supervisors Supervisors Supervisors Labours Assistants Labours Labours 12 | P a g e . Manager Asst. Manager Asst.General Manager Divisional Manager Production HR Finance Stores Maintenance Manager Manager Manager Manager Manager Asst. Manager Asst.

CHAPTER ² II PRODUCTION DEPARTMENT 13 | P a g e .

14 | P a g e . Kelambakkam. Phone: 0411474647. Pudupakkam. 40 kms from Chennai is equipped with Gleasan machinery and highly advanced in-house heat treatment facility to ensure that the gear systems that roll out from here meet international standards. 74847 TAFE GEAR DIVISION PLANT The Gears Division of TAFE manufactures BEVEL gears for tractors.HEAD OFFICE & MANAGING 861. Vandalur-Kelambakkam Road. The factory which is located at Pudupakkam. Kancheepuram district.Anna Salai Chennai-600 002. 603 103.PRODUCTION DEPARTMENT PLANT LOCATION REGISTERED OFFICE . GEAR DIVISION 51/1.

Hole Drilling Teeth cutting ² Roughing Machine Teeth cutting ² Roughing Machine Finishing Operation ² Convex & Concave cutting Finishing Operation ² Convex & Concave cutting Heat Treatment plant ² CGCF (or) SQF Heat Treatment plant ² CGCF (or) SQF 15 | P a g e .PRODUCTION PROCESS CHART Raw material ² semi finished ² Pinion Raw material ² semi finished ² Crown Wheel Hobbing ² Straight stains 12 .

Diameter & Dimension Inspection Storing 16 | P a g e . Diameter & Pilot Grinding Inner Diameter Grinding by Boring Machine Testing & Pairing Operations Lapping Operations Threading Operation for Pinion Quality.Straightening.

Packing Inspection Dispatch 17 | P a g e .

cutting & grinding. This drilling DRILLING process is made by Counter Boring Machine and moved to Teeth cutting process.PRODUCTION PROCESS Raw materials: Raw Materials for Crown wheel is called as blanks and for Pinion is Steel pillars. These raw materials are semi finished raw material. Machine Shop ² Soft cell: These raw materials are delivered to Pinion cell and Crown Wheel cell. STAGES PINION CELL The raw materials will be processed in Hob Cutter to create straight strains in the Pinion. STAGES HOBBING These cuttings of straight strains are done by Hob Cutter Machine and moved it to soft grinding stage. 18 | P a g e . These semi finished raw material are produced by vendors by forging the iron blocks for Crown Wheel and forging iron pillars. CROWN WHEEL CELL The raw materials will be processed for drilling 12 holes in the Crown Wheel. Note: . These purchased raw materials are stored in Stores and distributed to machine shop.In the following stages the COOLANT OIL & SOLUTIONS are used to reduce the friction heat of the Crown Wheel & Pinion while drilling. These raw materials are purchased by TGD.

To make a regular shape. MACHINE This process is done by Rough Teeth Cutting Machine and passed to the next stage for finishing operation In this raw material is processed for Convex & Concave cutting of teeth to reduce the sharpness of the teeth and for FINISHING finishing touch for the ROUGHING Teeth Cutting. In this process the teeth for the Crown Wheel is formed by SOFT GRINDING shape in raw material. 19 | P a g e . There is chance of irregular diameter STAGES CROWN WHEEL CELL In this raw material is processed for cutting teeth.STAGES PINION CELL In this raw material is grinded to bring it to fixed outer diameter. OPERTION teeth. the raw material is grinded with fixed outer diameter and passed to rough cutting stage. In this the Convex & Concave teeth cutting is made by a single machine Simultaneously and passed it to Heat Treatment Cell. In this raw material is processed for cutting teeth. In this process the teeth for the Pinion is formed by Rough ROUGHING Rough Teeth Cutting. This MACHINE process is done by Roughing Machine and passed to the next stage of finishing operation for Convex & Concave teeth cutting.

STAGES PINION CELL In this raw material is processed for Convex & Concave cutting of teeth to reduce the sharpness of the teeth and for finishing touch STAGES CROWN WHEEL CELL FINSHING OPERATION for the teeth. y Continues Gas Carburizing Furnace (CGCF) y Sealed Quenching Furnace (SQF) The Heat Treatment Cell will use any One or if needed use both the above furnace. to withstand heavy load and avoid worning out. ----- Heat Treatment Cell: The Raw Materials of Crown Wheel and Pinion processed in Machine Shop is brought to Heat Treatment Cell to mold those Raw Materials for long life. increase the strength. In this the Convex & Concave teeth cutting is made by 2 different machines (separate machine Convex & Concave Teeth Cutting) and passed it to Heat Treatment Cell. This Heat Treatment Cell consists of 2 types of furnaces. 20 | P a g e .

it takes more than 23 hours to complete the process. Shots are a kind of small steel balls. It is time consuming and more labour work compared to CGCF. The process of both furnaces will be explained in detail in machinery details of the furnaces. 21 | P a g e . After processing the raw materials in heat treatment it is passed to Shot Blasting. hardening operation. The Heat Treatment Cell mostly uses this furnace for operation because of easy and less time consuming. This process is for 10 to 15 minutes per batch. 1 batch contains 45 nos of Crown Wheel or 90 nos of Pinion. This is a continuous operation and takes 22 hours to complete its process. Its operation are degreasing. etc.. etc. tempering. carburizing operations. Shot Blasting: After tempering. y Sealed Quenching Furnace (SQF) This is a collection of small furnaces and it·s not a continuous process. press quench operations. hardening operations. heating. washing.. the Pinion and Crown wheel are subjected to Shot Blasting to give glossy appearance and to check and impart strength of the Crown Wheel and Pinion. After this process again the processed raw materials are passed to Machine Shop ² Hard Cell for further Finishing process. having hardness of 30 to 35 HRC. carburizing operation. cooling.y Continues Gas Carburizing Furnace (CGCF) This is big furnace for continuous operations includes degreasing.

major diameter and pilot grinding and passed to testing and pairing process. So to fix the diameter this bore grinding is used and it is passed to testing and pairing process. Those 3 grinding machines are used to GRINDING process the pinion for grinding minor diameter.Machine Shop ² Hard cell: STAGES PINION In this raw material is grinded by 3 grinding machines to bring it to required diameter. In this the processed Crown Wheel is tested to ensure its dense. Due to Heat treatment there is a chance of change in the diameter. required dimensions and TESTING & PAIRING finally Crown Wheel will be Paired with Pinion run together for testing to match each other and passed it to lapping process. required dimensions TESTING PAIRING & and finally Pinion will be Paired with Crown Wheel run together for testing to match each other and passed it to lapping process. 22 | P a g e STAGES CROWN WHEEL In this raw material is processed for bore grinding to bring required & fixed inner diameter of the Crown BORE GRINDING Wheel. In this the processed Pinion is tested to ensure its dense. .

to improve surface finish using Coolant Oil and Lapping powder by rubbing action and final washing in this process. The Pinion is processed in threading machine for threading operation for required dimensions on the middle of the Pinion.STAGES PINION The Pinion is processed in Lapping Machine for the purpose of polishing. to improve surface finish using CROWN WHEEL The Crown Wheel is processed in Lapping Machine for the purpose of polishing. --- 23 | P a g e . clearing carbon & grinding particles. This THREADING threading operation will be a fixed for required diameter. clearing carbon & grinding particles. This is the last process for Pinion and it will be moved to Quality Inspection of Finished goods. LAPPING Coolant Oil and Lapping powder by rubbing action and final washing in this process and passed to threading process. This is the last process for Crown Wheel and it will be moved to Quality Inspection of Finished goods.

Then the approved and qualified Crown Wheel and Pinion will be moved to Stores for other process. y SOFT CELL  PINION CELL: 1) HOBBING MACHINE: MACHINE MAKE OPERATION PERFORMED MACHINE PROCESS TIME HANDLING TIME TOTAL TIME : : : : : COOPER 010 SPLINE CUTTING 332 sec 10 sec 342 sec 24 | P a g e .Final Quality Inspection ² Finished Goods: The finished goods Crown Wheel and Pinion will be passed on to Final Quality Inspection. MACHINERY DETAILS The general layout of the TAFE Gear division factory consists of two main divisions viz:  MACHINE SHOP  HEAT TREATMENT CELL  MACHINE SHOP: The operation in machine shop includes both soft cell and hard cell. Here final inspection on the quality of the Crown Wheel and Pinion will be inspected by checking all dimensions and diameters of the Crown Wheel and Pinion should be as per the requirements. The critical parameters of the Crown Wheel and Pinion should be 100%.

2) SOFT GRINDING MACHINE: MACHINE MAKE OPERATION PERFORMED : : PARISHUDH MAJOR DIAMETER GRINDING MACHINE PROCESS TIME HANDLING TIME TOTAL TIME : 110 sec : 15 sec : 125 sec 3) ROUGHING MACHINE: MACHINE MAKE OPERATION PERFORMED MACHINE PROCESS TIME HANDLING TIME TOTAL TIME : : : : : GLEASON ROUGH CUTTING 205 sec 10 sec 215 sec FINISHING OPERATIONS: 4) CONCAVE MACHINING MACHINE: MACHINE MAKE OPERATION PERFORMED METHOD USED : : : GLEASON CONCAVE CUTTING COMPARATIVE METHOD MACHINE PROCESS TIME HANDLING TIME TOTAL TIME : : : 207 sec 10 sec 217 sec 5) CONVEX MACHINING MACHINE: MACHINE MAKE : GLEASON 25 | P a g e .

ROUGHING MACHINE: MACHINE MAKE OPERATION PERFORMED MACHINE PROCESS TIME HANDLING TIME TOTAL TIME : : : : : GLEASON 608 ROUGH CUTTING 337 sec 33 sec 370 sec 3. VMC CNC MACHINE: MACHINE MAKE OPERATION PERFORMED MACHINE PROCESS TIME HANDLING TIME TOTAL TIME : AMS : COUNTER BORING : 287 sec : 37 sec : 324 sec 2. FINISHING MACHINE: MACHINE MAKE OPERATION PERFORMED MACHINE PROCESS TIME : : : GLEASON 610 FINE CUTTING 280 sec 26 | P a g e .OPERATION PERFORMED METHOD USED : : CONVEX CUTTING COMPARATIVE METHOD MACHINE PROCESS TIME HANDLING TIME TOTAL TIME : : 223 sec 10 sec : 233 sec  CROWN WHELL CELL: 1.

GRINDING MACHINE .HANDLING TIME TOTAL TIME : : 35 sec 315 sec ** The job from soft cell undergoes heat treatment before it enters hard cell. GRINDING MACHINE . STRAIGHTENING MACHINE: MACHINE MAKE OPERATION PERFORMED TIME TAKEN : BEMCO : STRAIGHTENING : 61 sec 2.I: MACHINE MAKE OPERATION PERFORMED : : PARISHUDH MAJOR DIAMETER GRINDING TIME TAKEN : 298 sec 3.II: MACHINE MAKE OPERATION PERFORMED : : PARISHUDH MINOR DIAMETER GRINDING TIME TAKEN : 225 sec 27 | P a g e . ** y HARD CELL 1.

TESTING AND PAIRING MACHINE: MACHINE MAKE : GLEASON PAIRING OF PINION AND CROWN WHEEL TIME TAKEN : 173 sec OPERATION PERFORMED : 7.III: MACHINE MAKE OPERATION PERFORMED TIME TAKEN : KAIZON : PILOT GRINDING : 211 sec 5. BORING MACHINE : MACHINE MAKE : GCI 300 CNC INTERNAL DIA GRINDING (CROWN) TIME TAKEN : 271 sec OPERATION PERFORMED : 6. LAPPING MACHINE: MACHINE MAKE : GLEASON LAPPING 184 sec OPERATION PERFORMED : TIME TAKEN : 28 | P a g e .4. GRINDING MACHINE .

b) Sulphur based cutting oil is used in machine shop. c) Endothermic gas is used as a carrier gas in the Heat treatment process. y Continues Gas Carburizing Furnace (CGCF) (Or) Sealed Quenching Furnace (SQF) y Shot Blasting y CONTINUES GAS CARBURISING FURNACE : a) Low carbon alloy steel is used in Heat treatment.8. PHASES: 1) Degreasing furnace is operated at 250 Deg C (1 tray) 29 | P a g e . THREAD CUTTING MACHINE: MACHINE MAKE : SIEMENS THREAD CUTTING 346 sec OPERATION PERFORMED : TIME TAKEN :  HEAT TREATMENT CELL: In heat treatment cell the mechanical properties of the job is improved by the application of heat. This is done in two types of furnaces viz.

92 % 4 930 0.OF TRAYS 2 TEMPERATURE Deg C 930 CARBON POTENTIAL 0. 3) Air cooling chamber .  Duration for waiting degreasing is approximately 8 mins. 2) Main furnace has 18 separate trays at various zones.1 tray (no heating) 30 | P a g e .92 % 4 930 0. Degreasing is used to restrict sulphur oil by being combining with CO & CO2.90 %  The main furnace and reheating zone are operated with a carrier gas (Endothermic gas) and LPG for enrichment of C potential. ZONE Pre heat zone Carburizing zone 1 Carburizing zone 2 Diffusion zone 1 Diffusin zone 2 NO.90 % 4 930 0.92 % 4 930 0.  Duration for Degreasing is approximately 40 mins.  Operating pushing cycle time is approximately 48 mins for every tray.

alkali from the work piece will be removed.  Quenching process is carried out with Press Quench machine to minimize Gear teeth distortion and accurate flatness.  Quenching process is carried out with Quenching oil (Savsol 001).  Finally it is sent through Tempering furnace ² to relive the stress.Body Centered Tetrahedron.  Reheating is operated at 820 to 800 Deg C & Cp-0.4 trays.70% 5) Quenching  Quenching makes the steel to reach from (Austenite)FCC to BCT structure (Martensite)  BCT . Duration for cooling is approximately 7 mins to refine the core grains. 4) Reheating .  At Water washing both.  At Alkali washing bath. 31 | P a g e . the components are sent for washing through alkali bath and water bath. 6) Tempering  It can accommodate three separate trays (150 celsius for 90 mins). oil from the work piece will be removed.  After quenching process.

20% 1. The carrier gas (Endothermic gas) will have approximately 23% of CO and 0.7) Endothermic gas generator  LPG and Air are mixed in the ratio of 1:9.92% TIME TAKEN 5 min 450 min 360 min 20 min FUEL USED LPG + CO2 LPG + CO2 LPG LPG  After the process. It is operated to remove Sulphur based cutting oil.3% of CO2.5 and pass through a stainless steel retort at 1070 Deg C. which is used in machine shop. The gas will pass through a Nickel coated Ceramic catalyst in a Stainless steel retort to produce Endothermic gas. 2) Main furnace is a single chamber and the process is divided into 4 segments. the load is pushed from the furnace into the elevator (above quenching tank) and the load is quenched in oil below the elevator.10% 0. SEGMENT Segment 1 Segment 2 Segment 3 Segment 4 TEMPERATURE Deg C 930 930 930 820 CARBON POTENTIAL 1.20% 1.  Duration for Degreasing is approximately 120 mins.5 to 10. y SEALED QUENCHING FURNACE : PHASES: 1) Degreasing furnace is operated at 150 Deg C. 32 | P a g e .

 For Pinion.3) Hardening  Quenching process is carried out with Quenching oil (savsol 001). the components (pinion) are sent for washing through water bath along with the fixture.  At Water washing bath. Shots are a kind of small steel balls. having hardness of 30 to 35 HRC. the load is quenched along with the fixture. y SHOT BLASTING :  After tempering. 33 | P a g e . 5) Tempering  Pinions are sent through tempering furnace along with the fixture ² to relive the stress at (150 Deg C for 120 min). the Pinion and Crown wheel are subjected to Shot Blasting to give glossy appearance and to impart strength. 4) Washing:  After quenching process. oil and other contaminations from the Pinions will be removed along with the fixture.

CHAPTER ² III STORES DEPARTMENT 34 | P a g e .

spares. Flow Chart of Purchasing.. etc. accessories. Is a process of Stores department. Storing & Issuing Requirements Purchase Requisition Quotation 35 | P a g e Purchase Order (P.O) . The following flow chart will explain the process of purchasing.STORES DEPARTMENT PROCESS OF PURCHASING & STORING Purchasing of Raw Materials. equipments.

Approval Material Receiving Checking & Inspection Material Tagging Racking 36 | P a g e .

Storing Coding the Material through SAP Stock (Material) Issue Entering (Posting) Issues in SAP ACTIVITIES 37 | P a g e .

y Materials Rejection: Some Raw Materials may be rejected after Checking & Inspection due to damage or low quality. This GRN will be forwarded to Finance Department for payment process. Stores department will also maintain the entries of delivered finished goods in SAP. It also updates the issue of materials in SAP. This tagging helps to issue the materials easily and can find the shortages easily. The delivered finished goods will be given a code by SAP. y Storing: 38 | P a g e . Those rejected materials will be returned to vendors who supplied and payment will not be paid for the rejected materials. The Stores will be having 3 months Stock of Raw Materials for Reserves. SAP is software interlinked with all departments. y System Analysis and Program Development (SAP): The Stores department will enter the coding of the materials received in SAP.y Raw Materials: Raw Materials for Production purpose will be stored by Store Department in Stores. y Goods Receipt Note (GRN): GRN is prepared by Stores department for the materials received after Checking & Inspection. y Material Tagging: The received material will tagged according to the usage and will be placed according to the respective bin by Racking the material tagged in the racks of the stores. The Stores will place order on Raw Materials once in 3 months as a cycle.

The prepared Delivery Note will be forwarded to the Finance department for accounting. y Delivery Note: Delivery Note will be prepared by the Stores department as per the delivery of Crown Wheel & Pinion (CWP) to the Tractor manufacturing units or to Spare Parts. new machinery. 2 pairs of CWP is packed in a plastic box and if CWP is dispatch for Spare Parts. These packed boxes will be delivered to necessary place by chartered carrier Tractor manufacturing units or Spare Parts. Chart of Packing & delivery of CWP Receiving of CWP (Finished Goods) from Production Packing & Storing 39 | P a g e .. accessories. 1 pair of CWP is packed in a Card board. If CWP is for dispatch for Tractor manufacturing units. The Finished Goods will also be packed stored in Stores.The materials received by the Stores department from Vendors will be stored in Stores and issued for production at the time of need. etc. The Stores department also stores materials like spares. the Stores department will pack the CWP in a pair as matched by production Department. y Packing & Delivering: After Checking & Inspection of Crown Wheel and Pinion (CWP).

Delivering to Tractor manufacturing units or Spare Parts CHAPTER ² IV MAINTANENCE DEPARTMENT 40 | P a g e .

This Preventive maintenance activity helps the manufacturing unit to function without any disturbances or problems. It is also called as Planned maintenance. y Actual Maintenance: 41 | P a g e . By predicting the future problems for production and taking necessary steps to overcome and being ready to act on the problem immediately and solve the problem.MAINTANENCE DEPARTMENT Maintenance department is an essential department in this unit which follows the 4 major activities. For example: . y y y y Preventive Maintenance Actual Maintenance Planned Maintenance Special Projects & Developments ACTIVITIES y Preventive Maintenance: Preventive maintenance can be described as maintenance of equipment or systems before fault occurs. They are.Taking necessary steps to overcome the Electricity problems during summer season.

Special Projects & Developments are the activities like installing new machinery. etc. Planned Maintenance is a regular activity followed by the Maintenance department. upgrading the existing machinery.. For example: . Changing machinery oil periodically. In this the Maintenance department will be always ready any time to solve the unexpected problems while running of machines while production.Actual Maintenance is another major activity of the Maintenance department. The Maintenance department will prepare plan and follow the plan to maintain and develop the production process. Solving of the unexpected problems on the day to day process of production is called Actual Maintenance. y Special Projects & Developments: Special Projects & Developments is the major activity of Maintenance department to support the production process and develop the manufacturing unit. y Planned Maintenance: Planned Maintenance is the major activity of the Maintenance department. For example:Regular service for machineries. making add-ons for the machinery to make the production process easy and fast.Solving the failures of machinery while production. 42 | P a g e .

CHAPTER .V FINANCE DEPARTMENT 43 | P a g e .

For withdrawal of Impressed amount or other 44 | P a g e . immediately Head Office will issue a cheque for the requested amount to Finance department of TGD. the Manager of Finance department will make requisition to Head Office for shortage of Impressed amount.000 for operations of Finance department for production purpose. Finance department of TGD will be reporting to TAFE ² Head Office. 30.FINANCE DEPARTMENT ACTIVITIES y Powers: Finance department of TAFE Gear Division (TGD) is under control of Finance department of TAFE ² Head Office in Anna Salai. Chennai. y Funding Operations: Finance department of TGD is operated with Current A/C in Central Bank of India in Kelambakkam. If the Impressed amount decreases to Rs. 10. Finance department of TGD will maintain this Impressed amount. Finance department of TGD is restricted limited powers. y Impressed amount: TAFE Gear Division (TGD) is allocated with an Impressed amount (Reserves) minimum of Rs.000.

y Salary & Wages: Salary for the Management Staff is paid directly by TAFE ² Head Office by crediting the salary to the individual·s bank A/C. This process is called as Real Time Accounting.Sanctioned amount from Head Office for Production purposes and deposits of cash by Finance department of TGD by the Scrap sales is transacted through this bank. Large transactions for TGD production process are made by TAFE ² Head Office. It follows Petty Cash Accounting because it transacts with only small value of money. Petty Cash Accounting is recorded and filed through System Analysis and Program Development (SAP) by verifying and approving Petty Cash Receipt. y Tax: 45 | P a g e . y Petty Cash Accounting: Finance department of TGD follows the Petty Cash Accounting. y Credit: Finance department of TGD avails credit from the government for Excise duty for purchasing Raw Materials and will be adjusted with the Dispatch of Finished Goods to the TAFE Manufacturing unit and to Spare Parts. The Wages for the Contract Labours are paid by the Finance department of TGD which will be sanctioned and given by TAFE ² Head Office. Real Time Accounting is financial reporting provides financial information on a daily basis.

Finance department of TGD will be paying certain taxes like TDS (Tax Deducted at Source) ² 2% of Contract Labour Wages. CHART PROCESS OF PURCHASE & PAYMENTS Requisition & Quotation Approval 46 | P a g e . Focus Cost will be estimated by Divisional Manager of TGD unit and Manager of Finance department of TGD. TAFE ² Head Office will discuss with Divisional Manager of TGD make some adjustments in Focus Cost if necessary and approve for sanction. These taxes are unavoidable and Finance department of TGD is liable to pay the taxes. Focus Cost is prepared by the Finance department for future Production process. y Focus Cost: Focus Cost means Budget. Scrap Sales tax ² 1%. This Focus Cost will be sent for approval to TAFE ² Head Office by Finance department of TGD.

O) Delivery of purchase Requisition Goods Receipt Note (GRN) from Stores Invoice Verification Payment 47 | P a g e .Purchase Order (P.

CHAPTER ² VI HUMAN RESOURCE DEPARTMENT 48 | P a g e .

If the candidate passes the above process. the candidate will be interviewed by Senior General Manager in TAFE ² Head Office and a final interview by Divisional Manager of HRD in TAFE ² Head Office. the candidate will selected and employment offer will be given. The candidate will be first screened by Personnel officer and Head of the Department. CHART PROCESS OF RECRUITMENT & SELECTION Candidate Screening by Personnel officer & Head of the Department in TGD 49 | P a g e .HUMAN RESOURCE DEPARTMENT (HRD) ACTIVITIES y Recruitment and Selection: The candidate will be sent from TAFE ² Head Office to Production unit for Selection & Recruitment process. and then screened by Divisional Manager. After Divisional Manager·s screening.

Gen.Screening by Divisional Manager . Manager of TAFE ² Head Office Final Interview by Divisional Manager of HRD ² TAFE ² Head Office Candidate is Selected & offered Employment y Wages & Salary Administration: 50 | P a g e .TGD Interview by Sen.

51 | P a g e .  Performance Appraisal is made by rating every employee of TAFE Gear Division (TGD)  Performance Appraisal is processed by Performance Appraisal Team which consists of Personnel Officer. Superior of Appraisee & Divisional Manager ² TGD. The following is Performance Appraisal Process followed by HRD of TGD. y Employee Welfare: Many welfare activities are undertaken and followed by Human Resource department of TGD like. Salaries and wages will be increased and promotion is given if necessary. Attendance of employee is also taken for consideration for Performance Appraisal. y Performance Appraisal: Performance Appraisal is the major activity of the Human Resource Department.  Based on the Performance Appraisal employees & labours.  Salary Administration for Management staffs of TGD will be under the control of Centralized Payroll Department of TAFE ² Head Office.  Performance Appraisal is the activity of HRD of TGD for every Six months. Wage Administration for Contract Labour for Production Operations will be under the control of Human Resource Department of TGD.

 Training calendar is scheduled by Human Resource Department (HRD) of TAFE ² Head Office and followed by HRD of TGD. where free healthy lunch is provided for them.  Divisional Manager of TGD will give suggestions in framing the training calendar.  Induction & On the Job trainings are 2 types of training provided for new employees of TGD. y Training & Development:  Training on new machinery or to new production process is provided for existing employees  Training for new employees is provided. Canteen facility is availed for Management staffs & Contract Labour.  Uniform & Shoes are provided to Management Staffs at free of cost.  Transportation facility is availed for Employees of TGD.  Safety equipments are provided to Contract Labours for their safety.  Medical facilities & Allowances are provided for the employees of TGD. 52 | P a g e .

CHAPTER ² VII CONCLUSION 53 | P a g e .

.  TGD concentrates more on Production Department compared to other department. TAL.  TGD strictly follows 5.TGD is under control of TAFE. to avoid the labour unions.  TAFE is operating separate divisions like TGD.S principle.  In TGD many innovative production process are made as proto type. Bangalore (Doddaballapur) and to TAFE ² Spare Parts. etc. because it supplies is produced CWP to TAFE ² Tractor Manufacturing units in Madurai (Kallidaipatti).  Labours were employed through Contract Labour Agencies for contract in production unit.  TGD does not have separate department for Marketing activities.CONCLUSION y FINDINGS & INTERPRETATION:  TAFE Gear Division (TGD) is a sister concern of Tractors Farms &Equipments (TAFE).  TGD is fully interlinked with System Analysis and Program Development (SAP). strikes.. etc. tested and implemented. 54 | P a g e .

com/tafe/green/htm/areaoffice.htm y http://en.  TGD can increase Production by extending the Production Plant.org/wiki/TAFE_Tractors 55 | P a g e .frontpoint.com/ y http://www.y SUGESSTIONS:  TGD can sell the CWP to third party also by setting up Marketing Department to increase the revenue.wikipedia. TGD has all facilities to extend its Production Plant.  Separate Packing Cell can be setup for the purpose of Packing Finished Goods.com/ y http://www.tafechannel. REFERENCES y http://www.tafe.

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