TRAINING REPORT

OF

SIX MONTHS INDUSTRIAL TRAINING, UNDERTAKEN

AT

SML ISUZU LIMITED, ROPAR

IN

MAINTAINANCE DEPARTMENT

SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE

OF

BACHELOR OF TECHNOLOGY

IN

DEPARTMENT OF MECHANICAL ENGINEERING

Submitted By: Under the Guidance of:

Name: AKHIL VERMA Name: Mr. Jaspal Singh Designation: Manager

Department: Maintenance

ACKNOWLEGEMENT

“The aim of the training is to correlate theoretical course contents with practical applications and to get
to know the degree of one’s own capabilities when contributing to the conversion of scientific
knowledge into practical results.”

I humbly express my gratitude to Mr. P.K Bhardwaj, Chief Manager, SML ISUZU Limited, Ropar for giving
me the opportunity to undergo training in their prestigious organization. I also express my thanks to Mr.
N.K.Gupta , Manager ,Spare Part Division for his kind support during training. My sincere thanks to
Mr.Nijawahan and Mr.Kashmiri Lal Nagra for their kind help and friendly support.

I am sure that the knowledge & information that I have gained during this period would be of immense
value for my growth in the field of Mechanical Engineering.

I am also thankful to my colleagues and friends who helped me in the collection of field data and for
their cooperation during the course of my training. Last but not the least I would like to thank all of the
staff members, supervisors and workers for their help and co-operation during the training.

AKHIL VERMA

PREFACE

If you know the laws of buoyancy it doesn’t mean that you know how to swim. It is only through
jumping in the water that you get the feel of the depth. This is applicable to every aspect of life.
Therefore practical training is of utmost importance.
The object of undergoing this training was to get familiar with the weary waters of the industry and to
learn how to put theory into practice. I have been greatly privileged to have undergone training at SML
ISUZU LIMITED,ROOPNAGAR.

I am very fortunate to have had a chance to feel the gravity of what role Mechanical Engineering plays in
the industry. It was a golden opportunity for me to get a chance to experience what it feels to be in a
company where discipline, quality and hard work are the motto. This training helped me a lot in bridging
the gap between the theoretical and the practical aspects of my knowledge.

This report contains the extract of things I learned during my training period.

INDEX

Contents Page

1. Company Profile………………………………………………………………….5-7

2. Various Sections & Departments…………………………………………………8

3. Team SML ISUZU LIMITED……………………………………………………8

4. Models of SML ISUZU ………………………………………………………….9-10

5. Plant Layout………………………………………………………………………11

6. Introduction to Bus Body Shop………………………………………………… 12-18

7. Introduction to Paint Shop………………………………………………………..17-24

8. Vehicle Assembly Shop………………………………………………………… 25-34

9. Introduction to PPC 35-38

10. Technical Specifications of 3500-Series…………………………………………..39-42

11. Department Alloted & job Assigned………………………………………………49-44

12. Projects Undertaken……………………………………………………………… 45-50

13. Conclusion…………………………………………………………………………51

14. Bibliography……………………………………………………………………….52

COMPANY PROFILE

Swaraj Mazda Limited is a joint venture of Punjab Tractors Limited (PTL) and Mazda Motor Corporation
of Japan. The agreement between the two was signed on 5th October 1984. The Company decided on
bringing the latest Mazda Products under the name SWARAJ MAZDA T-3500.

The Swaraj Mazda Ltd. is collaboration between two giants in their own right-both committed to quality
and performance and showing profound development concern for customers, stockholders, business
partners and staff.
Swaraj Mazda found a very competent business partner in Mazda Motor Corporation of Japan and
enterprise of international repute. Founded in 1920 Mazda started manufacturing trust way back in
1931. Today this enterprise has the distinction of being the only company in the world producing
reciprocator petrol and diesel engine in the world & producing revolutionary rotary engines also. Mazda
is every reputed company in Japan. Mazda is ever seeing new areas of product excellence and
innovation. It adheres unflinchingly to a 2000 checkpoint inspection before declaring any vehicle road
worthy. The use of robots, sophisticated technology and production facilities enable Mazda to produce
vehicles of outstanding quality. No wonder Mazda have won recognition all over the world for quality
products with cars like Mazda 323 bagging the most prestigious awards through the years.

Swaraj Mazda Plant is located near Ropar at Village Asron (About 45 kms from the capital of Punjab
State i.e. (Chandigarh Swaraj Mazda Plant is located near Ropar at Village Asron (About 45 kms from the
capital of Punjab State).The plant has a captivating site. It spread over 100 acres of land surrounded by
the Shiwalik Hills. The barren silt hill has been leveled for construction, making it a beauty spot in the
hills. The construction of 100 crores plant, commenced on 16th January 1985.

Origin of the word “SWARAJ”

The word SWARAJ, in Hindi means “freedom from bondage”.

Since P.T.L. was the 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.

Units of SWARAJ Group

Originally, SWARAJ had set up its plant for the production of tractors. But with the passage of time, to
fulfill the requirements of Indian market, it diversified into other fields, with the collaboration of foreign
companies like Komatsu, Mazda etc. It is a fast growing company; it opened its new Division near
Chandigarh. Following are the five divisions of SWARAJ GROUP:

• SWARAJ COMBINE DIVISION

• SWARAJ FOUNDARY DIVISION

• SWARAJ ENGINE DIVISION

• SWARAJ TRACTOR DIVISION

• SWARAJ MAZDA DIVISION

MOTTO OF SWARAJ MAZDA ISUZU

“PRODUCTS WHICH ARE BETTER THEN THEY HAVE TO BE”

In the attainment of this motto the company follows the following codes which are:-

Seiri – Classify things into necessary and unnecessary ones. Discard what are unnecessary.

Seiton – Put the things order so that they are available when needed.

Seiso – Keep the work area and machine/tool clean so that abnormal condition is detected.

Shitsuke – Train, educate employees to follow rules, procedures & maintain standards.

Sieketsu – Develop standards; implement them to maintain safe and hygienic conditions at work.
The result of all this has been rapid increase in output of vehicles and sharp reduction in each loss.

SML ISUZU Limited gives due attention to the marketing part and employees higher qualified and
trained personnel for job. It has already organized a widespread dealer network. Zonal offices have been
opened in Mumbai, Luck now, Chandigarh, Chennai, Ahmadabad, and Calcutta. This helps substantially
in sales promotion. Export promotion, especially for hi-tech products is also being emphasized. It
exports it products to countries like Nepal, Zambia, Bangladesh, Kenya, Tanzania, Ghana, Ivory Coast,
Rwanda, Syria and Jordan.

The company's annual turnover for the year 2000-2001 exceeded 271 crores. It has a dealer network of
about 128 dealers spread throughout the country.

The corporate profile of SML ISUZU Limited projects a bright future for the company. That is how it
should be considering its importance for our economy. It is adding its share to the real asset and job
opportunities in the area both directly as well as indirectly. Company changes its name on 4jan ,2011
which is implemented on 11 Jan , 2011. At SML ISUZU Ltd. {Ropar} there are mainly four shops as given
below:-

Ø Assembly Shop

Ø Paint Shop

Ø Body Shop

Ø Pre Delivery Inspection Shop

These shops are attended under the strict guidance of shop incharges and shop engineers. On this
training, I learn many things which I could not imagine in my college labs.

VARIOUS DEPARTMENTS of SML-ISUZU LIMITED

Personnel Department R&D Department Quality Engineering Technology Department Accounts
Department Purchase Department Maintenance Department Marketing Department Sales Department

LIST OF DIRECTORS

Mr. S.K. TUTEJA - Chairman

Mr. HARKIRAT SINGH - Director

Mr. A.K THAKUR - Director

Mr. P.K NANDA - Director

Mr. K. MACHIDA - Director

Mr. M. SATO - Director

Mr. Y. WATANABE - Director

Mr. PANKAJ BAJAJ - Director

Mr. DONALD PECK - Director

Mr. STEVEN ENDERBY - Director

Mr. YASH MAHAJAN - Managing Director

Mr. KEIJI NAKAJIMA - Whole-time Director

Mr. T. HASHIMOTO - Alternate Director

Mr. T.NAGASHIMA - Alternate Director

MODELS OF SML ISUZU

Work at the plant started at a great tempo. The first vehicle rolled off the production line in record time
of one year of laying the foundation stone. The installed capacity of the plant is 10,000 vehicles per
annum which are targeted to be achieved in five years. The first 100 Swaraj Mazda T-3500 vehicles were
flagged off from the plant on 14th August 1985. This sophisticated plant manufactures following models
of light commercial vehicles which are:-

4.5 tonnes 14 ft Cargo Deck Commercial Vehicles. 6 tonnes 10 ft Cargo Deck Commercial Vehicles. 41, 32,
26, seater ordinary and Deluxe Buses. Windshield chassis. CNG Vehicles.

6. S7 (Standard School Buses)

Earlier known as Tokyo Kagyo Co. Mazda Motor Corporation of Hiroshima is the seventh largest
automobile company in the world. The company has the distinction of developing the ‘Wankel Rotary
Engine’ in 1967.It produces on an average, 1.2 million vehicles annually manufactured at its plant set up
in sixteen countries which include Korea, Malaysia, new Zealand, India & Pakistan.

.
Discipline and its right enforcement is an important hallmark of Swaraj Mazda. It is great significance in
evolving work culture. All the employees, irrespective of their position or status, have to punch their
cards when they report for duty.

. Many effective steps are taken to bring this about and important among them are:-

Common canteen and mess for all and there is one dinning hall in which all the employees dine together.
Same meals served to all and in identical utensils. Everybody has to stand in a queue and get his or her
meals. Common toilets for all. No separate cabins for all the members of higher hierarchy. All the
members of a department or a section sit and work in one hall with the manger facing the staff. Peons
are conspicuous by their absence. Every employee carries his or her files. Dignity or labour is thus
inculcated.

ENGINE COMPONENTS FROM WASHING MACHINE

ENGINE ASSEMBLY AND TESTING

TRANSMISSION COMPONENTS FROM WASHING MACHINE

TRANSMISSION ASSEMBLY AND TESTING

FRONT/REAR AXLE & DIFFERENTIAL ASSY.

AXLE COMPONENTS FROM WASHING MACHINE

LONG MEMBER STORAGE

TEMPORARY PART SETTING

TACK/FULL WELDING

STRAIN RELIEVING

CHASSIS PAINTING

VEHICLE ASSEMBLY LINE

PRE DELIVERY INSPECTION

ROAD/SHOWER TEST

CARGO BOX MOUNTING

RUST PREVENTIVE APPLICATION

VEHICLE TO STOCK YARD

PARTS FROM STORE

FLOOR ASSEMBLY.

CABIN ASSEMBLY
DOOR WELDING & ASSEMBLY

FINAL FITTING AND FINISHING

TO PAINT SHOP

CABIN PRE TREATMENT & BLACK DIPPING

BAKING

SEALANT AND PRIMER APPLICATION

BAKING

FINAL PAINTING

BAKING

INSPECTION

PAINTED CABIN TO VECH. ASSY.

CABIN DRESSING WITH SUB ASSEMBLY

CARGO BOX FROM STORE

CARGO BOX ASSEMBLY

SLEEPER ASSEMBLY

CARGO BOX WELDING

CARGO WASHING SEALANT APPLICATION

BAKING

FINAL PAINTING

BAKING

INSPECTION

BODY SHOP

ENGINE ASSEMBLY

CABIN WELDING

CABIN & CARGO ASSY & PAINTING

T/M ASSY LINE

AXLE ASSY LINE

FLOW DIAGRAM OF THE SML & ISUZU PLANT

BUS BODY SHOP

Body shop consists of three lines known as Frame line, Cargo line and Cabin line. After assembly, cabin
and cargo sent to the paint shop and the frame to the vehicle assembly shop. This shop involves the first
of operations which finally result in production in LCV.

This shop contains two lines

Ø Line For Chassis Frame Assembly

Ø Line For Bus Body Assembly Line

v STRUCTURE SHOP;

In this shop make a structure of bus. In this shop GI tubes used to make a structure of bus.

A. FIXTURE; This shop fixture are used to make a structure of bus. Many types of fixture

are used in this shop. These are following;

I. FLOOR FIXTURE

II. ROOF FIXTURE

III. L/S FIXTURE

IV. R/S FIXTURE

V. MAIN FIXTURE

After making all sides of structure then all sides attached each other. Also rear and front structure

Attached to this structure.

MIG weld used in this process 220-250A And 20-22V current used in this process.

TUBES: Tubes in this shop are GI. Because protect from rust,corrosion etyc.

v SHELL SHOP:

Shell of S7 bus

After structure shop the structure of bus send to the shell shop. It is most important shop of

Bus body plant. In this shop inspection of structure and after this coading of priemer at the
Welding joints. The inspection are following:

I. Full Welding

II. Grinding

III. Dents

IV. Riveting

V. Counting of screws

VI. Wiper bush

VII. Wiring of roof

VIII. Driver window

IX. Wheel arcs front &rear

X. Lid cover, etc

In this shop Plasma cutter is used . After this wheel arcs are sealing and check
The gap in this. Lid cover also welded in this shop which is used for air cleaner . Foot step also

Welded in this shop.

In this shop also fit GI panels . It panels fixed with the help of MIG weld. In this shop

Used two types of panels. Those are following:

v GI PANEL

v ALUMINIUM PANEL

`` MIG weld current ; 150A

20V

TYPE OF WELDING OPERATIONS IN BODY SHOP

Two types of welding operations are used in body shop these are:

Gas Metal Arc welding ( MIG) Resistance Spot Welding

(i) GAS METAL ARC WELDING

MIG is an arc welding process in which heat for welding is generated by an arc between a consumable
electrode and work metal. The electrode of M.S. Copper coated wire having diameter 1.2 mm is
continuously fed to the weld area by means of a D.C. Motor at speed of 9-12 m/min. This speed of
feeding the electrode can be adjusted according to the requirement. No flux is used but the arc and
molten metal are shielded by an inert gas, which may be argon, helium, carbon dioxide or gas mixture.
The steam of CO2 gas is to provide protection from atmospheric contamination to weld puddle, arc, and
adjusted area of base metal and the electrode. The direct current with reverse Polarity (i.e. electrode is
made positive and work is made negative) is used.

Working Specifications of MIG welding instrument are

Voltage 32-36 Volts

Current 180-200 Amp.

High speed Co2 is used as inert gas.

Principle of Operation

Proper current and wire feed speed is set and the electrical connections are ensured. The are is struck
by any one of the two methods. In the first method current and shielding gas flow is switched on and
the electrode is scratched against the job as usual practice for striking the arc. In the second method,
electrode is made to touch the job, is retracted and then moved forward to carry out welding; but
before striking the arc, shielding gas, water and current is switched on. About 15mm length of the
electrode is projected from the torch before striking the arc. During welding, torch remains about 10-12
mm away from the job and arc length is kept between 1.5 to 4 mm.

EQUIPMENT

a) Welding power source and cables.

b) Welding torch and wire electrode coiled on a spool.

c) Wire feed mechanism and controls consisting of a pair of driving rolls, electric motor, etc.

d) Shielding gas cylinder, pressure regulator and flow meter.

e) Controls for switching on and off the current, electrode wire and inert gas.

(ii) RESISTANCE SPOT WELDING

Resistance spot welding is a process in which surfaces are joined by the heat generation by resistance to
the floor of electric current through work piece that are held together under force by electrodes. The
surface in contact is heated, in the region of current concentration by short time pulse of low voltage,
high amperage current to form a fused nugget of weld meta