Project Report ATUL AUTO: June 2016

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Project Report ATUL AUTO
Technical Report · June 2016

DOI: 10.13140/RG.2.2.22399.00164/1
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Project Report
ATUL AUTO
Tejit Pabari
The Doon School
Cover Page: Atul Auto Plant, Rajkot
2
Abstract
Auto Rickshaws are a part of life of many Indian. Almost every city in India
has them. They are found on the road ferrying passengers from one place
to another. I have personally experienced riding in them en-number of
times. My school is on the outskirts of Dehradun and the one cheap way
to access them is through Autos.
Whenever I used to board an Auto, I used to be amazed by the sheer

design of it. I used to get intrigued by their working. I often wondered,
how can a machine so compact, run so smoothly, carrying as far as 5-6
passengers in a go? What goes in its making? What is its design that
makes it so smooth and sleek?
Thankfully, I found a company that was ready to cater to my burning

desires. Atul Auto, the leading auto manufacturing company in Gujarat,
allowed me to visit their plant and observe the making of rickshaws over
there.
This paper describes the functioning of the Atul Auto Rickshaw plant
located in Rajkot, as observed by me. It contains all the learning that I got
during my brief visit to the plant.
This paper starts with the a small introduction to the Automobile industry
in India. It then gives the history of the Atul Plant, an inspiration story, and
states the basic working of the plant. Thereafter, it describes the making
of a rickshaw, right from the joining of the frame of rickshaw (chassis) to
its painting, fitting the gears and wheel, fitting the engine, and its quality
check before it is released in the market. The processes described include
reasoning as well, i.e. the reason for doing that particular process in that
manner.
Project Report: Atul Auto
Concluding, it contains a flow chart of the process and the departments

behind the same.
3
Table of Contents
Abstract..............................................................................03
Table of Contents..............................................................04
Introduction........................................................................05
Decleration.........................................................................06
Note.................................................................................... 07
Acknowledgement...........................................................08
Automobile Industry.......................................................... 09
Atul Auto............................................................................ 12
Team Atul........................................................................... 13
Mission Statement..............................................................14
Production Plant................................................................15
Plant Basics.........................................................................17
Plant Stages........................................................................18
Stage 1: Storage................................................................19
Stage 2: BIW....................................................................... 20
Stage 3: CED...................................................................... 26
Stage 4: Painting................................................................31
Stage 5: Assembly Line..................................................... 33
Stage 6: Testing..................................................................38
Stage 7: PDI........................................................................39
Stage 8: Storehouse...........................................................42
Flow Chart...........................................................................43
Conclusion..........................................................................44
Bibliography........................................................................45
4
Introduction
Have you ever see a three legged machine, that runs on diesel, petrol or
CNG, is cheaper than a car (most models of a car), and houses as many
passengers as a normal car? Well if you haven’t, here it is:
This is an auto rickshaw - a daliy mode of transport for millions of Indians

and a mode of revenue for many others (not that it is not used in other
countries, in fact, it is found in South Africa, Bangladesh, China, Pakistan,
France, Italy and many more countries). It is found in most Indian cities
carrying passengers from one place to another. In fact, it is the only
mode of transport available for the public in my home town. There are no
Intercity taxis in Jamnagar
In my hometown most of the Auto Rikshaws used are of one brand - Atul.
They all originate from one factory, located in a place known as Sahapar
- about 30 km from Rajkot, a city in Gujarat. This place is where the Autl
Auto’s plant is located.
This project deciphers the process behind the making of this beautiful
three legged machine. It states all the stages that this machine goes
through, right from the its making from various small parts to its
assembling and Quality Test, before it is sold in the market. This project is
my observation of the plant in my own words.
So to the readers - Happy Reading!!
5
Decleration
I, undersigned Tejit Pabari, a student of the Doon
School, hereby declare that the following project entitled
“A Project Report on Atul Auto Limited” – on the working
of the Production plant in Atul Auto Limited, is my own
work. No part of it is plagiarized form any website or
journal. If any material is borrowed from anywhere, it
has been duly cited (see notice on the next page for
more information).
The information presented in this project is gathered

from understanding the working of the plant with the
help of Engineers in Atul. This information will not be
misused.
In case of any faults, no blame must be thrown on

anyone except me, as I bear the full charge of writing
this report.
Signature X______________________
(Tejit Pabari)
6
Note
Before you start reading the Project Report, I would like to bring some
points to your attention.
1. First:
All the matter that is written in this project work is done by me. No
part of this is plagrised and if I have borrowed any material from any
website, I have duly cited that site.
2. Second:
The citations can be found at the very end of the project report. The
citations are in MLA (Modern Language Association 7th Edition) format
with the URL - the link to the cite.
3. Third:
I was not allowed to take any pictures in the Factory. Therefore, any
picture you see in this project - except the test checksheets - are from
the internet.
Atul also has some pictures uploaded from the net. I have used those
pictures for explainatory purposes.
4. Fourth:
To distinguish between the real plant pictures (of Atul from net) and
the pictures borrowed elsewhere from the net, I have put a small atul
logo on the picture - either on the top right corner of the picture or the
bottom right corner.
5. Fifth:
One last point. I did not receive a certificate for this at all. This
was because I am not yet of 18 years - the age prescribed by the
government of India to Intern at any place. Therefore, there is not
certificate attached with this project report.

However, I did gain knowledge and that is the most important thing.
7
Acknowledgement
Before I begin I would like to thank some people without whose help, I
would not have been able to complete this project.
I would like to start by thanking the plant’s Chairman & Managing Director
– Mr. Jayantibhai J Chandra. Without his permission I could not have
completed this project report. I would also like to thank the Board of
directors for giving me this oppurtunity.
Next I would like to thank all the members of Atul Team and all engineers
who helped me with the visit and this report. They explained the whole
process to me until I fully understood it and answered all my questions
patiently. Without their help, this project would not exist.
I would also like to thank my family for supporting me through this project.
My parents and my sister boosted my morale many a times.
Lastly I would like to thank all thosse who helped me with this project.
If your name is not here, please pardon me. I could not, possibly, have
named each one of you. However, you will not be forgotten and shall stay,
forever, in my heart. Your kindness will be remembered.
8
Automobile Industry
Automobile Industry in India
The automobile industry in India is one of the largest and well established
industries in the world with an annual turnover of 23.37 million vehicles
(consisting of passenger vehicles, commercial vehicles, three wheelers
and two wheelers), in the Financial Year 2014 – 2015. In India, it
contributes about 7.1% percent to the Country’s gross domestic product
(GDP). This sector is led by the Two Wheeler industry, which accounts for
81% of the total revenue generated by the industry.
The automobile industry in India dates back to 1942, when Hindustan

motors was launched for the first time in India. Later, Mahindra
and Mahindra was established in 1945. All this was before India’s
Independence.
After Independence, the government of India appointed a traffic

commission to co-ordinate and look over the working of the automobile
Industry. Initially the growth was slow due to the license raj (the
government, at that time, followed a policy known as the license raj,
recommended by the traffic commission, that allowed only a certain
number of automobiles to be manufactured by the automobile companies
9
and if they wanted to manufacture more, they needed to upgrade their
license. The policy also cleaned out manufacturers with only import as
well as those companies with no Indian partner. This made the license
raj quite stringent!). The beginning of 1970 saw a rise in the automobile
industry, after the license raj came to an end (somewhat). However, cars
and jeeps were still machine for the elite.
Eventually, post 1992, companies such as Suzuki and Toyota were

allowed to invest in the Indian market. Maruti Suzuki became the first and
the most famous company at that time. Later, in 2000, the government
even started encouraging local manufacturers as well.
Thus, the automobile industry was developed.
10
Competitors in the Automobile Industry
The Indian automobile industry is divided into three major sectors:
• Sector 1:
Around Chennai – accounting for 35% of the revenue generated by the
automobile industry.
• Sector 2:
Near Mumbai – which accounts for 33% of the revenue generated.
• Sector 3:
In the north, around Delhi, which accounts for 32% of the revenue
generated.
In these sectors, the major players are:
• Fiat India Pvt. Ltd.

• Ford India Pvt. Ltd.
• General Motors India Pvt. Ltd.
• Hindustan Motors Ltd.
• Honda Siel Cars India Ltd.
• Hyundai Motors India Ltd.
• Maruti Udhyog Ltd.
• Skoda Auto India Pvt. Ltd.
• Tata Motors Ltd.
• Toyota Kirloskar Motor Pvt. Ltd.
• Force Motors Ltd.
• Mahindra & Mahindra Ltd.
• Ashok Leyland Ltd.
• Volvo India Pvt Ltd.
• Atul Auto Ltd.
• Bajaj Auto Ltd.
• Piaggio Vehicle Pvt. Ltd.
• Tvs Motor Co. Ltd.

• Royal Enfield Ltd.
• Suzuki Motor Cycle India Pvt. Ltd.
• Yamaha Motor India Pvt. Ltd
11
Atul Auto
Atul Auto Plant, Rajkot
Atul’s journey began in the 1970s, when the automobile industry was
still in its initial stages, growing slowly. Atul’s founder, Mr Jagjivanbhai
Chandra, had envisioned a company that developed a convenient and
affordable automobile that could traverse the rural, uneven roads of
Saurashtra (Gujarat). He turned his vision into action when he developed
the first three-wheeler automobile based on the design of a motorcycle,
and adapted engines from a golf cart, giving rise to the first ‘Chakkada’.
Mr. Jagjivanbhai Chandra then started this company that we now know as
Atul Auto.
Atul auto was incorporated (became a corporation by law) in 1986.

Thereafter, in the year 1992, it began its production.
The company began by producing ‘Chakkada’. It also started improving

upon the existing technology, constantly updating it to meet the norms and
competition around it. Mr. Jayantibhai Chandra took over the company
from his father and furthered his mission of providing a convenient
transport to Indians by developing a Diesel ‘Chakkada’.
Soon, Atul started manufacturing new varieties. It manufactured Shakti – a

convenient rickshaw, and many other vehicles under its brand name such
as Commercial 3-wheelers, half ton vehicles (carrying capacity) and more.
Currently, Atul is leading manufacturers of three wheeler transport in

Gujarat. It has managed to increase its production growth by two folds in
the last five years. It achieved a turnover of 528.01 crore for the financial
year 2014-2015.
12
Team Atul
The Board of Directors
• Mr. Jayantibhai J Chandra – Chairman & Managing Director
• Mr. Mahendra J Patel – Wholetime Director & CFO
• Mr. Niraj J Chandra – Wholetime Director
• Mr. Vijay K Kedia – Director
• Advocate Hakubhai J Lalakiya – Independent Director
• Mr. Hemantkumar J Bhatt – Independent Director
• Mr. Hasmukhbhai H Adhvaryoo – Independent Director
• Dr. Margie S. Parikh – Independent Director
ATUL Team
• Mr. Jitendra V Adhia – President Finance
• Mr. Paul Zachariah – President Marketing
• CS Paras J Viramgama – Company Secratary & Compliance
Officer
13
Mission Statement
Mission Statement:
To devote ourselves to cater to the common man’s

transportation needs by introducing environment-friendly
vehicles which are empowered by latest technological
advances.
Vision:
To contribute in eradication of poverty by making the common

people self-dependent with our state of the art technology,
products and services.
And the Atul team ensures that these words are followed to the
core!!
14
Production Plant
Basics Information
Some facts about Atul Autos Production plant:
• Atul auto is a single shift plant. Meaning it does not work day and night.
The shifts start from 9’O Clock in the morning and end at 5’O Clock in
the evening.
• Currently, the Atul auto plant can produce about 130 rickshaws per
day.
• Its annual turnover, in terms of number of vehicles, is 50,000 vehicles.
• For future, they would continue to innovate new and better technology
to make transportation easy and affordable for Indians. Here are few
vehicles which are under planning:
• Micro Commercial Vehicle to carry 750 Kg. Payloads

• Range of Electric Commercial Vehicles
• 4-Wheeler One Tonner LCV
15
Plant Location
The location of a plant is highly important for its working. If the plant is
located in a suitable place such that it can get the raw material easily, the
cost of the product will be less and the production capacity will also be
more.
An industry’s locations depends on a number of factors:
• Supply of raw material:

Raw materials are a necessity for the working of a plant. If the raw
materials are available easily, the production might increase and the
transportation cost might go down.
• Transportation facilities
If the transportation facilities and the roads are in working condition,
and if the place is located in an area were transportation is good, then
the production cost will decrease.
• Labor supply
Labor supply is important since this determines directly the production
ability of a plant.
• Availability of power
Power is an important raw input required for the working of the plant. If
a plant has power available with ease, the production cost will be less.
• Government policies
Government policies are a major factor in determining the produce of a
plant.
Atul is located in an area where all the following are available easily
and affordably, therby decreasing the producing cost and increasing the
production capability
16
Plant Basics
Any automobile can be divided into two parts:
• The Chassis of the Automobile:

The Chassis is the outer frame of an automobile which houses the
engine. It also houses the body of the automobile.
• The body of the Automobile:

The body of an automobile is the part where an object is carried. For
instance, in a truck, the rectangular container forms the body of an
automobile, while in an auto rickshaw, the seating compartment forms
the body.
With an Atul auto rickshaw, the same division is followed. The chassis of
the rickshaw is made in the BIW department, while the body is imported
from outside from two companies: P.R. Auto and Ganga R.K. Both are
joined in Atul’s plant and the rest of the parts are added to make the
complete rickshaw
The Atul plant I went to produces different types of rickshaws. However, at

the time I was there, there were only two types being produced.
• Atul Gem rickshaws
• Atul Gemini rickshaws

(The pictures are for representation purposes only.

Because both Gem and Gimini look highly similar,
so the pictures can be interchanged.)
Atul Paxx rickshaws are heavier than the Atul

Gemini rickshaws. That is the major difference
between the two.
17
Plant Stages
The Production Plant is divided into eight stages:
1. Warehouse / Storage
2. BIW
3. CED
4. Paint
5. Assembly line
6. Testing
7. PDI – Pre Delivery Inspection
8. Storage of Rickshaws
Step 1: Storage
18
Step 1: Storage
There are three stores departments.
• Fabrication stores of the BIW department

This is the department where all the goods used in the BIW department
are kept. According to the requirement, the goods are transferred to the
BIW department by the transportation department.
• Receive Stores
This is the department where all the raw material, except for the BIW
department, available from outside are kept. From here the material
goes to the required department again done by the transportation
department.
• General Stores
This is the store where all the finished parts from a department are
kept. Meaning, if a chassis has been made by the BIW department
and cannot be taken to the next department on the same day, then it is
stored in the general stores.
All in all the Storage department stores the raw material or the produced
parts for later stages.
The Storage department looks something like this
19
Step 2: BIW
The BIW department in Atul
The very first step in the production process is BIW
BIW is the department where the chassis is assembled. BIW stands for
Body in White. White here signifies no color. The name is such because
the chassis is not colored yet, it is in the very first stage where all the
welding marks can be seen.
The parts used to assemble the chassis come from various dealers. They
are imported by Atul and kept in a warehouse (BIW shop). These parts
are then taken to the BIW workshop, where they are assembled into a
rickshaw. The parts for Gem Paxx and Gemini are made from the same
material, however, their assembly is different. This assembly is what
makes the Gemini rickshaw lighter.
Step 2: BIW
20
In the BIW department various process take place:
• Spot Welding:
Welding is the process of joining two metals together. Spot wielding is
the welding of two metals by passing a high current.
The two metal plates to be joined are held together by clamps fixed
in the spot welding machine. The spot welding machine consists of
two copper alloy electrodes. A high current is passed through these
electrodes. These electrodes, in turn, concentrate this current on a
particular spot. This high current melts the metal, thereby joining the
two pieces together
Spot Welding Method Spot Welding Machine
• CO2 Gas Welding:

CO2 Gas welding is done in order to join two metal plates together. It
utilizes a third metal to do so. Thus, it melts the third metal in order to
join the two base metals.
The material to be welded with is made the electrode in this case.

This material is electrified by a high current/arc. The high current
melts the material, thereby joining the two base metals with this
material. CO2 is used as a shield, it protects the welded material and

the base metals from getting oxidized and from reacting with Nitrogen
or its compounds (since the metal and the material are at a high
temperature, they react readily with Oxygen or Nitrogen Compounds)
21
CO2 Gas welding is much stronger than spot welding. However,
it is not used to joint every part of the chassis. The reason is that,
although it forms a stronger weld, it is very expensive. Spot welding
is faster and cheaper than CO2 Gas welding. Thus, CO2 Gas welding
is used only in specific areas where the metals need to be joined
strongly.
CO2 Gas welding method CO2 Gas welding Process
• Drilling
After the above two processes are done, the metal chassis formed
is drilled to fix the bolts. This drilling is done by a driller machine with
drills of various diameters.
Step 2: BIW
Drilling Machine
22
• Brazing
The next step is Brazing.
Brazing is the mush like soldering a metal. In Brazing, a metal, in this

case Brass, is melted to join two metal parts together. The metal used
for joining has a lower melting point than the metal the parts are made
of.
Brazing differs from Welding in that it does not involve the melting of
the parent or the base metal. It differs from soldering since it uses a
lower temperature than used in soldering.
Brazing Process
Brazing Process
• Grinding
The last step in this cycle is grinding.
Grinding is the process of removal of any extra metal

from the part. A grinder, is like a toothbrush with metal
teeth. The metal teeth are rotated and the grinder is

moved against the part to remove the extra metal.
Grinding
This is the last step since it is like adding the finishing touch to the
chassis.
23
Quality Check:
There are three quality checks held before the chassis is passed on to the
next department.
1. The First Quality check for each part, or each attachment of the
chassis is done at the place of its fixture. For example, if a part is fit
in the frame using the CO2 Gas welding machine, a quality check
department guy is present there to ensure that the proper fixing of the
part takes place.
2. The second Quality check is done after the whole chassis is

assembled. This is done by the BIW department workers.
3. The third Quality Check is done by the Quality Check Department

Workers (PDI Department). Some representatives from the PDI
department are present in the BIW department, and they ensure that
each joint is perfectly fixed and the chassis is ready.
The chassis is now ready to be transported to the next department
Chassis of a Rickshaw In the final stages in the BIW department

Step 2: BIW
24
Cooling in BIW:
The electrodes in the Spot Welding machine, and the various machines
need to be cooled since the high current can easily heat them up. For this,
a cooling plant is installed outside the BIW department.
The cooling plant has two pipes connecting it with the BIW department.
One is colored red and the other green. The green pipe brings cold water
from the cooling plant to the machine, to cool them, while the red one
transports the hot water back to the cooling plant, so that it could be
recycled.
On top of these two pipes, another pipe runs in the BIW department – a
blue pipe. The blue pipe contains compressed air to be used in various
machines.
Other departments:
In the whole plant, while the workspace is named after one particular
department, many departments work together, coherently, to give the final
product. For instance, at the BIW department, many other departments
such as the Maintenance department (for maintaining the machines
in case they break), the quality check department (checking if every
step is done in the proper order and not piece comes out faulty) and
the transporting department (transporting and checking that every part
required to make the chassis is in the right place, with the right person)
are at work. Project Report: Atul Auto
25
Step 3: CED
The chassis from the BIW department and the Body of the Automobile
from the warehouse are transported to the CED Department.
CED is the department where the chemical processes happens. The

chassis or the body is cleaned and a layer of a chemical is applied on
the parts, to make the paint stick to them easily. CED stands for Cathode
Electron Deposition. This is a process that happens in this department.
Since this is the main process, the department is named after it.
This is a fully automated department. Only the consoles for the machines
need to be controlled. Rest, the dipping of the chassis or the body and all
the other process are taken care of by programmed machines. However,
various manned checkpoints are installed throughout the process, where
the engineers vigilantly observe the whole working. In case of any fault,
they jump right in!
The chassis or the body is connected to a metal frame by chains. The

metal frame is then picked up by the huge machines wandering overhead.
A metal frame is used so that the big machines do not harm or break the
part.
01. Step 1:
The first step in this process is the Pre-Degreasing tank. The part of
the automobile is dipped in this tank. The tank has an Alkali based
Solution in it for the removal of Oil and Grease from the surface of the
part (as explained by an engineer, the oil and grease are not added in
Atul’s Plant. Rather, they come on the surface because the parts that
come from the dealer – from outside – are oiled). The temperature of
the bath, the tub where the alkaline solution is kept, is about 50°C –
60°C. The chemicals used to make the alkaline solution are Guardo
Clean VP 4292-A and R.O. Water. The process time for this step
(time taken to complete the step) is 120 seconds. After this time, the
machines picks the frame and take it to the next step.
Step 3: CED
26
02. Step 2:
The next step in the process is again Pre-degreasing. This is done in
Tank two. The temperature of the bath and the chemicals used are
the same as in the previous step. However, the process time here is
180 seconds.
The Pre-Degreasing tanks look something like this
03. Step 3:
The third step is Water Rinsing. Water Rinsing is done for the
removal of the anti-degreasing chemicals used in the previous steps,
so that they do not contaminate and hinder the chemical process
in the next step. The PH of the water used here is between 7.5 and
8.5. The chemical used is R.O. Water and the process time is 60
seconds.
04. Step 4:
The fourth step in the process is de-rusting. In this step, the
respective part is dipped in a bath filled with acid (also known as the
acid tank). This removes the corrosion, if it is present, from the metal.
The chemicals used here are Gardacid 2055 and R.O. Water. The
process time for this step is 240 seconds.
27
05. Step 5:
The fifth tank is again a Water Rinsing tank (Water Rinse 2). It is used
to remove the chemicals from the previous step. The pH of the water
here is between 3.5 and 5.5. The chemical used is R.O. Water. The
process time is 60 seconds.
06. Step 6:
Tank 6 is the Activation tank. This tank is responsible for activating
the metal surface, to prepare the chassis or the body for the next
step (deposition of a fine and uniform coating of Phosphate). The
chemicals used in this step are Gardolene ZM and DM Water. The pH
of this mixture is between 8 and 9.5. The process time is 120 seconds.
07. Step 7:
Tank 7 is the Phosphate tank. This tank is responsible for the
deposition of a fine and even layered coating on the respective
part. The layer of phosphate is deposited to inhibit corrosion and to
increase the durability of the paint that would be applied in further
steps. The chemicals used in this process are Gardolene 249 TE,
Gardolene 249 TA, Gardolene ADD.CC NCO 1. The temperature of
the chemical mixture used in this tank is between 50ׄ°C and 60°C and
the pH is between 2.8 and 3.5. The process time is 180 seconds.
This is an important process and is supervised thoroughly by the
engineers.
The Phosphate tank looks something like this. (Couldn’t find a Picture with an
Auto Rickshaw in it!)
08. Step 8 & 9:

Next, the chemicals from the previous steps are removed by 2 Water
Step 3: CED
Rinsing Tanks. The pH of the Water used (D.M. Water) is between 5.5
and 7.5 and the process time is 60 sec.
28
10. Step 10:
Tank 10 is the CED tank. In this tank, the chassis or the body is
inserted in an electrolyte made of various pigments, emulsion solvent,
pH regulators and D.M. Water. The part inserted acts as the anode
with the current being passed to the part from the frame holding
it, while the cathodes are kept on the inner lining of the tank. The
cathodes contain the chemical to be applied on the part to make
the part easily available for painting. A rectifier is used to supply the
voltage to the anode and cathode.
The process takes 180 seconds to complete. The temperature of

the bath is between 30°C and 34°C and the pH of the electrolyte
is between 5 and 6. This is an important step in the process and is
regulated manually.
Body out from the CED Tank

11. Step 11 & 12:
Tank 11 and 12 are the Ultra filtration tanks. In this tank the excess
chemical from the previous step, if any, is removed from the body and
the chassis and a smooth finishing is obtained. The chemical used
here is D.M. Water at a pH of 4.5 – 5.8. The process time for this step
is 60 seconds.
29
13. Step 13:
Tank 13, the final tank in the process, is RCDM. RCDM stands for
Removal of Contaminants using DM water. And this is what it does. It
removes all the contaminants and the chemicals on the surface of the
chassis or the body, before sending it for the next step. The pH of the
D.M. water used is between 5.5 and 7.5 and the process times is 60
seconds.
The whole process takes about 1320 seconds or 22 minutes (when

counted directly) + the amount required for the machines to carry the part
from one tank to another. Thus, after every 30 minutes (approximately) a
chassis or head is taken out of the CED process and inserted in the CED
oven.
The CED oven is much like the ovens we use, it is used to bake
things. The parts from the CED process are baked in the CED oven at
a temperature of 180°C ± 5. This ensures that the chemical sticks to
the metal surface properly. After baking, the parts are sent to the next
department.
The chassis looks something like this when it comes out of all the CED tanks
Step 3: CED
30
Step 4: Painting
The next Department is painting.
For painting the part, the parts are loaded on a conveyor belt. The
conveyor belt keeps on moving, at a certain designated speed, and the
engineers keep on working on the parts.
Before being painted, each part is

cleaned using a tag rag. A tag rag is a
rag (a discarded cloth) with pores in it.
It also has certain chemicals in it that
help in cleaning the dust from the parts
of the automobile. The parts are also
aired, i.e. compressed air, air with a high
velocity, is used to clean the parts and
remove dust from them. The parts are
then painted.
The painting of the parts, also known as the Top Coat Painting,
is done in three steps:
• Primary Coat
Applying the first coat of paint
• Base Coat
Applying the next coat
• Clear Coat
Applying the third coat to ensure that no part of the chassis or the body
is left without color.
These steps take place as the conveyor moves the part forward. These
steps are done in order to ensure that no portion of the part is devoid of
color. After this step the parts are again baked, now in a bigger oven, to
ensure the proper application of paint.
31
A Baking Oven
The finally painted part is now sent to the quality department engineers in
the painting department. They determine whether the particular part has
been painted well and if it is ready to be sent to the assembly line.
It is possible that an error happens in the painting process. This would be

pointed out by the quality department. For instance there could be a run-
down error in the paint (one of the most common errors) – which means
that some extra paint is sprayed by mistake. In this case, the faulty part
is sent to the rework area located in the painting department. Engineers
from the painting department are available there who fix the fault and pass
on the part to the next department.
The next department in line is the Assembly Line.

Step 4: Painting`
The chassi of a rickshaw with pain coatings
32
Step 5: Assembly Line
There are two assembly lines in the Atul plant at Sahapar. One is for
Gem Rickshaws while the other for the Gemini Rickshaws. Their fitting is
different and thus they need to be separated at this point. However, the
major process and the quality check followed in each line is the same.
The assembly line is divided in two major stages –
• The Pre-conveyor Line:

This is the line where the chassis is completed - i.e. parts such as the
engine, the gears, the steering wheel, parts which lie in the chassis,
are fit.
• The Main Assembly Line:

This is the line where the body is fit and the rest of the work - such
as tightening the bolts, fixing some wires, fixing the fuel tank and the
battery etc. is done
The chassis from the paint department is transferred to the Pre-

Conveyor line. In the Pre-Conveyor Line the engine is pushed forward
through the use of Rails. After an engineer is finished with his/her work,
he/she pushes the chassis forward. The chassis moves to the next Pre-
Conveyor step in this manner.
The Pre-Conveyor line is further divided into four parts:
1. Pre-Conveyor 1
2. Pre-Conveyor 2
3. Pre-Conveyor 3
4. Pre-Conveyor 4
33
The working of the Pre-Conveyors cannot be separated from each other,
since it is interrelated. Thus, I have described it together here.
Most of the work is done manually in this Line. The chassis is first cleaned
and checked for any dent or scratch marks. Then, the front wheel is added
using a special triangular structure that is fixed in the front part of the
chassis. Next, the rear wheel mounts and rear wheels are added.
Next, a triangular Cone is added to the front of the engine for the fixing of
the steering wheel. The steering wheel (also called the steering column) is
then added. Then, the engine and the gearbox, which are together known
as a power pack, and added. The brakes are added and fixed properly.
The wiring for the brakes, the fuel and other parts is done as well.
All the parts added over here, such as the Engine, the gear box and the
steering wheel are obtained from various dealers. They are stored in the
warehouse and then brought to the Pre-Conveyor by the transporting
department. These parts are, however, not fully assembled. Thus, they
are assembled by engineers in the Pre-Conveyor line, in its sub-divisions
known as the Sub-Assembly. There is a Sub-Assembly for Steering
wheels, for Engines, for Gear Box and for many other parts.
The chassis is now partly ready and is transported to the main assembly
line.
Chassis from the Pre-conveyor Belt
34
Main Assembly Line
The Main Assembly line is further divided into 14 divisions. Each division
is responsible for fixing a certain area or a certain part of the Automobile.
The chassis from the Pre-Conveyor line moves to the first Division,
where it is lifted onto a conveyor belt. The speed of the conveyor belt
is fixed such that it gives ample time to the engineers of one division
to complete their work. Depending upon this time, the manpower for a
particular division is allotted as well.
The divisions are:
01. Division 01:

The first Division, to which the chassis from the Pre-Conveyor line
reaches, is responsible for the tightening of bolts.
02. Division 02:

The second division fits the fuel tank, the diesel filter tank and the air
filter tank in the chassis.
03. Division 03:

The Third division fits the headlights, Indicators (for sides) and the
cover.
04. Division 04 & 05:
The Fourth and Fifth division are responsible for the Fitting of the
Handle bar and the Brakes.
35
06. Division 06:
The Battery assembly and the Tire fitting is done by the sixth division.
07. Division 07:

All the cables are connected in this division.
08. Division 08:

The eighth division is responsible for the assembly of the silencer.
09. Division 09:

The door is assembled along with the door locks.
10. Division 10:

The glasses of the Automobile are assembled.
11. Division 11:

An important division, the body is assembled here and the battery
connections fixed.
12. Division 12:

The driver’s seat and the passenger’s seat (if it is a passenger
rickshaw) is attached.
13. Division 13:

Stickers are attached. Taillight is attached. All other small additional
parts are attached.
14. Division 14:

The Wiring and all the Electrical Components are checked ones again.
The Automobile is now ready. It comes off the conveyor belt and a
sensor kept in front increases the count on a board by one, indicating the
production of one more rickshaw.
Remember, while all this is happening, the maintenance guys and the
quality guys are present, attentively observing the whole process, ready to
find any mistake or error or to fix any machine.
36
A checklist followed by the engineers in the Assembly line is shown.
This checklist is kept inside the rickshaw and is ticked by the

respective engineers as the automobile passes through each Divisions.
This checklist lists all the parts that are to be fixed and with what
specifications. If there are any parts missing, or if any fault is observed
in the design or structure, the engineer mentions this in the remarks
section.
37
Step 6: Testing
The next department is the Testing Department. This is where the
various tests are done to confirm that the automobile meets the required
standards.
Step 6: Testing
A list of tests is shown. All these tests are performed in the Testing area by
a group of Engineers.
38
Step 7: PDI
The PDI department – Pre Delivery Inspection Department – is the final
department in the production assembly. Here the whole Automobile is
assessed by a group of engineers. Each part of the engine is examined.
The whole process of making the automobile is put under microscope.
Nothing misses the eye of the engineers in the PDI department. From
here, we get the final product.
The PDI department also follows a check sheet. This is displayed below.
39
This check sheet has two parts, one for any faults in the assembly section
Step 7: PDI
and second, for any faults in the paint section.
40
If there are faults found in the Automobile that correspond to the
Assembly line, then the engineer inspecting the Automobile writes on
this sheet, in the remarks sections, corresponding to the faults that
have been displayed. The automobile then goes to the Assembly line’s
Managing Director and from there on he directs it to the particular
division where the fault can be resolved. The automobile then arrives
back to the PDI section and the quality check is continued.
If there is a fault that could be fixed by the paint department, then

the inspecting engineer writes on the sheet and also marks the faulty
part with a tape. The automobile is then carried to the rework Paint
department, located nearby, where engineers from the paint department
are present to resolve the fault. The quality check is thereafter continued.
The check sheet shown previously is the outcome of a lot of work done
and a lot of surveys conducted and complaints of the dealers and the
buyers considered. The top right corner of the first page of the check
sheet displays this information. The Rev No. refers to the number of
times this check sheet has been revised since its creation. The Revision
Date shows the last date when the sheet was revised, while the Effective
Date shows the date of creation. Thus, this check sheet was revised 15
times in the past 4 years. This shows the dedication and the amount
of effort Atul’s engineers takes to incorporate the suggestions and the
complaints of the consumers of their product.
The Automobile – rickshaw – is now ready and is taken to the Store

House for Storing. Project Report: Atul Auto
41
Step 8: Store house
The storehouse stores all the rickshaws – the final products.
Step 8: Storehouse
Auto Rickshaw Storehouse
42
Flow Chart of Atul Auto Plant Made by me
43
Conclusion
To Conclude, it has been a really great experience learning in the Atul
Factory. I have learnt the whole process of manufacturing an Atul Auto
Rickshaw. It is indeed a marvel how such compact a machine requires
such huge a process to be manufactured.
Besides learning about the process, I tried to relate this project to my

school course as well. This project has enhanced my understanding of
many concepts that I already knew. I have also learnt new concepts that
I can apply in my course, especially in the CED department, which taught
me things related to chemistry and the BIW department and the Assembly
line which taught me things in physics.
Well, now I must say goodbye to you all. It has been great journeying with
you through the factory. I hope this project stood up to your standards.
In case you have any doubts or remarks to make, kindly mail them to me
at tejitpabari99@gmail.com.
Goodbye for now!!
44
Bibliography
• 22, PTI | May, 2016, and 01 35 Pm Ist. “Delhi Government Likely to Revise
Autorickshaw and Kali-Peeli Taxi Fares next Month.” The Economic Times. Web.
<http://economictimes.indiatimes.com/news/politics-and-nation/delhi-
government-likely-to-revise-autorickshaw-and-kali-peeli-taxi-fares-next-month/
articleshow/52385639.cms>.
• “Atul Auto.” Wikipedia, the free encyclopedia 16 Jan. 2015. Wikipedia.

<https://en.wikipedia.org/w/index.php?title=Atul_Auto&oldid=642733887>.
• Wikipedia, the free encyclopedia 16 Jan. 2015. Wikipedia. Web.

<https://en.wikipedia.org/w/index.php?title=Atul_Auto&oldid=642733887>.
• “ATUL AUTO LIMITED.” Web.

<http://www.atulauto.co.in/about.php>.
• “Automobile Industry in India, Indian Automobile Industry, Sector, Statistics.”

<http://www.ibef.org/industry/india-automobiles.aspx>.
• “Automotive Industry in India.” Wikipedia, the free encyclopedia Wikipedia.

<https://en.wikipedia.org/w/index.php?title=Automotive_industry_in_
India&oldid=727900519>.
• Wikipedia, the free encyclopedia 1 July 2016. Wikipedia. Web.

<https://en.wikipedia.org/w/index.php?title=Automotive_industry_in_
India&oldid=727900519>.
• “Auto Unions Irked over ‘Suspend First, Talk Later’ Rule | Latest News & Updates at
Daily News & Analysis.” dna. N.p., 27 Apr. 2015. Web.
<http://www.dnaindia.com/mumbai/report-auto-unions-irked-over-suspend-first-
talk-later-rule-2080927>.
• “Battery Rickshaw Approved By Government & Three Wheeler Manufacturer from

New Delhi.” Web.
<http://www.indiamart.com/divansuautomobileslimited/products.html>.
• “Besto Enterprise | Angel Grinder Machine.” Web.

<http://bestoindia.com/?dt_portfolio=machinery>.
• “Brazing.” Wikipedia, the free encyclopedia 2 June 2016. Wikipedia. Web.

<https://en.wikipedia.org/w/index.php?title=Brazing&oldid=723308731>.
• “Cathodic Electrocoating.” Web.

<http://www.coatecindia.com/cathodic_electro.html>.
• “ED Coating Plants, ED Coating Plant, CED Plants, Aurangabad, India.”

<http://www.integratedrobo.co.in/ed-coating-plants.html>.
45
Bibliography Contd...
• Gache, Gabriel. “How Spot Welding Works.” softpedia. Web.
<http://news.softpedia.com/news/How-Spot-Welding-Works-91337.shtml>.
• “K.J. JOHNSON | Bayfield, Ontario, Canada | Piaggio Apes - P501 - P601 | Piaggio
Ape Gallery.” Web.
<http://kjjohnson.ca/piaggio/pictures/Motocarro%20Mundo/ATUL%20AUTO%20
INDIA/?directory=.&currentPic=18>.
• “Lexus Tires in Kitchener Waterloo| Heffner Lexus Tire Centre.” Heffner Lexus.
<http://www.heffner.ca/lexus/tire-centre/>.
• “MIG Welding.” Web.

<http://www.engineerstudent.co.uk/mig_welding.php>.
• “Rent Free Welding Gas | MIG Welding, Argon | NGF.” Norfolk Gas Filling.
<http://www.norfolkgasfilling.co.uk/welding-gas/>.
• Roy, Nabanita Singha. “Atul Auto Limited 17.66% Sales Growth in March 2013.”
RushLane 9 Apr. 2013. Web. 28 June 2016.
<http://www.rushlane.com/atul-auto-limited-march-2013-1273591.tml>.
• “Society of Indian Automobile Manufactures.” Web.

<http://www.siamindia.com/statistics.aspx?mpgid=8&pgidtrail=9>.
• “Spot Welding.” Wikipedia, the free encyclopedia 21 June 2016. Wikipedia.

<https://en.wikipedia.org/w/index.php?title=Spot_welding&oldid=726341754>.
Atul Shakti
46
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Project Report ATUL AUTO

Technical Report · June 2016

HAM Radio View project

Removal of Heavy Metal Ions View project

The user has requested enhancement of the downloaded file.

Whenever I used to board an Auto, I used to be amazed by the sheer

Thankfully, I found a company that was ready to cater to my burning

Concluding, it contains a flow chart of the process and the departments

This is an auto rickshaw - a daliy mode of transport for millions of Indians

So to the readers - Happy Reading!!

The information presented in this project is gathered

In case of any faults, no blame must be thrown on

certificate attached with this project report.

The automobile industry in India dates back to 1942, when Hindustan

After Independence, the government of India appointed a traffic

Eventually, post 1992, companies such as Suzuki and Toyota were

Thus, the automobile industry was developed.

In these sectors, the major players are:

• Fiat India Pvt. Ltd.

• Tvs Motor Co. Ltd.

Atul auto was incorporated (became a corporation by law) in 1986.

The company began by producing ‘Chakkada’. It also started improving

Soon, Atul started manufacturing new varieties. It manufactured Shakti – a

Currently, Atul is leading manufacturers of three wheeler transport in

Project Report: Atul Auto

To devote ourselves to cater to the common man’s

To contribute in eradication of poverty by making the common

• Its annual turnover, in terms of number of vehicles, is 50,000 vehicles.

• Micro Commercial Vehicle to carry 750 Kg. Payloads

Project Report: Atul Auto

An industry’s locations depends on a number of factors:

• Supply of raw material:

• The Chassis of the Automobile:

• The body of the Automobile:

The Atul plant I went to produces different types of rickshaws. However, at

• Atul Gem rickshaws

• Atul Gemini rickshaws

(The pictures are for representation purposes only.

Atul Paxx rickshaws are heavier than the Atul

• Fabrication stores of the BIW department

The Storage department looks something like this

The BIW department in Atul

The very first step in the production process is BIW

Spot Welding Method Spot Welding Machine

• CO2 Gas Welding:

The material to be welded with is made the electrode in this case.

material. CO2 is used as a shield, it protects the welded material and

CO2 Gas welding method CO2 Gas welding Process

Brazing is the mush like soldering a metal. In Brazing, a metal, in this

Grinding is the process of removal of any extra metal

teeth. The metal teeth are rotated and the grinder is

2. The second Quality check is done after the whole chassis is

3. The third Quality Check is done by the Quality Check Department

The chassis is now ready to be transported to the next department

Chassis of a Rickshaw In the final stages in the BIW department

CED is the department where the chemical processes happens. The

The chassis or the body is connected to a metal frame by chains. The

The Pre-Degreasing tanks look something like this

08. Step 8 & 9:

The process takes 180 seconds to complete. The temperature of

Body out from the CED Tank

The whole process takes about 1320 seconds or 22 minutes (when