INDUSTRIAL TRAINING REPORT

TAFE MOTORS AND TRACTORS LIMITED

(EICHER TRACTORS LIMITED, MANDIDEEP)

SUBMITTED BY

PRADYUMN MANGAL
Enrollment No. 0902ME171038

Bachelor of Technology

(Mechanical Engineering – 3rd SEM)

(Under the Guidance of)

Mr. Krishnakumar Yaduvanshi Mr. Dinesh Narayan Bokade

(HR manager) (SR. MANAGER, POST PRODUCTION)

 DECLARATION

I hereby declare that the project work entitled ‘ Visionary Small and Medium Enterprises/
VSME & RFT’ is my original work carried out at EICHER TRACTORS A UNIT OF TAFE
MOTORS & TRACTORS LMITED MANDIDEEP, BHOPAL as requirement of THREE
WEEKS project in partial fulfillment for the award of degree of Bachelor of Engineering
(Mechanical engineering). TECHNOCRATS ISTITUTE OF TECHNOLOGY & SCIENCE
Bhopal under the guidance of Mr. VIKRAM PANDEY during 03rd JULY to 23th JULY
2019.

PRADYUMN MANGAL

(0902ME171038)

DATE: 23.07.2019

Certified that the above statement made by the statement made by the
student is correct to the best of our knowledge and belief.

Mr. Krishnakumar Yaduvanshi Mr. Dinesh Narayan Bokade

(HR manager) (SR. MANAGER, PRODUCTION)

 ACKNOWLEDGEMENT
First and foremost I would like to thank my University for giving me
the opportunity to pursue my training at Eicher tractors, Bhopal.

Then I would like to thank my training manager Mr.

Vikram Pandey and my reporting mentor Mr. Jai Prakash & Dinesh
Narayan Bokade for their guidance and continued encouragement
during the preparation of this major report. Indeed it was a matter of
great felicity and privilege for me to work under their aegis. I express
my thankfulness to them for their dedication, inspiration, lively
interest and patience. Without which it would have been impossible to
bring the project to near completion.

From my college I would like to thank Mr. Sohal Khan

(Director of training and placement) & Dr. Chaitanya Sharma (Head
of Mechanical dept.) for giving me a unique opportunity to come to
Eicher tractors, Bhopal.
I also pay my profound gratitude to all my employees of
Eicher tractors for making my stay in the company fun and
knowledgeable experience. In the end I will like to pay my gratitude
to, Human Resources department (Eicher tractors, Bhopal) especially
Mr. Krishna Yaduvanshi (HR) for finding me worthy in this
company and choosing me as one of their intern. I thank them for
their undying support throughout this tenure.
 PREFACE

Every student of bachelor of technology in Mechanical

Engineering has an essential requirement to do internship in any of
the well reputed organization. The purpose of this program is to
acquaint the students with practical applications of theoretical concept
taught to them during conduct of their course.

Really, it was a well opportunity to have a close comparison to

theoretical concept in practical field. This report may depict
deficiencies on my part but still it is an output of a student’s effort for
which I beg pardon.

The output of my analysis is summarized in a shape of internship the

contents of the report shows the detail of sequence of these.


 INDEX

Chapter 1
1. RFT
 Objective
 Working

Defects
I. Black paint on power steering spindle
II. Scratch on Bonnet, Bumper, Mudguard and Fuel tank cover
III. Harness of wire
IV. Sticker miss

Chapter 2
2. VSME
 About
 Part Identification
 Time Study

Chapter 3
3. Terracon Weight
 Aim
 Theory
 Analysis
 Procedure

Chapter 4
4. ACTION PLAN
 Aim
 Theory
 Procedure
  Learning

Chapter 5
 Conclusion
 Chapter 1

RFT (RIGHT IN FIRST TIME)

Objective - To improve the overall RFT for all models.

Basically the objective of this project is to ensure that all the activities occurring in assembly
shop are right and does not require any kind of re-work after the assembly of tractor. This
will decrease defects per unit tractor which in turn will increase the overall RFT.

Formula for calculating RFT-

RFT (%) = (No. of tractors direct pass through D1, D2 & D3 stage/ Total no. of tractors
inspected)*100

(D1, D2, D3 are quality check points where checking is done weather operator cause any
defect or not and if defect is found rectified by rework man)

Working-First time means correct in first go. When process input is 100 finished products
then the first time right is 100%. Any input which is not passing through first time because of
any reason will lead to some sort of rework and will reduce the first time right percentage.
My main Focus is to find defect caused by assembly or due to wrong process followed.

Defects-

I. Black paint on power steering spindle.

Problem-Black paint is identified on PS spindle on various quality check points.
Effect –Due to black paint it prevents steering from rotation and if steering is forced
to rotate o ring present in cylinder get broken.
Cause-Masking is done to prevent spindle from getting painted. After analysis it is
found defect is due to improper masking. Operator was using improper cutting tool.
Wrong procedure for cutting was followed.
Solution-Proper tool for cutting was suggested; Vice for holding masking cylinder is
suggested; new procedure for Masking is suggested.
II. Scratch on Bonnet, Bumper, Mudguard and Fuel tank cover
Problem-At various quality check points like D1, D2, D3 .Scratches on bonnet
bumper and mudguard is always in top 10 defects of every month.
Effect-Tractor loose shining and looks bad, chances of rusting increases.
Analysis-After analysis list of probable causes of scratch is made and started
monitoring every cause. Some of causes are in list during improper tooling,
monitoring loading, unloading. Apart from this during sub assy. of bonnet, mudguard
& fuel tank are arranged into 4 set single trolley and the area is so congested.
 Current procedure – firstly the mudguard & fuel tank arranged into a 4 set trolley
and during sub assembly it again put into a single mudguard trolley.

Solution – In post painting during sub assembly the bonnet, mudguard & fuel tank are
bring into a single-single trolley for sub assembly so that the scratches which are
generated due to fouling is so reduced.
III. Sticker miss
Problem-There is some safety sticker to be attached on battery box which operator
miss may times.
Analysis-Process of operator is studied what operation he does and how much time it
take and cause of miss is analysed.
Solution-It was find out operator has limited time to work on tractor on his station.
He paste sticker at end of after all process. Many times due to lack of Time or in hurry
he misses that process. In solution this process moved from last to first position and
there is decrease in defect of sticker miss.

IV. Harness of wire

Problem-routing wrong, clamping not done, fouling, connection not done .
Analysis-After analysis if was find out that the operator was following wrong
procedure
Solution-Process is improved .New process in introduced depending on time it take
and time available at his station. OPL provided to operator for proper routing & given
OJT to operators.
 CHAPTER 2

VSME

(Visionary Small and Medium Enterprises)

About-VSME is tool helps in development and increasing production of small and medium
scale industries. Main objective of VSME is “Make one, Sell one” means to reduce
inventory as much as possible. Other goals of VSME are to increase productivity and to
reduce work load on operator, eliminate all possible causes of defect occurring during
assembly and many more. VSME program nurtures manufacturing transformation. It aims to
create a win- win relationship between customers and suppliers. In VSME we make a plan of
whole day of production and focus is to achieve the objective. It also focus that activities are
carried out as per plan. By applying this tool it control the unwanted activities and increase
the productivity of a whole day. It is more convenience and economical for industrial purpose
therefore this plan is growing different areas now these days. Under this plan there are so
many activities are take place.

 Part Identification-
Aim-My Goal was to make part identification for operator and store man easier.
Analysis-There was increase in wrong part or hardware fitment because of which
rework increasing and RFT is decreasing. Other issues are store man supplying wrong
Hardware to wrong person. Just in one area (pre-Painting) there are more than 10
racks with more than 300 types of hardware To have proper supply and identification
of every hardware A list of hardware with item code description ,supply location and
bin location is made. Then we made stickers of every part with bin location and item
code and paste it on every bin such that there is no mistake by store man in supplying
products.

REFLECTION-I learned about so many different hardware. How these are used in
assembly. How these are differentiated depending on many factors.
 TIME STUDY

Aim – My Goal was to study about different models and calculating their time of assembly
in pre painting line.

Analysis- I analysis that there were so many activity are take place in main line assy.
in pre painting which are undesirable, because of that the current time was different
than actual time of main line assy. process and the extra time was taken to make a
tractor. Therefore the efficiency of main line and the rate of productivity are
decrease.By time study we have find the NVA( non-valuable activity) in main line
assy. and reduce them by another activities which are desirable. The different tools
are provided to the workers so that the time has become reduced for making a tractor.
After that we have find the rate of productivity is increases 20 to 30 per. in few
months.

Production related formulas:-

a. Line Efficiency = total minutes produced *100/ total hour worked *60

b. Man power utilization = Actual production output/ target production output

c. Cycle time = Actual time required for a worker to complete one cycle of his process

d. Time efficiency = total require time / total no of potential participants.

e. Productivity = amounts of units produced/ employee labor hrs.

.
REFLECTION – I learned about how to find the different data like efficiency of main line, calculating
the number of actual workers, productivity etc.
 CHAPTER-3

TERRRACON WEIGHT

AIM-To introduce assembly of Terracon weight on Main Line.

Theory-Terracon weight is used in place of bumper.it consist of 6 plates each of weight 17kg
net weight 102kg.Early it was attached in D3 by hand one by one then tighten by nut and
bolts. It took approx. 15 min per tractor.

Analysis-My aim was to introduce assembly of Terracon weight on line. Per station approx.
time allotted is 4.5 min. I did time study of each station and analyzed where assembly is
possible such that it don’t effect sub assembly of any other part near that station. A station
was selected and we started working on reducing assembly time from 15 min to 4.5 min.
Various methods were tested finally we achieved assembly time in 4.5 min.

Current procedure-Firstly weights are divided into 2 equal sets. These sets are tighten with
nut bolt. Each set lifted by tackle at RHS and LHS and assembly is made on Tractor. At last
both sets are Tighten by big nuts and bolts and tackle is removed.

Conclusion-In last there is a lot to learning and gain of experience through this process. I
applied time study concepts which I learned in college. When we were thinking of tackle
there were very complex designs coming in my mind but my mentor said make it simple and
in end simple belt is connected biggest reason for selecting belt is it won’t generate much
scratches.
 CHAPTER -4

ACTION –PLAN

Aim – To make the Action Plan chart for post painting.

Theory-An action plan is a document that lists what steps must be taken in order to achieve a
specific Goal. The purpose of an action plan is to clarify what resources are required to reach
the goal, formulate a timeline for when specific tasks need to be completed and determine
what resources are required. This typically includes an outline of goals, objectives
,measurements, action steps and responsibilities for each step.

PROCEDURE -

Creating an Effective Action Plan:-

1. Choose an appropriate goal and clearly define your objective.

2. Use a team to create your action plan
3. Choose action steps that are concrete, measurable and attainable
4. Identify time & who is responsible for each action steps and who will be supporting
them.
5. Define what action will be taken by you and result that you find after action.

Reflection :- An action plan is a plan that contains enough detail to achieve an

objectives or goals. I learn about the systematic way of procedure to identify
the problems and how to reduce them by applying definite action.
 Chapter -5

Conclusion

On the whole, this internship was a useful experience. I have gained new knowledge, skills
and met many new people. I achieved several of our learning goals. I got insight into
professional practices currently advocated in the industry. I learned different the different
facets of working within a well-established industry. Related to our study I learned more
about the manufacture, assembly and testing of three phase distribution transformers.

Furthermore I have experienced that it is of importance that education is objective and that
I have to be aware of industrial aspects of the topics I study this internship program was not
one sided, but it was a way of sharing knowledge, ideas and opinions.

The internship was also good find out my strength and weakness. This helped us to define
what skills and knowledge I have to improve in coming time. I can confident assert that the
knowledge I gained through this internship is sufficient to contribute towards my future
endeavors. At last this internship has given us new insights and motivation to pursue a
career in core mechanical departments.