DECLARATION

This report was written by Nikhil verma, a student in the Electrical

Engineering Department at Laxmi devi institute of engineering and
Technology (LIET) it has not been altered or corrected as a result of
assessment and it may contain errors and omissions. The views
expressed in it together with any recommendations are those of the
students.

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 INDEX
TOPIC PAGE NO
 Declaration 1
 Index 2
 Acknowledgement 3
 Abstract 4-5
 Meaning of project 6-7
 Introduction of tafe 8-11
 Company profile 12-13
 Introduction of eicher engine 14-15
 Eicher engine product range 16
 Various engine specification 17
 Models of engine gensets 18-19
 Details of specification of model 20-25
 Technical specification of 25 KVA DG 26-27
 Modles of eicher tractors 28-31
 Introduction of plant layout 32-34
 Working committee for TPM 35
 Function of TEAM 36-38
 Conclusion 39

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 ACKNOWLEDGEMENT
Life of any human being is full of interaction. No one is completely self
sufficient by himself. In our daily life we go ahead by acquiring
something from each other. This project work of mine would not have
re ached its fulfillment hadn’t been the guidance shown to me by the
various people.

I am extremely thankful to the management of EICHER ENGINES

ALWAR for giving me the opportunity to carry out my project
assignment as a summer trainee. I would like to express my profound
gratitude to Mr. G. D. Agarwal (Manager of HRD, Eicher Ltd., Alwar) for
giving me the opportunity to do my summer internship in the
Engineering Department.

I am indebted to my project guide MR.Nitin Tiwari for his support and

guidance. His continuous feedback and encouragement contributed
toward making this project a good learning experience for me.

My Special thanks to all the employees of EICHER ENGINES, who help

me throughout this entire project.

I pay my deep regards to my parent and friends whose blessings made

this project work a success.

NIKHIL VERMA
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 ABSTRACT
Summer training in business organization infuses among students a
sense of critical analysis of the real engineering problems to which they
are exposed. This gives them an opportunity to apply their conceptual,
theoretical, imaginative and technical skills in a real life situations and
to evaluate the results there of.

I am lucky that I got an opportunity to work at

EICHER ENGINES LTD. I visited the concern for 8 weeks and prepared
my report and the study done is divided into various chapters to get full
knowledge. The training has helped me boosting up my confidence and
determination; which will help me to face real life situations in years to
come.

This project report is a comprehensive work, with lucid and systematic

presentation of subject matter. Each concept is explained with number
of illustration and diagrams for easy understanding. Report also
provides information about organization, their profiles, and history,
product and service areas.

Preface report, provides conceptual framework and explains the

assembling of an engine and its various parts. This report also tells

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about the Control Plan. This report is written account of what I learnt
and experienced during my training. I wish those going through it, will
not only find it readable but will also find it as a useful information. I
trust and believe that the blinding of my academic and practical
experience has made the report useful not only to the company but
also to engineer.

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 MEANING OF THE PROJECT
The meaning of the project is to give physical existence to the brain
ideas and thoughts. Project is a great source to develop technical skills
in the students. During the programming of the project, students go
through different problems and experiences. A student gets a chance to
climb on the roof of practical, step by step through ladder of theory.
Thus, he gets adequate practical knowledge of economizing. A very
important aim of a project is that it should be as feasible and
economies as possible.

Actually the word project consists of seven alphabets; each of them has
separate meaning.

“P” FOR PLANNING

Planning is must to start a work or scheme. If planning is good and

impressive, half work is done.

“R” FOR RELIABLE SOURCES

Practical and theoretical material, an inspiring guidance and assistance

is achieved from different sources to promote the functions of planned
area.

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 “O” FOR OVERALL EXPENSES

Overall expenses to provide final design to any project are also

considerable. These expenses are analyzed for each concept and
methods of working on the computer.

“J” FOR JOINT EFFORT

Joint efforts are very necessary for programming and results of any
project. Many a time’s battles are won by help from others.

“E” FOR ECONOMIC FEASIBILITY

It is important that the planned scheme is economically feasible. It is a

must to analyze & estimate too for completion of the project.

“C” FOR CONSTRUCTION

After analyzing the program, complete project report is done to give

logical existence of planned scheme.

“T” FOR TESTING

Testing of program is done before submitting the project. After testing

it is judged whether the project is OK for use or not

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 INTRODUCTION OF TAFE:
Chennai based, Amalgamations Group which is one Tractors and Farm
Equipment Limited (TAFE), is a member of the Rs 37000 Core of India's
largest Light Engineering Groups. Apart from being among the top five
tractor manufacturers in the world, TAFE also has a diverse interests in
the manufacturing of Diesel Engines, Automobile components, Tractors
and related farm machinery, Lubricants, Panel Instruments, Hydraulic
Pumps, Engineering Plastics, Storage Batteries, Paints, Engineering
Plastics, Automobile franchises and Printing apart from interests in
Agribusiness, book selling and publishing. The group's leadership
technology is based on foreign method. TAFE was launched in 1961 to
produce and market different Massey Ferguson tractors and similar
farm equipment in India. Being one of the largest tractor manufacturers
in India, TAFE aims at becoming the first choice of customers in India
and to make its mark in international markets. TAFE aims at delivering
the most quality oriented services due to which it has become the first
choice of the buyers. Because of its experience in the same field, buyers
also rely on it without giving it any second thought.

Its manufacturing units are located in Tamil Nadu, Karnataka, Madhya

Pradesh, Rajasthan and Himachal Pradesh. The TAFE group’s major
business area is Tractors, where they produce a range of Tractors from
24 to 90 HP under the Eicher, Massey Ferguson and TAFE brands. The
group is now a close second in the Indian Tractor market and its
tractors have been the first choice of the farming community. The

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group has significant exports to South Asian, European, and US
markets. In December 2003, TAFE acquired Eicher’s tractor plant at
Mandideep, Engines Plant at Alwar and Transmission plants at
Parwanoo through the formation of a wholly owned subsidiary, TAFE
Motors and tractors Limited (TMTL).

TAFFE

Eicher Tractors Eicher Engines Eicher Tractors Gear

Mandideep, Bhopal Alwar, Raj. div. Parwanoo

TAFE is an ISO 9000 and ISO 14001 certified company. Its quality
orientation is reflected in the fact that in TAFE quality is not something
that is inspected or input to its products. It is an innate desire to be the
best that is with in all of us at work, and at home and ripples out into
the world around us.

TAFE’s other business areas produced products that are preferred

suppliers to leading OE manufacturers of automobiles, consumer
durables and IT applications.

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TAFE has a joint venture with AGCO Corporation, headquartered in
Duluth, Georgia, which is amongst the largest manufacturers, designers
and distributors of agricultural equipment in the world. Its products are
marketed in more than 140 countries. With a chain of more than 500
dealers, branches, service outlets as well as its own sales offices and
depots all across India, TAFE is inclined to deliver complete farming
solutions to its buyers thus in a way enhancing farm productivity,
prosperity and profits. Besides achieving heights in the tractor market,
company has spread its reach to several other fields as well.
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). TAFE, through TAL
is also involved in the marketing and distribution of lubricants and
greases for tractors through its dealer network. TAFE is also involved in
the packaged power industry through its Power Source Division. TAFE
also has a section for the manufacturing of Hydraulic pumps and Gears
for tractors. The company also produces panel instruments, not only for
captive use but also to meet the demands of the growing automobile
industry in India TAFE has broadened its sphere into Engineering
plastics and production of tools and dies for this industry. Its
Doddaballpur plant, being the major supplier of the needs for precision

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plastic components of the white goods, IT, automobile industries, has
clamp capacities ranging upto 1300 tons.

TAFE started its production of the popular tractor model, Massey

Ferguson 1035 in 1961. Now they manufacture tractors under two
brand names, TAFE and Massey Ferguson. The company has a ready
export market in USA, Canada, South Africa, Kenya, Tanzania, Sri Lanka,
Bangladesh, Maldives, Australia, New Zealand and Turkey. TAFE has
technical collaboration with leading companies like Massey Ferguson,
U.K, which is the leading manufacturer of tractors in the world,
Mckechnie Plastic Components and Amco-Yuasa batteries, Japan. The
company is also planning to open a new assembly line in Madurai to
meet the growing demand of its tractors world wide.

TECHNICAL TIEUP:-

Technology transfer from Ricardo of UK for developing air cooled

engines

Technology transfer from SISU (VELMET) Finland, for higher

horsepower.

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 Eicher Engines Alwar

1. COMPANY’S PROFILE: -

Office and Factory : TAFE Motors and Tractors Limited

Address Itarana Road,
Alwar – 301001 (Raj.) India.
Depots : Six
Product : Automotive Engines
Stationary Engines
Spare Parts for these engines
Year of : 1982
establishment
Type of Ownership : Limited company
Other system under : TPM (Total Productive Maintenance)
implementation 5S

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 (Seiri,Seiso,Suketesu,Seiton,Shitsuke)
JH (Jishu Hozen)

KK (Kubatsoo Kaizen)
Customer category : Tractor Manufacturers
Individual users, through Engine
Marketing Dept.

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2. INTRODUCTION OF EICHER ENGINES:
The company Eicher Engines Alwar (EEA) till December 2003 was known
as Eicher Tractors, Alwar (A unit of Eicher limited) .This Company is
situated at Itarana road Alwar covering an area of 17.8 acres producing
engines up to 62.5hp engine. The company has been rechristened as
Tafe Motors and Tractors Limited (TMTL), Alwar and is being
functioning as a separate business unit.
Tafe Motors and Tractors Limited, Alwar has adopted the principles of
Total Quality Management (TQM) not only to increase technology
dependency, product and process conformance and product reliability,
but more fundamentally in the drive towards a vibrant human culture,
in the nurturing of quality mind and the growth of each individual
personnel as an intrinsic part of the whole.
The concepts of training & development, SGA, kaizen, 5-S, Jishu Hozen,
Poka Yoke, Cross functional teams, sports & cultural activities and TPM
have become a way of life for the company.
The company has been thrice awarded national productivity council
recognition towards productivity performance the company Eicher
Alwar is operating a quality management system since the year 1996.
Company was certified ISO-9001. Eicher engines, Alwar was certified for
ISO 9001-2000 & ISO 14001-1996 in July’2004.The Eicher is also TS
16949 Certified Company which is applicable for only all automobile
companies Eicher has always contributed its bit towards the
improvement and conservation of environment, hospitals, population
control, culture & heritage conservation and up liftmen of the society.
Major activities are:

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The company (Eicher engines, Alwar) helps the local authorities in
maintaining the aesthetics of the city by taking care of a road-crossing
garden termed “Ashoka circle” in Alwar. The company celebrates its
annual day by involving all the employees and their families. The
marketing office of the company is at Faridabad and it operates 6 depot

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3. EICHER ENGINES PRODUCT RANGE:
This unit of Eicher is producing one of the world’s most economical
tractor engines which include 24 HP, 30 HP, 35 HP, 42 HP 4-Strokes Air
Cooled Diesel Engines and 61 HP 4-Strokes Water Cooled Diesel Engines
The assembly of engine is divided into four parts. These are known as
115, 298, 398 and Valtra assembly.
The above numbers are given according to their characteristics, such as
–

For 115 - 1 means single cylinder

15 stands for 115 mm bore

diameter.

For 298 - 2 means double cylinders

98 stands for 98 mm bore diameter.

For 398 - 3 means triple cylinders

98 stands for 98 mm bore

diameter.

For Valtra - This technology is developed by

Valtra Inc., Finland.
In the machine shop there are 7 machining lines where some main
parts of engine are machined. After, machining all parts goes to the
assembly lines for assembly.

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4. VARIOUS ENGINE SPECIFICATIONS:
Table: 1

Engine No. ES-222 ES-322 ES-321 ES-422 ES-421 ES-461 ES-621

No. of Cylinders 1 2 2 3 3 3 3

Power (In Hp) 22 24 32 38 45 52 61

Diesel Tank(Lt) 30 45 45 45 45 45 45

Fuel
Consumption In 175 164 164 160 160 - -
(gm/bhp/hr)

Lubricant
Less than Less than
Consumption In 1.5 .5 .5 - -
0.5 0.5
(gm/bhp/hr)

Cooling Air Air Air Air Air Water Water

Handle/
Starting Self Self Self Self Self Self
Self

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5. MODELS OF EICHER GENSETS:

Fig 1: Eng.222HS Fig 2: Eng-322-ES

Fig 3:Eng.881ES (62.5KVA) Fig 4: Eng.322ES

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 Fig 5:
Eng.222ES
Fig 6:
Eng.461ES/621ES

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6.DETAILES SPECIFICATION OF MODELS

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 MODLE – 222ES AGRO
Type – Air cooled DI Diesel Electric start

No of Strok - 4

No of cylinder – 1

Bore xStroke – 115x150 (mm)

Cubic capacity – 1558cc

Power out put – 20HP

Rated speed – 1500 rpm

SFC - <175gms/bhp-hr

Engine weight (kg) with fly wheel – 350

Mechanical efficiency - >85%

Weight – 350 kg

MODLE – 322ES- GENSET

Type – 4-Stroke Air Cooled DI Diesel

No of cylinder – 2

Bore x Stroke – 105 x125 (mm)

Cubic capacity – 1963cc

Power out put – 23.8 HP

Rated speed – 1500 rpm

S F C - < 164 gms/bhp – hr

Engine weight(kg) with fiy wheel - 325

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 MODLE
MODLE
– 222HS
– 881 ES GENSET
Type –Type
Air –cooled
Inline,Water
DI Diesel
Cooled DI Turbo IC

Aspiration
No of–cylinder
Natural – 3

No of Bore
stroke
x Stroke
– 4 – 108 x120

No of Displacment
Cylinder 1 3298 cc

Bore xCompression
Stroke – 115ratio
x150–(mm)
17: 1

Firing order 1- 2- 3

Rated speed – 1500 rpm

Power output – 80 HP (62.5 KWA)

SFC - 159 gm/ kw – hr

MODLE – 322 ES
Type – DI

Engine fule – HSD

Aspiration – Natural
Displacement 1558 cc
No of stroke – 4
Compression ratio – 17.8: 1
No of cylinder – 2
Rated speed – 1500rpm
Bore x stroke – 100 x125 (mm)
Rated power – 20HP
Displacement – 1963cc
Direction of rotation – Anti clock wise
Compression ratio – 17:1
High ideal speed – 1600 rpm
Rated speed – 1500
Low Ideal speed – 500 rpm
Rated power – 23.8 HP
Mechanical efficiency - >85%
Mechanical efficiency - >85%

NAME = NIKHIL VERMA Weight

Page – 350 kg
22 Weight – 360 kg
MODLE – 461 ES (30- 35kw)
Type – Water cooled DI Diesel
 TECHNICAL SPECIFICATION OF 25 KVA
DG SET:

MODLE – 25 KVA ULTRA COMPONENT

Dimension – L= 2250 W= 900 H = 1290 ( cm)

Noise level – 72 dba at 1mt

Acoustic Insulation – FU PUfoam

Phase ( option) – 3ph. Or 1ph

Fule tank capacity – 100 lt

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Voltage ( option) – 415 VAC , 230 VAC

Power factor – 0.8 lag

Amps – 34.75@ 415 VAC & 109 @ 230 VAC

Frequency – 50 HZ

Engine modle – 422 ES

Engine power – 25 KW / 34 HP

Rated speed – 1500 rpm

Aspriation – Naturally aspriated

Cooling – Air cooled

SFC at 100% load – 160 gm/bhp/hr

Conopy weight – 350 kg

Gross DG weight – 900 kg

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 7. MODLES OF EICHER TRACTORS:

(1) Eicher 242NC: 24 Hp, 4-Stroke, air-cooled

(2) Eicher 312: 30 Hp, 4-Stroke, air-cooled

Diesel-Powered Engine.

(3) Eicher 364: 35 Hp, 4-Stroke, Air Cooled

Diesel-Powered Engine

Table 1:

HP Range Variants
 Air Cooled – Wet And Dry Land
 Dual And Single Clutch
35 HP
( 364)

(4) Eicher 368 SUPER DI:

Table 2:

HP Range Variants

37 H.P.  Air Cooled – Wet And Dry Land

 Dual And Single Clutch
 Sheet Metal( Standard And Super DI)

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 (5) Eicher 380
Table 3:

H.P. Range Variants

35 HP  Water Cooled
 Speeds ( Overlap / Non Overlap )
 Dual And Single Clutch

(6) Eicher 485:

Table 4:

HP Range Variants
 Air Cooled – Wet And Dry Land
 Dual And Single Clutch
45 HP
( 485 SUPER DI)

(7) Eicher 480:

Table 5:

HP Range Variants
 Water Cooled
 Dual And Single Clutch
45 HP
( 480)

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 EICHER 368

EICHER 242 EICHER 312

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 EICHER 380 EICHER 480

EICHER485 EICHER 386

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 8.INTRODUCTION OF PLANT LAYOUT :

The plant layout can be design on the basis of few sound principles of
plant layout are

1. Integration
2. Minimum Movement and Material Handeling
3. Smooth and Continuous Flow

4. Cubic space utilization

5. Safe and improved enviroment

6. Flexibility

These all sound principle are used for the designing of the plant lay out
of EICHER ENGINES (A unit of TAFE Motors and tractors Ltd.)

Plant layout may be classifide in two fundamental types

1.Process layout

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2. Product layout

The plant layout of EICHER ENGINES is process based layout . The

process which is performed on machine shop .The machine shope is
devided in seven machine line according tothe machining operation on
component . These machine lines are

1. Carter line (Single cylinder crank case)

2. Head line (Cylinder head line for both multi as well as single cylinder
engine)

3. Crank case / Crank housing line (Multi cylinder)

4. Control Housing line (Multi cylinder)

5. Control Housing line (Single cylinder)

6. Liner line

7. Balancing line.

We receive the casting of respective component from various vendor

companies. In machine shop we performing various machining
operation according to the sequence like facing, dawdling milling,
drilling, reaming and tapping etc operation are done in machine shop
after that the finished component goes to the different assembly.

 There are three assembly line:

1) Assembly- 115

2)Water coolded engine Assembly

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3)Multi cylinder engine Assembly

In this plant per day 253 all types of engine is assembled . There are 70 -
3cylinder air cool engine , 13- 3cylinder water cool engine , 30-
2cylinder engine , 140 – single cylinder engines are assembled per day in
plant.

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 9. WORKING COMMITTEE FOR TPM:

Fig.:3

This team is fully responsible for TPM work in this team all type of
member is involved from all different work but mejor work load on
maintenance department.

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 10. FUNCTION OF TEAM:
Main function of team is found out the problem in the machine. The
team leader and all members watched the machine daily at 11:00 to
11:20. During this 20 minutes period all team members watched
machine and found problem the operator of the machine is also team
member. There are two types of tags is used in the TPM process. They
are Red tags and White tag .There are some meaning of colure of tags.

1. ANALYSIS OF BREAKDOWN:

Breakdown: “in a simple way breakdown means failure of a machine in

such a way so that it cannot be operated and the production on that
machine will stop until machine is repaired”.

Breakdowns in a machining shop results loss of productivity because in

machining line if a machine breakdown occur that will cause stop of
whole machining line.

Reasons for breakdown: breakdown reasons can be classified in three

categories

 Mechanical reason : Under this category failure of mechanical

component in machine, failure of hydraulic units,
 Electrical reason: Under this category any fault in wiring, short
circuit, proxy wire and limit switch setting and connections, PLC
related problem

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  General reason: In general reasons less maintenance of machine,
overloading, manmade mistakes, loose wiring, and leakage
vibration.
 CONCLUSION:

 By implementation of TPM we can reduce plant machine

breakdown time and loss of production due to breakdown of
machine be reduced. Some other benefits of TPM are reducing
maintenance cost and increase service life of machine because
small problem is detected with help of TPM process.
 By analysis of breakdowns we can take appropriate action to stop
occurring of repetitive problems in a machine. Also prepare
predictive maintenance plan to reduce future breakdowns. This
analysis helps to give information about machine that frequently
breakdown so that we can take preventive and predictive
maintenance plan for such machines and reduce breakdown

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 TOTAL QUALITY

SECULAR

A POLITICAL

EITHICAL

FAIRNESS

TAFE’s

VALUES HUMAN
APPROACH

OPENNESS

TRUST

EMPOWERMENT
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 CUSTOME

CONCLUSION
On the whole, this internship was a useful experience for me. I have
gained new knowledge, skills and met many new people. I achieved
several of my learning goals. I got insight into professional practices
currently advocated in the industry. I learned the different facts of
working within a well established industry. Related to my study I
learned more about the manufacture, assembly and testing of breakers

Furthermore I have experienced that it is if important that education is

objective and that I have to be aware of the industrial aspect of the
topics I study. This internship program was not one sided, but it was a
way of sharing knowledge, ideas and opinions.

This training was also good to find out what our strengths and
weaknesses are. This helped us to define what skills and knowledge we
have to improve in the coming times. I can confidently assert that the
knowledge i gained through this training is sufficient to contribute our
future endeavours. At last this training has given me new insights and
motivation to pursue a career in core electrical departments.

With warm regards

Yours faithfully

NIKHIL VERMA

3rd year EE diploma

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