FINAL TRAINING-CUM-PROJECT REPORT

B.TECH

INDUSTRIAL TRAINING PART-1

Name of MSM Ltd. Swaraj Division, Plant 2

Company / Organization

Address Chapar Chiri, Mohali, Punjab-140307

Period of Training 01-01-2023 to 30-04-2023

Project Report Learning of New Models

Whether Certificate from Company Yes

attached

TRAINING MANAGER/GUIDE SUBMITTED BY

Name: Rajinder Sharma Name: Priya Verma

Designation: Manager Branch: Mechanical Engg.

Department: Assembly Univ Roll No. : 2008135

Seal: Date of submission:

Email: 9532priya@gmail.com

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 FINAL TRAINING-CUM-PROJECT REPORT

B.TECH

SOFTWARE TRAINING PART-2

Name of INFOWIZ ( A Software Solution )

Company / Organization

Address SCO 118-120, (Near State Bank of

India), Sector 34A, Chandigarh, 160022

Period of Training 01-05-2023 to 30-06-2023

Project Report Auto CAD 2D & 3D

Whether Certificate from Company Yes

attached

TRAINING MANAGER/GUIDE SUBMITTED BY

Name: Mrs. Kitty Sharma Name: Priya Verma

Designation: Training Manager Branch: Mechanical Engg.

Department: Auto CAD Univ Roll No. : 2008135

Seal: Date of submission:

Email: 9532priya@gmail.com

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 ACKNOWLEDGEMENT

Sometimes words fall short to show gratitude, the same happened with me during this project.

It was a great opportunity for me to work with Swaraj Tractor division, pioneers in the field of farm
equipment manufacture, a part of Mahindra and Mahindra Ltd. I am extremely grateful to the entire
team of Swaraj Tractors, SAS Nagar (Mohali) who has shared their expertise and knowledge with me
and without whom the completion of this project and my industrial training would have been virtually
impossible.

My sincere gratitude to Mr. Satya Dev Sharma (HOD of Assembly, Swaraj division, Mahindra and
Mahindra Ltd, SAS Nagar(Mohali)) for providing me with an opportunity to work with them as a
trainee who has provided me with the necessary information and his valuable suggestion and comments
on bringing out this report in the best possible way.

I feel great pleasure to thank Mr. Lavneet Yadav(Manager) and all other team members. I am also very
thankful to my friends, partners during the training period and all the workmen at the Swaraj Division,
Plant -2 and who helped me in the completion of my projects. I am thankful to that power that always
inspires me to take right step in the journey of success my life.

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 TABLE OF CONTENTS

Report TOPIC Page No.

No.
1. Introduction 9-14

2. Safety & General Training 15-19

3. Department Introduction 20

4. Major Learning 21-22

5. Project Completed 23

6. Major defect 24-25

7. Important Concept Learned 26-28

8. NSM Models 29-33

9. Various Departments in Swaraj 34-76

8. Conclusion 77

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 1. Introduction
India is mainly an agricultural country. Agriculture accounts for approximately 25 percent
of India’s GDP. Agriculture in India is the means of livelihood of almost two thirds of the
workforce in the country and employs nearly 62 percent of the population. It accounts for
13 percent of India’s exports. About 42 percent of India’s geographical area is used for
agricultural activities. It is therefore

considered a vital sector of the Indian economy.The Indian tractor industry is the largest
in the world, accounting for one third of global production. The other major tractor markets
in the world are China and the USA. The global spotlight on tractor manufacture in terms
of unit volume seems to be swinging away from the USA, UK and Western and Eastern
Europe towards India and China, where growth in the number of producers and the total
volume of production in recent years has been impressive. Until 1960, the demand for
tractors was met entirely through imports. Indigenous manufacture of tractors began in
1961, but India continued to import tractors to bridge the total volume needs up to the late
1970s. The Indian Tractor Industry has come a long way since then. Volume growth in the
past four decades show a compound annual growth rate of 10 percent, despite seasonal
variations that cause natural fluctuations in the demand for tractors, subsequently
impacting the industry volumes.

The Indian tractor market is traditionally a medium-horsepower market consisting of

mostly 31-40 hp, which constitutes almost 51 percent to growth in this category. Growth
of the Industry is closely related to growth in this category. In other-size categories, 41-50
hp category achieved the second highest growth of 34 percent and constitutes 24 percent
of the total market share. The rest of the

market share is largely with the 21-30 hp category followed by the category of tractors
having more than 50 hp.

The Indian Tractor Industry has numerous challenges, some of them being:-

1. Reducing the average age of tractor buyers from the age group of above 40 to younger people

2. Development of new products using latest technology and advancements in the field of

electronics and mechatronics and making the tractors more comfortable, stylish and yet
keeping them in range of a farmer.

3. Reduction of emissions in accordance with the new international emission standards

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Timeline of Mahindra Swaraj :

Year Event

1965 Govt. of India's research institute (CMERI) at Durgapur initiates design and
development of SWARAJ tractor based on indigenous know-how.

1970 Punjab Govt. through PSIDC acquires SWARAJ tractor's design from CMERI
and establishes Punjab Tractors Ltd. (PTL) for its commercialization.

1971-73 PTL sets up SWARAJ Project for 5,000 tractors per annum at a capital outlay of
Rs. 37.0 million with an equity base of Rs 11.0 million.

1974 Swaraj 724 (26.5 HP) tractor commercially introduced.

1975 2nd tractor model SWARAJ 735(39 HP) developed by own R&D,

commercially introduced.

1978 3rd Tractor model SWARAJ 720 (19.5 HP) developed by own R&D,
commercially introduced. Maiden equity divided declared.

1980 Guided by social concerns and responsibility, PTL takes over PSIDC's sick
scooters unit - Punjab Scooters Ltd. (subsequently renamed as SWARAJ
Automotives Ltd.)
India's first Self propelled Harvester Combine - SWARAJ 8100 developedby
own R&D, commercially introduced.
SWARAJ Foundry Division set up in Backward area.

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1981 Issue of maiden Bonus Shares (2:5), paid-up equity moves to Rs 15.4 million.

1983 4th Tractor Model - SWARAJ 855 (55 HP) developed by own R&D,
commercially introduced.
Expansion of annual capacity to 12,000 tractors per annum at Plant 1.

1984 SWARAJ MAZDA Ltd. promoted in technical and financial collaboration with
Mazda Motor Corporation. & Sumitomo Corporation. Japan for
manufacture of Light Commercial Vehicles. PTL's equity participation is
Rs.30.4 million (29%) and that of Mazda and Sumitomo's Rs. 27.0
million(26%).

1985 Industrial Forklift Trucks developed by own R&D, commercially introduced.

1986 SWARAJ ENGINES Ltd. promoted in technical and financial collaboration

with Kirloskar Oil Engines Ltd.(KOEL) for manufacture of diesel engines.
PTL's equity participation is Rs. 6.9 million (33%) and that of KOEL's Rs 3.6
million (17%).

1989 1st Right Issue (1:1) at a premium of Rs 50/- per share (plus reservation of 200
Shares per employee) paid up equity moves to Rs 31.6 million.

1990 2nd Right Issues (1:2) at a premium of Rs 60/- per share (plus reservation of
200 Shares per employee) paid-up equity moves to Rs 50.6 million.

1992 1st right issue of Bonus Shares (1:1), paid up capital moves to Rs. 101.2
million.

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1993 Annual tractor capacity expanded to 24,000 per annum at Plant 1.

1995 Setup of tractor Plant II at Village Chappercheri, SAS Nagar with annual
capacity of 12,000 per annum.

1996 3rd issue of Bonus Shares (1:1), paid up equity moves to Rs. 202.5 million.

1998 Commencement of expansion to 60,000 tractors (30,000 at each plant).Capital

outlay of Rs 1000 million, funded mainly through internal accruals.

1999 5th and 6th tractor models - SWARAJ 733 (34 HP) & SWARAJ 744 (48 HP)
developed by own R&D, commercially introduced. FY 1999's divided @ 250%
was corporate India's highest.

2000 Expansion of annual tractor capacity to 60,000 completed. 4th issue

of Bonus Shares (2:1), paid up equity moves to Rs 607.6 million.

2001 PTL won National Championship trophy in competition organized by All

India Management Association (AIMA) for young managers. Economic
times and Boston Consulting Group selects PTL as one of the India's
finest 10 companies out of Economic times top 500
Companies.

2002 Cumulative tractor sales crosses 500,000.

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2003 PSIDC's disinvestment of its entire Equity holding (23.49%) in PTL in
favour of CDC Financial Services (Mauritius) Ltd. With this, total holding of
CDC & its associates in PTL stands at 28.48%.

2004 7th & 8th tractor models - Swaraj 939 (41 HP) & Swaraj 834 (34 HP)
developed by own R&D, commercially introduced

2005 PTL disinvested 15,73,000 equity shares of Rs. 10/- each of Swaraj Mazda
Ltd. (constituting approx. 15% of SML's paid up capital) in favour of Sumitomo
Corporation, Japan, a joint venture partner in Swaraj Mazda Ltd. at a total
consideration of Rs. 629.2 million

2007 CDC/Actis Group and Burman Family's disinvestment of their

Equity holding in PTL (43.3%) in favour of Mahindra Group (M&M).
M&M made open offer to shareholders for another 20% equity of the
Company.
Mahindra Group's equity holding in the Company stands at 64.6% Cumulative
Tractor Sales cross 600,000.
Swaraj Track Type Combine designed and developed by in-house
R&D, commercially launched

2008 Swaraj 3 Tonne Battery forklift, designed and developed by in-house R&D,
commercially launched

2009 Mahindra & Mahindra Ltd. completes the acquisition of Punjab Tractors
Limited, making it a wholly-owned subsidiary. The Swaraj brand becomes a
part of the Mahindra Group.

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2011 Mahindra Swaraj Plant 1, a state-of-the-art manufacturing facility, is
inaugurated in Mohali, Punjab. It is equipped with advanced technology and
processes to produce a wide range of Swaraj tractors.

2012 The Swaraj Division of Mahindra & Mahindra Ltd. celebrates the production of
its one millionth tractor, marking a significant milestone in its journey.

2015 Mahindra Swaraj introduces the Swaraj 963 FE, its most powerful and
technologically advanced tractor at that time. It offers higher productivity and
efficiency for farmers.

2019 Mahindra Swaraj Plant 2 is established in Mohali, Punjab, to meet the growing
demand for Swaraj tractors. The new facility enhances the manufacturing
capacity and supports the introduction of new models.

2020 Mahindra Swaraj introduces the Swaraj 9630, a high-horsepower tractor

designed for heavy-duty applications. It offers advanced features and superior
performance to cater to the evolving needs of farmers.

2022- New Tractor introduced for planting and New Plant has been introduced near
onwards ambala road mohali

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2. Safety & General Training
At Mahindra Swaraj Plant 2, safety is a top priority, and comprehensive safety training programs and

rules are implemented to ensure the well-being of all employees. Here are some key aspects of safety

training and rules at Mahindra Swaraj Plant 2:

1. Induction Training: All new employees undergo a comprehensive safety induction training
program upon joining the plant. This training familiarizes them with safety policies, procedures,
and emergency protocols. They receive information about potential hazards in their work areas
and are educated on the importance of adhering to safety rules.

2. Job-specific Training: Employees receive specific training related to their job roles and
responsibilities. This includes training on operating machinery and equipment safely, handling
hazardous substances, using personal protective equipment (PPE), and following standard
operating procedures (SOPs). Job-specific training ensures that employees are well-prepared
and competent in carrying out their tasks safely.

3. Regular Safety Training: Mahindra Swaraj Plant 2 conducts regular safety training sessions to
reinforce safety practices and address specific safety concerns. These sessions cover topics such
as fire safety, electrical safety, machine safety, ergonomics, and hazard identification.
Employees are updated on new safety regulations, equipment, and procedures to ensure their
knowledge remains current.

4. Safety Committees: The plant has safety committees comprising representatives from various
departments and management. These committees meet regularly to discuss safety issues, review
safety performance, and propose improvements. They actively engage employees in safety-
related initiatives, encouraging them to provide suggestions and feedback for enhancing safety
measures.

5. Safety Rules and Procedures: Mahindra Swaraj Plant 2 has well-defined safety rules and
procedures that are communicated to all employees. These rules cover various aspects such as
PPE requirements, safe work practices, machine guarding, lockout/tagout procedures, material
handling guidelines, and emergency response protocols. Employees are expected to strictly
adhere to these rules to maintain a safe working environment.

6. Hazard Identification and Reporting: Employees are encouraged to actively participate in hazard
identification and reporting. They are trained to identify potential hazards, unsafe conditions,
and near-miss incidents. There are reporting mechanisms in place, such as incident reporting

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 forms or online systems, to ensure timely reporting of safety concerns. This allows for prompt
corrective actions and preventive measures.

7. Safety Inspections and Audits: Regular safety inspections and audits are conducted at Mahindra
Swaraj Plant 2 to assess compliance with safety standards and identify areas for improvement.
Trained safety officers or external experts conduct these inspections to evaluate the
effectiveness of safety measures, identify potential hazards, and recommend corrective actions.

8. Emergency Preparedness: The plant has well-developed emergency response plans in place.
Employees receive training on emergency procedures, evacuation routes, assembly points, and
communication protocols. Regular emergency drills and simulations are conducted to ensure
employees are prepared to respond effectively in case of fire, chemical spills, natural disasters,
or other emergencies.

9. Safety Awareness Programs: Mahindra Swaraj Plant 2 organizes safety awareness programs and
campaigns to foster a culture of safety among employees. These programs may include safety
competitions, quizzes, posters, newsletters, and safety-themed events. Such initiatives create
awareness, encourage employee involvement, and promote a positive safety culture throughout
the plant.

By implementing robust safety training programs and rules, Mahindra Swaraj Plant 2 prioritizes the

well-being of its employees and aims to maintain a safe working environment. These measures ensure

that employees are equipped with the knowledge and skills to perform their tasks safely while adhering

to the highest safety standards.

Safety Points (HIRA, JSA, SOP, BBS, LOTO, FTU, ISO-4500)

1. HIRA (Hazard Identification and Risk Assessment): HIRA is a systematic process of identifying
potential hazards and assessing associated risks in the workplace. It involves identifying
hazards, evaluating their potential impact, and implementing control measures to mitigate risks.
HIRA helps in proactively identifying and addressing safety concerns before they lead to
accidents or incidents.

2. JSA (Job Safety Analysis): JSA is a systematic procedure for analyzing job tasks to identify
potential hazards and determine appropriate safety measures. It involves breaking down a job
into specific steps, identifying hazards associated with each step, and developing controls and
safe work practices to mitigate those hazards. JSA helps in ensuring that tasks are performed
safely, and employees are aware of potential risks.

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 3. SOP (Standard Operating Procedure): SOPs are step-by-step instructions that outline safe work
practices and procedures for specific tasks or processes. They provide clear guidelines on how
to perform tasks safely, including the use of equipment, handling of materials, and adherence to
safety protocols. SOPs ensure consistency in work practices, minimize human errors, and
promote a safe working environment.

4. BBS (Behavior-Based Safety): BBS focuses on promoting safe behaviors and preventing unsafe
actions in the workplace. It involves observing and analyzing employee behaviors, providing
feedback and coaching, and implementing reinforcement mechanisms to encourage safe
practices. BBS aims to create a safety-conscious culture by focusing on individual actions and
their impact on overall safety performance.

5. LOTO (Lockout/Tagout): LOTO is a safety procedure used to control hazardous energy sources
during equipment maintenance or servicing. It involves locking and tagging equipment to
prevent its operation or accidental energization while maintenance work is being performed.
LOTO ensures the safety of maintenance personnel by preventing unexpected startup or release
of stored energy.

6. FTU (First Aid Treatment Unit): An FTU is a designated area or facility equipped with essential
first aid supplies and equipment to provide immediate medical assistance in case of injuries or
illnesses. FTUs are strategically located within the workplace and are easily accessible to
employees. They help in providing prompt first aid treatment, stabilizing injured individuals,
and minimizing the severity of injuries until professional medical help arrives.

7. ISO 45001: ISO 45001 is an international standard for occupational health and safety
management systems. It provides a framework for organizations to establish, implement,
maintain, and continually improve their occupational health and safety practices. ISO 45001
focuses on hazard identification, risk assessment, employee involvement, emergency
preparedness, and compliance with applicable legal requirements.

These safety points and systems play a vital role in promoting a safe working environment, preventing

accidents and injuries, and ensuring the well-being of employees. Implementing and following these

practices demonstrate a commitment to safety and contribute to the overall success and sustainability

of an organization.

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Awards (TPM, TMW, Deming Surveillance Audit, TMSW, MQW, WCM)
overview of some notable awards and recognition received by Mahindra Group, of which Mahindra
Swaraj is a part:

Deming Prize: The Deming Prize is a prestigious international award for Total Quality Management
(TQM) and is considered one of the highest honors in quality management. Mahindra & Mahindra Ltd.,
the parent company of Mahindra Swaraj, was awarded the Deming Prize in 2003 for its outstanding
efforts in implementing TQM principles.

J.D. Power Asia Pacific Awards: Mahindra & Mahindra Ltd. has received several J.D. Power awards in
recognition of its product quality and customer satisfaction. These awards include the "India Tractor
Customer Satisfaction Award" and the "India Customer Service Index (CSI) Award" in the agricultural
tractor segment.

India Design Mark: The India Design Mark is a recognition for excellence in industrial design and
innovation. Mahindra & Mahindra Ltd. has received the India Design Mark for various products,
including its range of tractors. This award acknowledges the company's commitment to design
excellence and user-centric product development.

Golden Peacock Award: The Golden Peacock Awards are prestigious accolades that recognize
excellence in various business domains, including corporate governance, innovation, and sustainability.
Mahindra & Mahindra Ltd. has been honored with multiple Golden Peacock Awards for its commitment
to ethical practices, environmental sustainability, and corporate social responsibility.

Manufacturing Excellence Awards: Mahindra & Mahindra Ltd. has been recognized with numerous
manufacturing excellence awards for its commitment to operational efficiency and excellence. These
awards acknowledge the company's efforts in implementing worldclass manufacturing practices,
process improvements, and quality control measures.

Quality & Productivity (ISO-9000, SAP, 5S, Kaizen, POKA YOKE)

Quality and productivity are critical aspects of any organization's operations. Mahindra Swaraj, as part
of the Mahindra Group, focuses on implementing various practices and methodologies to ensure high-
quality products and efficient productivity. Here are some key approaches and tools utilized by
Mahindra Swaraj:

ISO 9000: Mahindra Swaraj follows the ISO 9000 series of standards, which provide guidelines for
establishing and maintaining an effective quality management system. These standards focus on
customer satisfaction, process improvement, and adherence to quality control measures. ISO 9000

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certification demonstrates the company's commitment to delivering consistent, high-quality products
and services.

SAP (Systems, Applications, and Products): Mahindra Swaraj employs SAP, an integrated enterprise
resource planning (ERP) system, to streamline and optimize various business processes. SAP enables
efficient management of production planning, procurement, inventory, quality control, and other critical
functions. It helps enhance productivity, minimize errors, and ensure effective resource utilization.

5S: 5S is a methodology focused on workplace organization and visual management. It comprises five
principles: Sort, Set in Order, Shine, Standardize, and Sustain. Mahindra Swaraj implements 5S
practices to create an organized and efficient work environment, reduce waste, improve safety, and
enhance productivity.

Kaizen: Kaizen is a continuous improvement philosophy that emphasizes small, incremental changes
in processes and systems. Mahindra Swaraj encourages a culture of Kaizen, where employees at all
levels contribute ideas and suggestions for process optimization, efficiency enhancement, and quality
improvement. By fostering a Kaizen mindset, the company achieves continuous improvement and
maintains a competitive edge.

Poka Yoke: Poka Yoke, also known as mistake-proofing, involves implementing mechanisms to
prevent errors or defects in the production process. Mahindra Swaraj utilizes Poka Yoke techniques to
design and develop systems that minimize the possibility of human errors or mistakes. This helps in
ensuring consistent quality, reducing rework, and enhancing overall productivity.

By integrating these quality and productivity approaches, Mahindra Swaraj aims to achieve excellence
in manufacturing operations, deliver superior products, and continually improve customer satisfaction.
These practices contribute to the company's overall competitiveness and growth in the agricultural
machinery sector.

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3. Department Introduction

Assembly shop ||

The Assembly line at Swaraj Tractor division deals with the assembly of tractor
models 722, 724, 733, 735 FE, 735 XM, 744, 834. Assembly is the joining of various
constituents to form a final product. The assembly process is carried out on the main
line, which has various sub-assemblies along its length.

Assembly shop can be divided in two main areas: -

A. Differential loop.

B. Dismounting loop.

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4.Major Learning:
NSM Gap & Flushness Observation such as:
Gap & Flushness b/w
 Hood Top & Side Panel
 Head light plate & Side Panel Upper
 Side Panel & Side Panel Perforation
 Top Hood & Head light mtg plate
 Upper Panel & Front Shield
 Side Shield & Side Panel Lower
 Quality control
 workstation layout
 Operation sequences ❑ Defect management.
 SOP: A Standard Operating Procedure
 JSA: A Job Safety Analysis (JSA)
 BBS: Behavior-Based Safety (BBS)

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5.Project Completed:
Coordinated with manger for permanent NSM Hood Sub Assembly Operators.

Station 1: Operator 1: Hood Lifting + Bazel Plate fit + Front Grill Fit

Operator 2: Hood Lifting + all bolt tight + Hood Lock & Knob Fitment

Station 2: Operator 3: Panel Sticker Pasting

Station 3: Operator 4: LHS Perforation + Beading + Gromet

Operator 5: RHS Perforation + Swaraj Logo

Station 4: Operator 6: Hinge Bkt fitment + LHS Parting Plate + Harness

Operator 7: RHS Parting Plate Fitment + Gas Strut + Dust Seal + Bazel Plate Tight

Station 5: Operator 8: All bolt tightening + Sticker release paper remove

Operator 9: Head Light Fitment + Vertical Channel Fitment

Operator 10: Hood Unloading

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6.Major Defects encounter in NSM:
1. Battery cover wing nut miss

2. Hand throttle Grommet Open

3. Angle Bkt Bolt Loose

4. Top link pin bend

5. Gear box plastic plug miss

6. Gear lever boot not seated proper

7. Fender chart miss

8. Drive seat seal miss

9. Bonnet to hood gap not ok

10. Dashboard paint scratch

11. Paint scratch on rim

12. Bonnet lock not ok

13. Differential Oil excess

14. RPTO sticker air bubble

15. Dashboard & Hood sticker Air bubble

16. Electrical not ok

17. Silencer wrong fit

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7.Important Concept Learned:
TIMWOOD: TIMWOOD is a framework for identifying waste in the workplace.

T: Transportation (Unwanted movement of component)

I: Inventory (Materials not being used)

M: Motion (Unwanted motion of workers)

W: Waiting (Time Spent waiting for materials)

O: Overproduction (Production of more than needed)

O: Overprocessing (unnecessary adding steps)

D: Defects (Product unusable by customers)

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The chassis
and the

for washing
and drying
and then it
goes to the
paint shop
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NSM Models

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 VARIOUS DEPARTMENTS IN SWARAJ TRACTOR
DIVISION

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INTRODUCTION
The manufacturing of Tractor is performed in various steps. It is manufactured

after passing through various processes in various shops. Firstly, various operations on

various parts are performed in the L.M.S. (Light Machine Section) and H.M.S. (Heavy

Machine Section). In H.M.S. generally there are four major heavy parts that are given

proper machining operations. These include Gear Box Casing, Differential Housing,

Trumpet Housing and Rear Cover. Similarly, in L.M.S. the light parts are given proper

machining. These include various parts such as Gears, Shafts, Cage Assembly casing

etc.

In Heat Treatment Shop, the light parts such gears, shafts etc are given the
heat treatment to ensure their strength. Firstly the part after passing through various
operations in L.M.S. is taken to the Heat Treatment Shop. Here the part is kept in the
furnace for suitable time period up to certain high temperature. Then it is taken to the
Quenching tank where it is dipped in the oil tank. After that it is taken to washing tank
for washing of dirt and oil etc. Then it is taken to the Assembly line.

In Assembly line various parts are being assembled into a single unit termed
“Tractor”. During assembling the various parts are being fitted according to the stage.
This would includes the assembly of important parts such as Rear Cover, Gear Box,
Differential Housing and trumpet Housing. Firstly the Various sub-parts of the Rear
Cover are being fitted. Then the various parts such as gears, shafts, bearing, oil rings,
clutch actuator and circlip etc are fitted into the Gear Box. After that both the Rear
Cover and the Gear Box are taken to the line where Gear Box if fitted ahead of the
Differential Housing whereas the Rear Cover on the Top. Then various things such as
Brakes, P.T.O. Shaft, Cage Assembly, Trumpet Housing etc are fitted to the Differential
Housing. Then this whole assembly is fitted with the engine against the Gear Box.

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 After whole assembly is fitted with the Engine, this assembly is taken to the
Chassis Paint Area where it is washed and dry followed by Paint on the chassis.

Then the tractor reaches to the Final stage where certain electrical and other
accessories such as Battery with Battery cover, Steering Wheel, radiator etc are fitted.
Proper level of Engine oil is also filled into the Differential and Gear Box. Greasing of
various parts is also performed with Grease Gun. After that the Tractor is taken out of
the line after taken it out from the hooks. This stage is termed as “Dismounting
Stage”.

Then the Testing of the Tractor is performed which include the checking for
vibrations, noise, brakes, oil level and other factors that effects the performance of
tractor.

LIGHT MACHINE SHOP

Introduction: L M S is the largest section of the factory. All transmission components

like shafts and gears used in tractors are manufactured here. L.M.S comprises of 117
machines. Except the bevel gear generator & gear shaver, which have been imported
from W M W & Churchill of Germany respectively, all other machines are from HMT
Ltd. 160 highly experienced operators and inspectors manned this shop.

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 Types of machines:

S.No.M/C Job Operations Description

Bull Gear Line

1. ECO-5 CNC Bull Gear Turning

2. Broaching machine Bull Gear Cutting Internal Spline
3. Gear hobbing Bull Gear Cutting Outer Spline
4. Deburring machine Bull gear For removing rough edges
5. Shaving machine Bull Gear Shaving or finishing

Bull Pinion Shaft Line

6. Center Facing BP shaft Facing, Centering machine
7. Femco Turning BP shaft Rough, Finish turning
(first 4 steps)

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DIFFERENT MANUFACTURING OPERATIONS IN L M S:

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• Facing: It is the operation of finishing the ends of the work to make the ends
flat and smooth and to make the piece of required length.
• Under cutting: It is similar to grooving operation but is performed inside a
hole.
• Chamfering: It is operation of beveling the extreme end of the work pieces,
chamfer is provided for better look.
• Rough turning: In this operation max Metal is removed and very little over
size dimensions are left for further machining.
• Finish turning: Here minimum metal is removed and very fine finish is
obtained on the work surface.
• Grooving: It is operation of turning the groove or neck in order to terminate
a thread or to provide adequate clearance enable nut to pass freely on
threaded work piece to remove burs and to protect the work piece from being
damaged.
• Knurling: It is the process of embossing a diamond shaped regular pattern
on the surface of the work piece using a special knurling tool.
• Broaching: It is the method of metal removal by a tool that has successively
higher cutting edges in a fixed path. Each tooth removes a fixed amount of
material.
• Drilling: It is the process of making hole in an object by forcing a drill.
• Boring: It is the process of enlarging a hole that has already been drilled.
• Grinding: It is generally used for sharpening the cutting tool, grinding
threads and better surface finish etc.
• Shaping: The process of cutting gears on the shaper is known as Shaping.
The tool used in shaping for teeth’s cutting is a multi-point cutting tool.
• Hobbing:
Hob: - Hob is a cutting tool used for cutting gears or similar form gears by
the generating principle.

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 A Hob resembles a worm in appearance its cutting teeth on the outside
of a cylindrical body following a helical path corresponding to the thread of a
worm. It is useful to think of a hob as a cylinder with a series of racks being
parallel to the hob axis or nearly so and each one slightly displaced axially with
respect to the preceding racks. As the hob rotates in fixed rotation with the
blank each row of teeth successively cuts the next portion of the gear tooth
spaces.

Hobs can be broadly classified as

• Single start
• Double start  Triple start.

Hob material
1. High speed steel (HSS) - M2
2. HSS with 8% cobalt (M35) 3. Power
metallurgy (ASP 30)
4. Carbide.
5. Tool steel.
 Gear shaving: Gear shaving is a metal cutting operation for finishing the gear
cutting process.

Shaving is a low pressure, free cutting, finishing operation applied to a hobbed gear to
achieve the following:-

1. Correct eccentricity and errors in index, helix angle and tooth profile.
2. Improve tooth surface finishing.
3. Maintain tooth size.
4. Eliminate tooth-bearing conditions by producing a crowned tooth form.
HEAVY MACHINE SHOP (H. M. S.)

40
 All heavy casting of tractors is machined in this shop with the help of variety of
special machine (SPM). These machines are tailors made by IIMT to suit component
requirements. In addition, facilities of this shop include general-purpose turning,
drilling and milling machines. About 20 SPM and 30 GPM are installed in a covered
area of 47,000 sq. Ft. At a cost of 20 million, 2600 tones of castings are machined
every year on a two-shift basis. In addition to the machining of casting for the tractor,
some jobs are also performed for Swaraj Mazda Limited.

COMPONENTS MACHINED IN THE SHOP

• Gearbox housing (Material R-33, Casting, 180-230 BHN, 76-Kg wt.).

• Differential housing.

• Rear cover.

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 • Trumpet housing

• Brake housing

DIFFERENT MANUFACTURING OPERATIONS IN HMS:

42
 • Milling- It is a process of smoothing a surface by a rotating tool called milling
cutter.
• Drilling- It is a process of making holes in workpiece by a tool called drill.
• Boring- It is a process of enlarging a drilled hole.
• Tapping- It is a process of putting thread on internal side of drilled hole. This is
done by a tool called tap. Different taps are available for different pitch angles.
• Chamfering- It is a process of making a seat on a drilled hole. Seat is made either
to place head of bolt or for tapping purposes.
• Turning- It is a process of making cuts on a rotating workpiece in lathe machine.
• Grooving- It is a process of making an internal cut in a hole.
• Side Milling
• Facing

CONCEPT OF DOWELLING

The main aim or purpose of doweling is to act as a guide to the work piece
setting proposes prior to machining. Use of this process helps in reducing the setting
time considerably during machining of heavy components. It is very difficult to set the
work piece in required position prior to machining, this process is very time
consuming, hence when initially the cast piece is brought dowel holes are drilled which
act as the pivot around which the whole machining takes place. Dowel hole act as the
reference point for machining of all the other holes on the work piece all the operation
to be performed on the work piece are taken in reference to the dowel holes thus the
hole act as the reference to all the operations.

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PROCESS OF SETTING PRIOR TO DOWEL

Before the dowelling the cast piece is clamped manually, there are three points to be
touched. It follows the phenomena of 3-2-1, which means that we have to restrict the
motion in three directions i.e. x, y, z direction, two to restrict horizontal and vertical
motion and one act as reference point, this process is known as “butt and clamp”. By
dowelling it is all about locate and clamp hence there is lot of saving of time.

REFERENCING
Dowel act as reference, all the dimension of the work piece i.e. all the
machining operations are from the reference of Dowel hole.

44
Types of Machines :-

45
 15. HMT SBCNC 35 Finishing (outer face)

16. SPM Drilling, Tapping

17. TICO mul purpose machine Milling, Drilling, Tapping

Rear Cover Assembly

18. Free Spindle SPM Milling(1 Ver cal,2

horizontal)

19. CNC milling machine Milling

20 Horizontal HC 630 CNC Drilling, Boring, Milling

21. VA 50 Drilling, Milling, Tapping

22. XLO Boring (one way)

HEAT TREATMENT SHOP

Heat treatment shop plays a very important role in every industry. In automobile
industry all the gear and shafts need to be heat treated to impart desired strength and
increase life of the component. The H.T. shop at PTL is equipped with several gas
carbonizing furnaces, quenching tanks, induction hardening machines and shot blasting
furnaces.

Heat Treatment is an operation or combination of operations involving heating and

cooling of metals and alloys in the solid state to produce certain desired properties. All
the heat treatment processes may be considered to consist of three main parts:

1. The heating of the metal to pre-determined temperature.

2. The soaking of the metal at that temperature until the structure becomes uniform
throughout the mass.

46
 3. The cooling of the metal at some pre-determined rate to cause the formation of
desirable structures within the metal/alloy for the desired purposes.
PURPOSES OF THE HEAT TREATMENT

Changes in properties result from the micro-structural changes in the material produced
by heat treatment operation. However, these serve one or more of the following
purposes:

1. Improve machinability.
2. Relieve internal stresses.
3. Improve mechanical properties such as ductility, strength, hardness, toughness etc.
4. Change in grain size.
5. Increase resistance to heat and corrosion.

METHODS OF HEAT TREATMENT

Various methods depending upon the nature of job .i.e. it material, use etc are
employed for giving then Heat Treatment. These methods used are:

Annealing

Normalizing

Hardening

Quenching

Tempering

Case

Hardening

a)carburizing

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 b)Cyaniding

Induction Heating.

ANNEALING
Annealing means softening of the material by heating and cooling process. The cooling
stage may be performed by regulating the fall of the temperature in the furnace or by
buried the article in sand or lime, and quenching in oil or water, according to the
material being treated.

NORMALISING
In this process the material is heated steadily through out its mass to just beyond the
critical temperature, and then withdrawn from the furnace and allowed to cool in still
air. With the normalizing process there is not soaking period, for the work is held at the
desired temperature for a period only sufficient to give uniformity through out the
mass.

HARDENING

The operation of hardening is applied to all the tools and some important machine parts
intended for especially heavy duty service, as well as to all machine parts made of
alloy steel. Hardening of steels is done to increase the strength and wear properties.

QUENCHING

Quenching is the act of rapidly cooling the hot steel to harden the steel. Oil is used
when a slower cooling rate is desired. Oil quenching results in fumes, spills, and
sometimes a fire hazard.

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TEMPERING

It is an operation to reduce the internal stress and brittleness. With plain carbon steel,
tempering operation consist in slowly heating the hardened material from room
temperature up to maximum of about 600oC and then quenching in water or oil, the
temperature and length of soaking period being dependent in service requirement. Thus
if plain carbon steel is to be hard without any appreciable ductility, a temperature of
about 150oC will be required.

CASE HARDENING (CARBURISING)

It is method of producing hard surface on steel. The steel used for this purpose is
usually a low carbon steel of about 0.15% carbon, which does not respond appreciable
to heat treatment. In course of the process, the outer layer is converted into high carbon
steel with a carbon content ranging from 0.9% to 1.2% carbon.

PAINT SHOP

Paint Shop is the place where the different sheet metal components are painted. They
are made to pass through various chemicals before they are actually painted. The
painting method opted is that of Spray Painting.

NEED FOR PAINTING

Long life
Rust resistance
Better look (more appealing)

The various operations performed in paint shop are:

Surface Preparation (Pre Treatment Cell) - carried out for sheets and rims.

Painting – JOST 1(dash board, rear frame, front shield, top bonnet), JOST 2(fenders,
side panel), CHASIS BOOTH (washing, primer, washing zones), FINAL TOUCH UP.

49
 Inspection

Rejection (Reprocessing)-for sheets and rims

PAINTING

The process (sheet and rim painting) includes

Full Primer + one coat of paint (30-40 microns)

Flash off (This is the distance given so as to allow paint to dry)

Baking (120-130 degree centigrade)

Rubbing

Cleaning with tag rag

Final painting

Flash off

Baking

CHASIS PAINTING

Washing

Drying

Primer painting
Flash off

Final painting

Flash off

Baking

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 After painting inspection is carried out inspection is carried out and the

product is passed or rejected.

Various parameters checked are:

Depth of penetration of paint

Thickness of paint coating

Smoothness

Uniformity

INDUSTRIAL ENGG DEPARTMENT

The department allocated to me was Manufacturing Engineering (M.E). This

department is commonly known as Industrial Engg. department. This department is
backbone of the industrial unit. All shops come under this department. It deals with the
activities related to industrial engg.

About the Industrial Engg department

Introduction

The Manufacturing Engg. department (M.E.) plays a vital role in efficient and smooth
working of the manufacturing and developing programs of the company.

The American Institute of Industrial Engg. (AIIE) has defined this special field as:

“Concerned with design, improvement and installation of integrated system of people,

materials, equipment and energy.”

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Industrial Engineering is engineering approach to the detailed analysis of the use and
the cost of the resources of an organization. The main resources are men, money,
material, equipment and machinery. The Industrial Engineer carries out such analysis in
order to achieve the objective and policies of an organization. It is not associated with
meeting cost factors, but with organization structure, administration, technology and
human problems etc.
Earlier it was mainly employed to manufacturing industries for improving methods of
production, to develop production work standards and to formulate production contract
and wage policies. But with the advancement of technologies and industries, I.E also
spread to non-manufacturing like construction, transportation etc.

It is the most important and result oriented department in terms of production,

planning, designing, optimization of methods etc. Some functions involve planning of
layouts of all the shops to get maximum benefits of available space, setting workers’
time standards to perform a certain job by motion study and implementing standards
laid. Other function of this department also includes selection of tooling, fixture etc.

In PTL the I.E. department is further divided into three sections: -

• Process planning
• Plant and machinery
• Work- study
Job responsibilities of I.E.

• To set up production norms for all production departments i.e. to set up time
standard for the entire job.
• To design / improve work place arrangement to improve productivity and to
create good working conditions and environment for work place.
• To design / improve material handling system to make its use and optimize its
cost.
• To design material storage system for optimizing utilization and minimizing cost.
• To calculate efficiencies of shops and thereby incentives.
• To set up new machines and to make process plan.
• Design formats for management reports like rejection of manpower facilities,
production target v/s production efficiency.
• Plant layouts: best optimum utilization of space can be achieved by optimum
layout.
• Installation of new machines and conveying systems. Another important function
of I.E. is to get the new machinery installed according to the proposed layout.

52
 Functions of I.E. department

• Receiving components and drawings from R&D.

• Prepare and release of process sheet.
• Assessment of direct labour requirements.
• To make decisions for required equipments.
• To make decision for purchasing new machines.
• Installation of new machines at proper places.
• Releasing of jigs, tools and fixture drawings.
• Preparation of release of operating conditions of machines.
• To study the machining time.
• To make operation research.
• Miscellaneous and advisory functions.

Applications of I.E.

• Earlier it was mainly applied to manufacturing industries for improving

methods of production, to develop work standards or to formulate production
control and wage policies.
• Later on, the use of I.E. also spreaded to non-manufacturing activities such
as construction and transportation, farm and air-line operations and
maintenance, public utilities, government and military operations.
• But today it finds its major application in manufacturing plants and
industries.  In an industry besides the production, other department’s
utilization I.E. concept is marketing, finance, purchasing and industrial
revolution etc.

Process planning

The process planning system deals with LMS, HMS, Assembly, Paint Shop and Heat
Treatment Shop. In this, first I.E get drawings of components to be manufactured in the
plant from R&D. Then I.E lay down the sequence of operation to be performed on the
material. After this workstation is decided, on which the respective operation is to be
performed. Through work-study, I.E standardize the time for setting, tooling and
operation. After getting all the information, I.E prepare the summary of the operation
sheet comprising the operation no., operation work center, time, weight, quantity,
material used etc.

53
 After this I.E prepare a detailed operation as for each operation, comprising operation
details, part no., machining condition, rpm, feed, depth of cut, workstation, quantity,
description of standard tooling and special tooling, jigs, fixtures, which are prepared in
plant, according to the requirements.
Operation sheets also have space for drawing of the corresponding component showing
the position of clamping, resting, flatness, surface finish and there is column for
amendment.

Work Study

Under this section comes incentive scheme and time study. This section is mainly
concerned with incentive scheme, as they have already worked on time study and
prepared the charts referring the time taken by different operations on respective
machines in respective shops and departments. Time study is generally done when a
new machine is being installed, some new aid is being given to the workers on the
machine for easy working or some new method is being used for increasing the
productivity.

QUALITY ENGINEERING

QUALITY IMPROVEMENT SYSTEMS

1. COMPONENT DRAWINGS.
2. PROCESS SHEET WITH SUMMERY SHEET. (REF. SCD PROCESS SHEETS).
3. FIRST PC. SETTING OK RECORD
4. RUN CHART FILLING BY OPERATOR & AUDIT BY QE ON RUN CHART.
5. CHECKLIST ON FRONT SIDE & PDI ON THE BACKSIDE OF THE SHEET.
6. IN PLANT REJECTION & THERE DEFECT ANALYSIS.
7. PERIODIC INSPECTION AND MAINTENANCE OF TOOLS/GAUGES &
MACHINES.
8. MASTER SAMPLE SHOULD BE AVAILABLE FOR EACH SHEET.
9. MATERIAL SHOULD BE PROPERLY STACKED IN BINS .(NO MATERIAL
SHOULD BE ON SHOP FLOOR)
10. TOOLS & GAUGES SHOULD BE KEPT PROPERLY AT THEIR ENMARKED
PLACE.

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 11. WORKSTATION SHOULD BE ACCORDING TO LAYOUT PLAN.
12. MATERIAL SHOULD BE TRANSPORTED TO PTL IN BINS &
ARRANGEMENT SHOULD BE AVAILABLE FOR LODING BINS INTO LCVs.
13. THE RESPONSIBILITY OF IMPLEMENTING AND MAINTAINING THE
VERIOUS RECORDS SHOULD BE CLEARLY DEFINED AND THE NAME OF
THE PERSON TO BE INTIMATED TO VDC AND BUY.
14. SUBMISSION OF SELF-APPRAISAL FORM

ASSEMBLY SHOP

The Assembly at SWARAJ TRACTOR DIVISION deals with the assembly of

tractor models 722, 724, 733, 735, 744, and 834. Assembly is the joining of various
constituents to form a final product. The assembly process is carried out on the main
line, which has various sub assemblies along its length. Assembly shop can be divided
in two main areas: -

1) Before paint area

2) After paint area.

BEFORE PAINT AREA

The area before painting can further be divided into sub assemblies/ loops
namely  Differential loop.

• Gearbox loop.
• Rear cover loop.
• Engine assembly loop.

DIFFERENTIAL LOOP
• Differential casting mounted on trolley after washing.

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• Bull pinion Shaft left and right fitted.
• Cage assembly fitted. It consists of:

1. Crown wheel.
2. Tail pinion assembly.
3. Roller bearing.
4. Bevel wheels.
5. PTO shaft fitted.
6. Rear axle/trumpet is fitted.
7. PTO shifter assembly fitted.
8. Gearbox assembly is lifted.9. Rear cover assembly fitted.
10. Brakes are fitted.
11.Parking brake.
12.Suction pipe

13.PTO cover

14. Trailer hook is fitted.

15. Angle bracket is fitted.
16. Rocket link is fitted.
17. Footboard is fitted.
18. Clutch pedal is fitted.

GEAR BOX LOOP

• Gearbox housing mounted on trolley.
• Drive shaft & input shaft assembly.
• Output shaft assembly.
• Lay shaft and connecting shaft assembly.
• Shifter rod assembly.
• Steering assembly.

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REAR COVER LOOP

• Rear cover mounted on trolley.

• Control valve and response valve assembly.
• Ram assembly. (This consists of cylinder, piston and piston rods.)  Testing
of hydraulic lift.

ENGINE ASSEMBLY LOOP

• Engine mounted on trolley  Dynamo is fitted.
• Self-motor is fitted.
• Oil pump is fitted.
• Front axle beam and bracket is fitted.
• Clutch plate is fitted.

After that the chassis is carried to the next level by the lift where the engine & the
3point assembly of the tractor along with the other components are fixed. The parts
fitted here are:

• 3-point linkage which contains the following parts:

 Bracket.
 Lower link fitted at the left side.
 Leveling rod fitted at the right side.
 Stabilizer stainer.
 Draw bar.
 Top link.

• Battery frame.
• Front frame.

57
 • Tie rod attached with the drop arm of the steering system.
• Accelerator link.
• Delievery pipe.
• Engine attachement.

The engine is attached with the chassis system in this level of assembly. The
engine is also carried to this level with the help of the lift crane, which lifts the engine
assembly & delievers it to this level. Shlug is applied at the corneror we can say at rhe
circumference of the gearbox where engine is attached with studs & bolts. Shlugs
works as gaskets or seals & avoid the oil leakage & water mixing in the engine. the
engine, which is suplied to this level of assemble where the engine is attached contain
the following parts attached on it:

• Front axle.
• Extension in the front axle used for the setting of the wheels.
• K.P.S.A. (King Pin Shaft Axle) with the wheel disc & nuts fitted in there for the
fitting of the wheels.
• Drop arms.
• Tie rods.
• Bucket.  Clutch plates  Alternator.
• Self starter.  Fuel pump.

The above parts are already fitted with the engine when it comes to the engine
chassis assembly. The make of the engine is KIRLOSKOR or SWARAJ
KIRLOSKOR depending upon the model as 3-cylinder, 2-cylinder or 1-cylinder. The
engine was imported from this company from Pune. SWARAJ also has its own engine
plant where the engines are assembled. After assembling the chassis & engine
arrangement, the fitments are checked by the workmen appointed there at this level & if
there is some part missing, it is attached here. Then the whole assembly is mounted over

58
the conveyor, which takes that piece to different chambers of washing, drying,
primering, baking, painting & again baking.

After painting the conveyor takes the assembled piece to the DISMOUNTING
STAGE where different parts & components are fitted on the tractor & the tractor was
completed. After that the testing of the tractor is done. A tractor has to pass through
different tests to claim itselfs to be as perfect & if there is some problem coming out in
this stage, the tractor is send to the recovery shop, where the problem of the tractor is
recovered. After the recovery the tractor is again tested & after passing the test the tractor
finally send to the yard from where it is send to the R & D Complex for further tests.
Now we shall discuss the DIFFERENTIAL, GEAR BOX, REAR COVER AND
DISMOUNTING STAGE in detail.

59
GEAR BOX

The power, which the engine develops, is transmitted to the wheels of the tractor
by certain essential parts. The application of engine power to the driving wheels
through these parts is called “POWER TRANSMISSION”. These parts are clutching,
gear box, differential and rear axles.

To start a tractor from rest, the inertia of its whole weight must be overcome.
Diesel engine does not develop its full power at low speed. It has to run at fairly high
speed before it develops maximum power and torque.

Since much power is needed in starting, climbing uneven land and in pulling
varying loads, a provision must be made to permit the engine to run at high speed
while the wheels run at lower speed. This is achieved by a system called “GEAR
BOX”.

With the help of gearbox we can achieve this and pulling power of the tractor
can be increased or decreased by varying the speed of tractor. For these tractors
gearbox used is of the type of “SLIDING MESH GEAR” type.

FUNCTIONS

• To convert the power of the engine running at high speed into low speed at high
torque, this is required for starting.
• To exchange the forward motion into reverse motion of the vehicle.

60
 • To disconnect the engine from the rear wheels by putting the gearbox into the
neutral position.

TYPES OF GEAR BOX

• Selective gearbox.
a. Sliding mesh type
b. Constant mesh type.
c. Synchronous type.

• Planetary gear transmission.

• Automatic gearbox.

GEAR BOX SUB-ASSEMBLY

It consist of following sub-assemblies:-

1. Input Shaft:
This shaft transfer the power from the engine to the gear box. One end of the
shaft is splined which is connected to the engine and second end is the integral
constant mesh pinion which transfers the power to the constant mesh gear
splined on the lay shaft.

2. Lay Shaft:-
Gears are in the fixed position provided by the spacers. Gears on the lay shaft
can only rotate but can not move axially. It consists of one constant mesh (CM)
gear and three straight teeth gear. CM gear of lay shaft is in mesh with the CM
gear of the input shaft, due to which lay shaft moves with the constant speed.
All the gear on the lay shaft moves with the constant speed. Lay shaft also
gives drive to the PTO shaft.

61
3. Intermediate shaft:-
It is the splined shaft consist of three gear which are axially movable on the
shaft. All the gears are provided with the collar, so that forks are fitted in these
collars and help the gears to move axially. These gears are meshed with the
gears on the lay shaft to have the correct gear pair with required gear ratio.
Only one pair is in mesh at one time so to avoid double engaging.

4. Three forks:-
• One fork is used for:
(a) Engaging reverse gear with the help of idler cluster.
(b) Engaging 1st gear
• Second fork used for engaging 2nd gear
• Third fork used for engaging 3rd and 4th gear.

5. Epicyclic gear train:-

It is used to have high speed ratio between input shaft and output or
intermediate shaft. This is done by engaging hi-low gear. This gear train consist
of following sub-assemblies:
• Internal gear.
• Planet gears (3 in number).
• Sun gear, which is the splines of the intermediate shaft itself.
• Planet carrier.
• Hi-low sleave.
• Hi-low shaft.

Different views of assembled Gear Box

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WORKING IN GEAR BOX

The Constant Mesh (CM) gear is rigidly fixed to the input shaft or clutch shaft. It
remains always connected to the drive gear (also CM gear) of the lay shaft. Three other
gears are also rigidly fixed to the layshaft. They are the second speed gear, first speed
gear and reverse speed gear. Two gears are mounted on the splined main shaft or output
shaft (also known as intermediate shaft) which can be slided by the shifter fork when
the shaft lever is operated. These gears are the second speed gear and first and reverse
speed gear. They can be connected to the corresponding gears of the layshaft and
always remains connected to the reverse gear of the layshaft.

Gears in neutral: When the engine is running and clutch is engaged, the CM gear
drives the layshaft gears. The layshaft rotates opposite in direction of the clutch shaft.
Note that in neutral position, only the CM gear is connected to the CM gear of the
layshaft. Other gears are free, and hence the transmission intermediate shaft is not
turning. The vehicle is stationary.
First or low speed gear: By operating the gear shift lever, the larger gear on the
intermediate shaft is moved along the shaft to mesh in the first gear of the layshaft.
The intermediate shaft turns in the same direction as the input shaft. Since the
smaller layshaft gear is engaged with the larger intermediate shaft gear, a gear
reduction of approximately 3:1 if obtained. That is, the input shaft turns three times
for each revolution of the input shaft. Further gear reduction in the differential at
the rear wheels produces a still higher gear ratio, approximately 12:1, between the
engine crankshaft and the wheels.

63
Second speed gear: By operating the gearshift lever, the larger gear of the
intermediate shaft is demeshed from the first gear of the layshaft and then the
smaller gear of the input shaft is meshed with the second gear of the layshaft. The
intermediate shaft turns in the same direction as the input shaft. A gear reduction of
approximately 2:1 is obtained. The differential gear reduction increases this gear
ratio to approximately 8:1.

Third, top or high speed gear: By operating the gear shaft lever, the second gear
of the intermediate shaft and layshaft are demeshed, and then the second and top
gear of the input shaft is forced axially against the CM gear of the input shaft.
External teeth on the input shaft gear mesh with the internal teeth in the second and
top gear. The intermediate shaft turns with the input shaft and the gear ratio of 1:1
is obtained. The differential reduction reduces a gear ratio of about 4:1 between the
engine crankshaft and the wheels.

Reverse gear: by operating the gear shaft lever, the larger gear of the intermediate
shaft is meshed with the lever idler gear. The reverse idler gear is always in mesh
with the layshaft reverse gear. Interposing the idler gear between the layshaft
reverse gear and intermediate shaft bigger gear, the intermediate shaft turns in the
direction opposite to that of the input shaft. This reverses the rotation of the wheels
so that the vehicle backs.

High/Low Gear: High/low gear shifter enables to achieve either high torque-low
speed or low torque-high speed with the help of planet gear & carrier assembly.

HIGH GEAR: Low torque-high speed is achieved when hi-lo shifter is shifted in
high gear position. Coupling intermediate shaft and output shaft with the help of
sleeve transmits the power.

64
 LOW GEAR: High torque-low speed is achieved when hi-lo shifter is shifted in
low gear position. The power is transmitted to output shaft from intermediate shaft,
planet gear and carrier assembly and sleeve. The planet gear & carrier assembly
reduces the high speed and subsequently torque is increased.

LAY and INTERMEDIATE Shafts with required GEARS

DIFFERENTIAL SYSTEM

If the car travels in a straight line, the two rear wheels turn on the road exactly at the
same speed. There is no relative movement between the two rear wheels. The propeller
shaft may be geared rigidly, in the case, with the rear axle to rotate the rear wheel
together. But when the car takes the turn, the outer wheel travels on the longer radius
than the inner wheels. The outer wheel turns faster than the inner wheel, i.e., there is
the relative movement between the two rear wheels. If the two rear wheels are rigidly
fixed to a rear axle, the inner wheel will slip which will cause:-

• Rapid tyre wear.

• Steering difficulties.
• Poor road holding.

65
 Therefore, there must be some devices to provide relative movement to the two
rear wheels when the car takes a turn. And here comes the purpose of differential.

The differential is a device that splits the engine torque two ways, allowing each output
to spin at a different speed.

The differential is found on all modern cars and trucks, and also in many all-wheel-
drive (full-time four-wheel-drive) vehicles. These all-wheel-drive vehicles need a
differential between each set of drive wheels, and they need one between the front and
the back wheels as well, because the front wheels travel a different distance through a
turn than the rear wheels.

Part-time four-wheel-drive systems don't have a differential between the front and rear
wheels; instead, they are locked together so that the front and rear wheels have to turn
at the same average speed. This is why these vehicles are hard to turn on concrete
when the four-wheel-drive system is engaged.

66
The differential has three jobs

• To aim the engine power at the wheels

• To act as the final gear reduction in the vehicle, slowing the rotational
speed of the transmission one final time before it hits the wheels
• To transmit the power to the wheels while allowing them to rotate at
different speeds (This is the one that earned the differential its name.)

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 PICTURES OF ASSEMBLED DIFFERENTIAL

DIFFERENTIAL ASSEMBLY

It consists of following sub-assemblies:-

1. Cage Assembly:
a. Left Cage: It consists of following parts: Four planet gears

which are bevel pinion.

 • One cross (or spider) housing the planet gear.

• Two bevel gears with internal splines.

b. Right cage: It consist of :-

• Crown Wheel having spiral teeth

2. Tail Assembly: It consists of following sub-assembly:

a. Tail Pinion Carrier.

b. Tail Pinion.

c. Taper roller bearing.

Tail Pinion is integral with Tail Pinion Shaft. Other end having splines to
take power from the Gear Box.

3. Left Bull Pinion Shaft (LBPS):

It consist of two taper bearing. It has a bore on its right side which
provide place for the entry of the RBPS so to support it with eccentricity.

So LBPS is also known as female type of shaft.

4. Right Bull Pinion Shaft (RBPS):

 It also consist of two taper bearing. It is the male type of shaft of which
very few part enters into the bore of the LBPS to have eccentricity.

5. PTO Shaft:
Both ends of this shaft are splined. One end is connected to the lay shaft
of the gear box, while the other end (only the splined part) is outside the
differential housing. PTO shaft transfers the torque from the gear box to
other agricultural equipments like Reaper, generator, etc.

6. Two Bull Gear:

These gears transfers torque from the Bull Pinion Shaft(BPS) to the rear
axle through trumpet assembly.

7. Differential Housing:
It is the casting that houses all the above Sub-Assemblies.
 REAR COVER ASSEMBLY

Rear cover is mounted on the differential assembly. It is used to cover the differential assembly. It
performs various other operations also.

The different components are as follows:

• Hydraulic cylinder.
• Control valve.
• Operating sector components.
• Response valve.
• Sensor tube.

FUNCTIONS OF DIFFERENT COMPONENTS

• HYDRAULIC CYLINDER: This hydraulic cylinder completes lift arm mechanism.

• CONTROL VALVE: It is used to control the position of the lift arm.
• OPERATING SECTOR COMPONENTS: Position lever is required for positioning of the lift
arm. Draft lever is used to give the maximum and minimum position to the lift arm.
• RESPONSE VALVE: This is used to give response to the lift arm.
• SENSOR TUBE: Its function is to operate the lift arm on uneven surface. It automatically lifts
the arm when any hard surface is hit.

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 Different views of assembled rear cover

AFTER PAINT AREA:- This stage is also called the DISMOUNTING

STAGE of the tractor.

DISMOUNTING STAGE

INTRODUCTION

DISMOUNTING means the removing of the complete assembled tractor piece from the conveyor.
The conveyor is a long rail like carrier system, which carries the tractor chassis & engine assembly
through the different chambers of washing, drying, primering, baking & then to the dismounting stage.
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After the attachment of the complete assemblies of differential housing, gearbox & engine fitting, the
assembled piece is mounted on the conveyor which takes the assembled piece to the different
chambers of washing, drying, primering, baking & then further to the dismounting stage. First of all
the chassis & engine part is washed in the washing chamber. After washing the assemble piece is dried
with the blowers in the drying chamber. After that the assembled piece is coated with the primer in the
primering chamber. A primer makes a thin layer on the assembled piece, which helps the paint to be
attached to the assembled piece. After the primering the assembled piece is dried out. Then the
assembled piece travels to the painting chamber & paint is sprayed on the assembled piece of the
tractor containing the chassis & the engine. After the paint section, the assembled piece travel to the
baking chamber. In this the paint dried out & fixed on the assembled piece. Then at last the assembled
pieces reaches to the dismounting stage. In this stage the wiring, sheet metal work attachment & other
parts of the tractors like radiator, steering, fuel tank, etc. is fitted. When the fitting of the parts of the
tractor is complete the tractor piece is removed from the conveyor called the DISMOUNTING of the
tractor. Then the further test like road testing, rig test, engine test, etc. is done.

After the dismounting stage, we get the complete tractor but without testing. So testing of the tractor is
done after dismounting & after passing the tests, the tractor is sent to the yard from where it is
supplied to R & D COMPLEX. Here further testing of the tractors is done on the engine & other parts
like lifting, etc. & improvement or development is done in the tractor for better performance. After all
this procedures of testing etc., the tractor is ready to be supplied to the market.

DISMOUNTING STAGE:

After the processes of washing, drying, painting, baking, the assembled piece is finally arrived to the
DISMOUNTING STAGE through conveyor. This dismounting stage is further divided into different
small stages & in each stage, 2 persons works at a time, on an assembled piece of chassis & engine.
The work is divided between these 2 men at the different stages. The dismounting stage is divided
into 5 different stages in which the parts of the tractor are fitted on the assembled piece of chassis &
engine & in every 6 minutes, we got a complete tractor, which is removed from the conveyor of the
dismounting stage.

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STAGE 1:

• Alternator connection
• Horn
• Brake rod
• Brake switch connection
• Fan belt

STAGE 2:

• Speedometer wire
• Rear frame
• Fuel tank
• Overflow pipes
• Felt pads

STAGE 3:

• Fan
• Radiator
• Hose pipes
• Dash board (it mainly has instrumental panel which contains engine oil meter, fuel
gauge, ampere meter, temperature gauge, speedometer)
• Dash board cover
• Number plate

STAGE 4:

• Battery
• Steering wheel
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 • Head lights
• Clutch connection
• Hooks and side panel
• Knobs and covers  Sealings

STAGE 5:

• Seat
• Sheet metal covers (side panel covers, side shield, bonnet, front grill)
• Fenders
• Tyres fixing
• Batter cover
• Torque checking
• Engine oil pouring and greasing
• Charts and stickers

After completing all the above stages the tractor reaches the point where it is removed from the
conveyor, which is known as the DISMOUNTING STAGE of the tractor. A platform is there
& when the tractor reaches the platform the conveyor is removed & the tractor is free. After
that the tractor slides down the platform & reaches the stage, which is the final stage after the
dismounting of the tractor. This stage comes before the testing of the tractor. In this following
functions & equipments are fitted on the tractor:

• Air cleaner
• Exhaust
• Front tyres distance check and adjust
JOB-ASSIGNED

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 I was working under the guidance of Mr. Navjot Singh (Officer Heavy Machine Shop)
during the training period. The main areas of interest which my job includes are as follows:-

1. To study the FANUC operating system which is widely used uin HMS.

2. To study the LAYOUT plan of all the lines

3. To note down any problem/fault occurred during the shift.

MAINLY TO DO ALL THE TPM WORK ON M/C No. 488.01,491.03,491

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CONCLUSION
Overall, my internship training experience at Swaraj Plant was a valuable learning opportunity. I
gained practical skills and knowledge in skill chart creation, troubleshooting, and human resources
management and problem solving.

The experience helped me grow both personally and professionally by exposing me to new ideas and
challenging me to think critically.

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