Thermax Limted, Pune

GOVERNMENT COLLEGE OF ENGINEERING, AMRAVATI
(An Autonomous Institute Of Government of Maharashtra)

DEPARTMENT OF MECHANICAL ENGINEERING REPORT

“Reduction in unloading time of cut plate parts from CNC machines and thus increasing productivity of many plants in Thermax”
SESSION 2011-2012
GUIDED BYMR. PRASAD JAMADADE

SUBMITTED BYSarang Kale MECHANICAL ENGINEERING IIIRD YEAR

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CERTIFICATE
This is to certify that this project report has been prepared by Sarang Kale, students of third Year, Mechanical Engineering, “GOVERNMENT COLLEGE OF ENGINEERING, AMRAVATI” in an acceptable manner as a complete fulfillment of the In-plant Project during the academic session 2011-12 . He under the guidance of Mr. PRASAD JAMDADE & carried out the Project at THEMAX LIMTED, PUNE in a satisfactory manner. We take this opportunity of wishing them all the success in their future endeavors. PUNE DATE: - / /2012

PRASAD JAMADE post (THERMAX Limt., PUNE)

KIRAN KHIRSAGAR (THERMAX Limt., PUNE)

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ACKNOWLEDGEMENT
I express my heartfelt thanks to THERMAX LIMITED, PUNE for their kind co-operation & support in enabling me to complete my project. I wish to specially thank Mr. PRASAD JAMDADE whose guidance helped me a lot in understanding the project. I also express our sincere gratitude and thanks to Mr. ANUP GANDHI, Asst. Manager-HR, for giving me the opportunity to understand work culture and imbibing in me the discipline from this reputed plant. Last but not the least, my thanks is also due to each and every staff member of the industry. I hope that this training will help us in boosting our confidence & will encourage me in handling future projects.

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PREFACE
During the preparation of any shell of boiler or any other required accessories, the metal sheet has to be loaded under the CNC machine where it undergoes cutting operation as per the requirement, then that cut required part and remaining scrap has to be unloaded from that CNC bed. In above mentioned cycle, the main problem is that the unloading time is very high as compared to loading time (near about 10-15 times). This excessive extra time causes the reduction in productivity of company, and hence causes the economic loss as well.

This project is to find solution to decrease that excessive extra unloading time of the cut metal parts and remaining sheet scrap.

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CONTENTS
1. History 2. Introduction 3. Engine Assembly Plant 4. Organization Chart 1 5 7 8

5. Engine Assembly Process

12

6. Flow Diagram of Engine Assembly Process

21

7. Project :Pre-Modification Flow & Post Modification Flow

26

8. Products of Mahindra & Mahindra 9. Conclusion

28 30

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10.References

31

HISTORY
Mahindra & Mahindra Limited is the flagship company of the Mahindra Group, a multinational conglomerate based in Mumbai, India. The company was set up in 1945 in Ludhiana as Mahindra & Mohammed by brothers K.C. Mahindra and J.C. Mahindra and Malik Ghulam Mohammed. After India gained independence and
Pakistan was formed, Mohammed immigrated to Pakistan where he became the

nation's first finance minister. The company changed its name to Mahindra & Mahindra in 1948. Mahindra & Mahindra was set up as a steel trading company in 1945. It soon expanded into manufacturing general-purpose utility vehicles, starting with assembly under license of the iconic Willys Jeep in India. Soon established as the Jeep manufacturers of India, Mahindra & Mahindra later branched out into the manufacture of light commercial vehicles (LCVs) and agricultural tractors. Today, Mahindra & Mahindra is the leader in the utility vehicle segment in India with its flagship UV Scorpio and enjoys a growing global market presence in both the automotive and tractor businesses. Over the past few years, Mahindra & Mahindra has expanded into new industries and geographies. They entered into the two-wheeler segment by taking over Kinetic Motors in India. Mahindra & Mahindra also has controlling stake in REVA Electric Car Company and acquired South Korea's SsangYong Motor Company in 2011. The US based Reputation Institute recently ranked Mahindra among the top 10 Indian companies in its 'Global 200: The World's Best Corporate Reputations' list.
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Awards & Achievements
 Bombay Chamber Good Corporate Citizen Award for 2006-07  Business world FICCI-SEDF Corporate Social Responsibility Award – 2007
Business world and FICCI joined hands in 1999 to recognize the companies that take corporate social responsibility as seriously as their business. The outcome of that association was the Business world-FICCI SEDF Corporate Social Responsibility Award, which went through its seventh edition in 2007. This year‟s jury, chaired by Abid Hussain, former Indian Ambassador to the US, declared Mahindra & Mahindra the winner for its special focus on educating the underprivileged. The first runner-up was Tata Tea for its focus on helping the disabled. NTPC was declared the second runner-up for its immaculate waste management programme. The jury gave a special commendation certificate to Apollo Tyres for its attempt to contain the spread of HIV/AIDS. Two other shortlisted companies, MSPL and ONGC, were awarded certificates of appreciation. The winners were felicitated by finance minister P Chidambaram at a ceremony on 16 May 2008, at FICCI Federation House, New Delhi.

 DEMING PRIZE
The Deming prize, established in December 1950 in honor of W. Edwards Deming, was originally designed to reward Japanese companies for major advances in quality improvement. Over the years it has grown, under the guidance of Japanese Union of Scientists and Engineers (JUSE) to where it is now also available to nonJapanese companies, albeit usually operating in Japan, and also to individuals recognized as having made major contributions to the advancement of quality. The awards ceremony is broadcast every year in Japan on national television.
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 JAPAN QUALITY MEDAL IN 2007
Your Company has been awarded the Japan Quality Medal (JQM) in 2007, by the Union of Japanese Scientists and Engineers (JUSE), Tokyo, Japan. JQM is a rare honour given to a Company for excellence in Total Quality Management (TQM). The Company is the only Tractor Company in the world to win this Award. The Company had also won the Deming Application Prize in 2003. Both of these prizes are recognition of the Company‟s customer focus, commitment to TQM practices and demonstration of results by significantly improving product and process quality. The US$ 6.3 billion Mahindra Group is among the top 10 industrial houses in India. Mahindra & Mahindra is the only Indian company among the top three tractor manufacturers in the world. Mahindra's Farm Equipment Sector has recently won the Japan Quality Medal, the only tractor company worldwide to be bestowed this honour. It also holds the distinction of being the only tractor company worldwide to win the Deming Prize. Mahindra is the market leader in multi-utility vehicles in India. It made a milestone entry into the passenger car segment with Logan. Mahindra is the only Indian company among the top tractor brands in the world and has made an entry in two wheeler segment. The Group has a leading presence in key sectors of the Indian economy, including the financial services, trade and logistics, automotive components, information technology, infrastructure development and After-Market. With over 62 years of manufacturing experience, the Mahindra Group has built a strong base in technology, engineering, marketing and distribution which are key to its evolution as a customer-centric organization. The Group employs over 70,000 people and has several state-of-the-art facilities in India and overseas. The Mahindra Group has ambitious global aspirations and has a presence on five continents. Mahindra products are today available on every continent except Antarctica. Mahindra & Mahindra has one tractor manufacturing plant in China, three assembly plants in the United States and one at Brisbane, Australia. It has made strategic acquisitions across the globe including Stokes Forgings (UK), Jeco Holding AG (Germany) and Schoneweiss & Co GmbH (Germany). Its global subsidiaries include Mahindra Europe Srl. based in Italy, Mahindra USA Inc. and Mahindra South Africa.

Major Achievements of Mahindra Group
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 Mahindra & Mahindra made the first indigenous Jeep in the country in 1949.  On August 24, 2009, Economic Times announced the Lifetime Achievement Award 2008-09 for our Chairman, Mr. Keshub Mahindra the award has been bestowed on his for „decades of service to Corporate India.  Mahindra‟s Automotive Sector has won the all India award for export excellence instituted by the Engineering Export Promotion Council. The Automotive Sector has been crowned the Star Performer for 2007-08 on the basis of its growth in exports over previous years.  Mahindra & Mahindra ltd. has featured in Forbes‟ Asian Fabulous 50 list.  Fourth largest tractor company in the world.  Largest manufacturer of tractors in India.  Largest manufacturer of MUVs, offering over 20 models.  The gross revenues and other income for half year ended September 09 grew by 5.2% to 16150.31 crores.

INTRODUCTION
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Mahindra & Mahindra is one of the leading tractor brands in the world by volume. It is also the largest manufacturer of tractors in India with sustained market leadership of over 25 years. It designs, develops, manufactures, and markets tractors as well as farm implements. Mahindra Tractors (China) Co. Ltd.

manufacturestractors for the growing Chinese market and is a hub for tractor exports to the USA and other nations. Mahindra & Mahindra has a 100% subsidiary, Mahindra USA, which assembles products for the American market. Mahindra & Mahindra is a major automobile manufacturer of utility vehicles, passenger cars, pickups, commercial vehicles, and two wheelers. Its tractors are sold on six continents. It has acquired plants in China and the United Kingdom, and has three assembly plants in the USA. Mahindra & Mahindra has partnerships with international companies like Renault SA, France and International Truck and Engine Corporation, USA. Mahindra & Mahindra has a global presence and its products are exported to several countries. Its global subsidiaries include Mahindra Europe Srl. based in Italy, Mahindra USA Inc., Mahindra South Africa and Mahindra (China) Tractor Co. Ltd. Mahindra & Mahindra made its entry into the passenger car segment with the Logan in April 2007 under the Mahindra Renault joint venture. Mahindra & Mahindra will make its maiden entry into the heavy trucks segment with Mahindra Navistar, the joint venture with International Truck, USA. Mahindra & Mahindra's automotive division makes a wide range of vehicles including MUVs, LCVs and three wheelers. It offers over 20 models including new generation multi-utility vehicles like the Scorpio and the Bolero. It formerly had a joint venture with Ford called Ford India Private Limited to build passenger cars.
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At the 2008 Delhi Auto Show, Mahindra executives said the company is pursuing an aggressive product expansion program that would see the launch of several new platforms and vehicles over the next three years, including an entry-level SUV designed to seat five passengers and powered by a small turbo diesel engine. True to their word, Mahindra & Mahindra launched the Mahindra Xylo in January 2009, and as of June 2009, the Xylo has sold over 15000 units. Also in early 2008, Mahindra commenced its first overseas CKD operations with the launch of the Mahindra Scorpio in Egypt, in partnership with the Bavarian Auto Group. This was soon followed by assembly facilities in Brazil. Vehicles assembled at the plant in Bramont, Manaus, include Scorpio Pik Ups in single and double cab pick-up body styles as well as SUVs.

ENGINE ASSEMBLY PLANT
 Engine Assembly:-

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F06, Nagpur was producing only H-1 models of engines-AVL on one assembly line with a capacity of 174 per day & 235 and 245 on another assembly line with a capacity of 50 per day.  Machining:a] AVL crank case capacity was84 per day. b] The manufacturing strategy was o have a capacity of 165 per day.  ASSEMBLY FEATURES: Each station can carry/ cater to the fastening requirements of any model of engine (Excellent fastening quality with limited investment).  Rails on frictionless nylon wheels (Reduction in operator fatigue).  Material movement on trellis. No pallet movement inside assembly area (Improvement in work environment).  Common engine assembly conveyor for all models.  Air conditioned assembly enclosure.  Frictionless lifting & shifting facility with KBK rails.  Common testing trolley.  Effective control over process.

ORGANISATION CHART
PGL
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ENGINE PG

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Maintenance Manager

Engine & Testing Manager

Machining Manager

Process Engg. Manager

DY. manager

DY. Manager

8 DY. Managers

3 DY. Managers

DY. Manager

Cell Member

WST

Cell Member

WST

WST

Cell Member

WST

ENGINE
Diesel Engine

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In 1892 Rudolf Diesel developed and obtained the German patent for the diesel engine. His goal was to create an engine that was highly efficient. Much more efficient than the gasoline engine that was invented in 1876 and was not very efficient at all. Especially at that point in time. There are two main differences between a diesel engine and a gasoline engine. A gasoline engine intakes a mixture of gas and air, compresses it and ignites the mixture with a spark. A diesel engine takes in just air, compresses it and then injects fuel into the compressed air. The heat of the compressed air lights the fuel spontaneously. A gasoline engine compresses at a ratio of 8:1 to 12:1, while a diesel engine compresses at a ratio of 14:1 to as high as 25:1. The higher compression ratio of the diesel engine leads to better efficiency. Gasoline engines use either a carburetor or a fuel injection system to deliver the fuel to the cylinder. With a carburetor the fuel is mixed as it enters the intake manifold, long before it gets to the cylinders. In a fuel injection system the fuel is injected just before the intake stroke at the intake valve Diesel engines use direct fuel injection (DI), that is to say the diesel fuel is injected directly into the cylinder. The diesel engine has no spark plugs. The air it takes in is compressed and the fuel is injected directly into the cylinder where the heat caused by the air compression ignites the fuel. In the old days this meant that it exploded and expanded very quickly, making a noisy engine. This is why most diesel cars were IDI (indirect injection); the rough behavior was fixed by injecting the fuel into a small pre-combustion chamber that is connected to the cylinder by a narrow passage.
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This slows down the explosion, as the gasses have to escape from through the narrow passage into the cylinder. This gives a softer bang and a smoother engine, but the gasses have to work harder, which lowers the efficiency a little. However the newer breed of DI engines use other techniques to tame the behavior of the engine, such as two stage injection, electronic control, and acoustic shrouds and shock absorbing engine mounts to mask the rattle. The injector on a diesel engine is its most complex component and has been the subject of a great deal of development and innovation. On any specific engine it may be located in a variety of places. The injector has to be able to withstand the temperature and pressure inside the cylinder and still deliver the fuel in a fine mist. Getting the mist circulated in the cylinder so that it is evenly distributed is also a problem, so some diesel engines employ special induction valves, pre-combustion chambers or other devices to swirl the air in the combustion chamber or otherwise improve the ignition and combustion process. One major difference between a gas engine and a diesel engine is in the injection process. Most car engines use port injection or a carburetor rather than direct injection. In a car engine all of the fuel is loaded into the cylinder during the intake stroke and then compressed. The fuel/air mixture limits the compression ratio of the engine. If it compresses the air too much, the fuel/air mixture spontaneously ignites and causes knocking. A diesel compresses only air, so the compression ratio can be much higher. The higher the compression ratio, the more power is generated. Compared to gasoline-powered vehicles, diesels are more fuel efficient, and they can travel significantly farther on a tank of fuel than their gasoline counterparts.
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Diesel engines produce more torque, and they tend to be more durable. They don't need an electric ignition system, which reduces their complexity. However, they also create more noise, they can be difficult to start in extremely cold weather and they sometimes require more frequent routine maintenance than gasoline engines.

ENGINE ASSEMBLY PROCESS
The assembly of engine is done step by step process which is given in below: In this process the crank case enters by means of the continuous moving conveyer into station where the bearing shells are provided.
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 In this process the crank shaft is assembled and after that the linear (sleeve) is added in the crank case. The co-ring is provided in the sleeve and oil is used as the lubricant. Oil is used for met-log purpose which provides jamming between parts.  In this process the piston assembly is done. The connecting rod is assembled and then tight by means of dc nut runner by providing torque as 115N-m. After that front plate is provided on the top of the crank case. The idler gear is provided on the front plate and the function is transmitting the rotation of crank shaft to FIP gear. The idler gear & front plate is tight by providing the torque 70 lbft through dc nut runner. The starter motor is provided for starting purpose. 1 lbft = 1.35 N-m

 The adopter plate is provided in front plate for holding the FIP. Then the FIP assembly is done & between the FIP and front plate the gasket is provided. The FIP is tight by means of providing torque 85 N-m. The cooling jet is added for providing the oil for cooling as well as for lubricating. The cooling jet is fixed by providing torque 10N-m. The bolts are tight by providing torque 20lbfp. For fixing the oil pump 27 lbft torque is provided. Mainly 4 types of oil pump are used which are turbo595, junset295, regular & junset575.  In this process the float checking is done by means of micro-gauge & the all gears are check by manual inspection using torque range tool.  Front cover is assembled in this stage by providing the rotational torque 25N-m. Then ROSR (Real Oil Seal Retainer) assembly is done. Sealant is provided for avoiding the oil leakages. For oil seal adjustment hydraulic oil seal pressure machine is used. Then pulley is assembled by providing torque 100N-m. Oil pan is assembled by providing rotational torque 25 N-m. After that the amount of fuel is decided by using the IS (Ignition Gauge) gauge &
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PIS (Pre-Ignition Gauge) gauge. For FIP locking 36 N-m rotational torque is provided. After that gasket is provided on the top of crank case then cylinder head assembly is done. Torque provided for fixing the cylinder head is between 250-300N-m. After that the push rod, rocker arm assembly is done.  In this stage the tappet setting is done means the clearance is cheeked. The decided value of clearance for inlet and exhaust are 12&16 thau respectively. Then the spill pipes are provided for preventing the overflow of fuel. Then the high pressure line is provided those function is to provide high pressure fuel to injectors. After that alternate bracket, tappet cover & flywheel are assembled. All these processes are manufacturing process, now we see the dressing process as follows:1] D1 ENGINE NO. PUNCHING: -In this process the engine no is provided on the engine by means of hand punching. 2] D2 OIL FILTER FITMENT: - In this process the oil filter is assembled by means of dc nut runner (torque provided is 25 N-m). 3] D3 LPP FITMENT: - In this process the LPP pipe are assembled. Then the water cooling pipe, thermostat value are also assembled. The function of thermostat valve is to prevent the evaporation of cooling water. 4] D4 ALTERNATOR & BETL TENSION: - In this process the alternator is assembled in the engine body whose function is to charge the battery when engine runs. The pulley is connected to the alternator by means of belt. 5] D5 OIL FILLING: - In this process engine oil is filled in the engine.
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6] D6 QP2:- In this process the external checking is done manually. And the various joints and bolts are checked. So in this way the engine assembly is done. TORQUE VALUES STAGE OPERATION a) Main Oil gallery-plug fitment. b) Side Oil gallery- plug fitment. c) Oil Pressure Adopter. d) Studs for Water Pump. e) Water Drain Plug. f) FIP stud Fitment. g) FIP Stud Plug Fitment. a) M. B. Cap Fitment. b) Crank Pinion Bolts Tightening. c) Starter Motor Fitment. AVL 16 – 20 lbft 8 – 10 lbft NEF 20 ± 2 N-m

12 ± 2 N-m

15 lbft 12 -14 lbft

20 ±2 N-m
--------

CC1

14 -16 lbft -----------90 -95 lbft

25 ± 3 N-m 20 ± 2 N-m 10 ± 2 N-m 168 ± 8 N-m

M-2

-------

65 ± 3 N-m

-------

49 ± 5 N-m

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a) Cam Shaft S/A Fitment.

20 -25 lbft

125 ± 6 N-m to Cam Gear Mtg bolts. 25 ± 3 N-m to Cam thrust Plate. ------

-------

b) Starter Motor Fitment.

20 -30 lbft

M-3

c) Front Plate Fitment.

4 -6 N-m For Screw. 18 -22 lbft For 5/16” 8 -12 lbft For 1/4”

-------

-------

------65 ± 5 N-m

d) Piston S/A Fitment.

40 -45 lbft

e) Idler Gear Fitment

-------

25 ± 3 N-m

a) Idler Gear Fitment. b) FIP Fitment. c) Oil Pump Fitment.

65 - 75 lbft 18 – 22 lbft 25 – 30 lbft

---------

-----------------

M-4

d) FIP Gear Fitment. e) Piston Cooling

35 -40 lbft

85 ± 5 N-m

-------

10 ± 2 N-m

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Jet Fitment.

a) Front Cover Fitment.

18 -22 lbft

25 ± 3 N-m

M-6

b) IPG Cover Fitment. c) Fuel Filter Bracket Fitment. a) Water Pump Fitment. b) ROSR Fitment.

18 -22 lbft

25 ± 3 N-m

18 -22 lbft

---------

25 - 39 lbft

---------

25 -30 lbft ----------

25 ± 3 N-m 100 ± 5 N-m

M-7

c) Pulley Fitment & Torquing. d) Oil Pump Fitment. a) Fitment of Oil Pan.

----------

49 ± 5 N-m

07 -09 lbft

25 ± 3 N-m

M-8

b) Drain Plug Fitment. c) Oil Pan Fitment.

30 lbft

85 ± 5 N-m

-------

20 ± 2 N-m

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a) Spill Cut-Off Selling.

04 -05 N-m on Inspection Cover Screw. 25 -30 lbft on Mounting Bolts.

04 -05 N-m on Inspection Cover Screw. 36 ± 2 N-m on FIP mtg Bolts. 12 ± 2 N-m on lub Oil Banjo.

M-9
b) FIP Lub Oil Pipe & Banjo Bolt Fitment.

08 -10 lbft on lub Oil Banjo.

M-10

Cylinder head S/A Fitment

60 -65 lbft 60 -65 lbft on Bolts.

90N-m, 60⁰, 60⁰. ---------

M-11

Rocker-Arm Fitment.

25 -30 lbft on Nuts.

36 ± 3 N-m on Nuts.

a) Water Pump Belt Fitment.

10 -22 lbft on Lock Nuts.

----------

M-12

b) Exhaust Manifold Fitment.

25 -30 lbft

----------

c) HPP & Overflow Pipe Fitment.

d) Spill Pipe Fitment.
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25 -30 lbft on HPP Nuts. 04 -06 lbft on Overflow Pipe Nuts. ----------

25 ± 2 N-m -----------

10 ± 2 N-m

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e) Rear Lifting Eye Fitment. f) Alternator Bracket Fitment. g) Valve hsg Cover Fitment.

----------

49 ± 5 N-m

----------

49 ± 5 N-m

----------

25 ± 3 N-m on Mounting Bolts.

a) Flywheel Fitment. b) Pulley Torquing.

60 -65 lbft

168 ± 8 N-m

115 -135 lbft 225 -260 N-m on Nuts

---------------

M-13

a) Oil Filling FIP. b) Fuel Filter Fitment.

18 -22 lbft 18 -22 lbft

18 -22 lbft on Filler Plug. ----------

D-1

c) LP Pipes Fitment.

18 -22 lbft on Inline FIP Banjo. 15 lbft on Overflow Banjo Rotary.

----------

----------

d) Pull to Stop Bracket Fitment.

----------

25 ± 3 N-m

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a) Oil Filter Fitment. b) By-pass Tube Fitment. c) By-pass hose Fitment.

25 -30 lbft

-----------

08 -10 lbft

------------

03 -04 lbft

------------

D-2

d) Oil Cooling Circuit sub Assembly Fitment. e) Exhaust Manifold Stud Fitment. f) Exhaust Manifold Fitment. a) Alternator Bracket Fitment.

---------

25 ± 2 N-m

----------

25 ± 2 N-m

---------

25 ± 3 N-m

18 -22 lbft

----------

D-3

b) Fuel Filter Fitment. c) Low Pressure Pipe Fitment. d) Water pump & hose Fitment.

--------

25 ± 3 N-m

---------

30 ± 3 N-m on Banjo Inline FIP 25 ± 2 N-m

---------

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a) Oil Cooler Pipe Fitment.

---------

10 ± 3 N-m

D-4

b) Oil Filter Fitment. c) Alternator Fitment.

---------

12 ± 3 N-m

------------------

49 ± 5 N-m to mtg Bolts. 25 ± 3 N-m to Bolton tioner plate. ------------

Front Axle

135-140 lbft

So these are the torque values for different stages.

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FLOW DIAGRAM OF ENGINE ASSEMBLY PROCESS
M1- CRANK CASE LODING & MB CAP REMOVAL
(THE BERARING SHELLS IS ASSEMBLED.)

CRANK SHAFT SUB ASSEMBLY

M2- CRANK SHAFT FITMENT
(CRANK SHAFT IS MOUNTED ON THE CRANK CASE.)

PISTON M3- PISTON FITMENT SUB
(PISTON PART, FIP & OIL PUMP IS FITTED IN CRANKCASE)

ASSEMBLY

M4- TIMING GEAR FITMENT
(IDLER GEAR, CAM GEAR & FIP GEAR ARE MOUNTED ON CRANK CASE.)

M-5 QP-I
(QUALITYVISE PROCESS MEANS ALL GEARING ARRENGEMENT IS CHECK MANUALLY)

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Cont…………

FRONT COVER SUB ASSEMBLY M6- FRONT COVER FITMENT
(THE FRONT COVER IS PROVIDED FOR HOUSING PURPOSE)

M7- ROSR FITMENT
(REAL OIL SEAL RETAINER IS FITTED ON CRANK CASE WHOSE FUNCTION IS TO PREVENT THE FLOW OF OILL)

M8- OIL PAN FITMENT
(OILPAN IS FITTED BY APPLYING ROTATIONAL TORQUE25 N-m)

M9- SPILL CUT OFF
(AMOUNT OF FUEL IS DECIDED & FIP LOCKING IS DONE)

M10- CYLINDER HEAD FITMENT
(BY USING DC NUT RUNNER (TORQUE BETWEEN RANGE 250300N-m) THE CYLINDER HEAD IS FIXED.)

M11- ROCKER ARM FITMENT AND TAPPET SETTING
(LUBRICATION PIPE, PUSH ROD AND FINALLY ROKERARM IS ASSEMBLED AND THEN TAPPET SETTING MEANS CLEARANCE IS CHECKED)

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Cont…………

M12- HPP & EXHAUST MANIFOLD FITMENT
(HIGH PRESSURE PIPE (P=512bar), SPILL PIPE & EXHAUST MANIFOLD ARE ASSEMBLED BY APPLYING ROTATIONAL TORQUE.)

M13- FLYWHEEL FITMENT
(ALTERNATOR BRAKET (torque = 6 lbfp), TAPPET COVER (torque=25 lbfp) & FLYWHEEL (torque= 168N-m) IS LOADED ON THE BODY.)

M14- ENGINE UNLOADING

So, all this processes are manufacturing process of engine assembly. Now we will see the dressing process which is done in various stages as follows:-

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Cont……… …

D1- ENGINE No. PUNCHING
(THE ENGINE NO IS PUNCHED IN THE ASSEMBLY MANUALLY.)

D2- OIL FILTER FITMENT
(FUEL FITER & OIL FILTER (Torque=25N-m) IS ASSEMBLED AT THIS STAGE)

D3- LPP FITMENT
(LOW PRESSURE PIPE LINE, WATER COOLING PIPE AND THERMOSTAT VALVE ARE TIGHT AT THIS STAGE)

D4- ALTERNATOR & BELT TENSION
(ALTERNATOR IS PROVIDED AT THIS STAGE WHOSE FUNCTION IS TO CHARE THE BATTERY & BY USING BELT THE ALTERNATOR IS CONNECTED TO THE PULLEY.)

QP-II
(EXTERNAL CHECKING IS DONE HERE.)

D5- OIL FILLING
(ENGINE OIL IS FILLED AT THIS STAGE)

ENGINE TESTING SECTION
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 ENGINE TESTING:In the engine testing section basically two engine models are checked which are:A] Regular AVL (Australian vehicle limited) B] NGEF (New Generation Engine Family) The problem which tested in the engine testing are leakages, part –missing, specific fuel Consumption & Average of engine is checked by means of eddy current dynamometer. The time required for testing of engine is around 1 hour for AVL and for NEF is around 1 hour 10 minutes. Generally 300ml fuel is used for engine testing. Formula for Calculating Specific fuel Consumption is:S.F.C. = Where, 1ml=0.84gm, B.H.P. = Where, Dynamic Constant= 7024.26

So by using these two formulas the values are calculated & the engine testing is done.

PROJECT: - Pre-Modification Flow
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& Post-Modification Flow
FINISH ENGINE STORAGE SPACE

MATERIAL STORAGE
ENGINE TESTING SECTION

INSPECTION ROOM METALLURGY LAB

TOILET

RACKS

M A
CRANKCASE CLEANING

I N W A Y

ENGINE DEPARTMENT OFFICE

ENGINE ASSEMBLY SECTION

SECTION

CYLINDERHEAD CLEANING

ENTRANCE
SECTION WASH ROOM

PASSING WAY

TOILET

GENRAL ENGINE PLANT LAYOUT

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In this project, I observed the plant layout of “ENGINE ASSEMBLY DEPARTMENT” & “ENGINE ASSEMBLY LINE”. I have seen that the plant layout is process type that means the all processes are related to each other. For example: - the bearing shells are provided at CC-1 station & then the crank shaft is assembled at CC-2 station. During the training, I made different sheets of engine plant layout which shows every section of engine assembly that sheets are attached in this report. During my training some modifications are maid in the engine assembly line, where as the position of sub assembly stations are also changed for reducing the cycle time and reducing the various problems which occurs during the assembly.

Reasons of changing layout:More no. of movements of operator is required during assembly in previous plant layout. The cycle time of assembly is more in that so the required changes are maid to improve the productivity.

Effect In Production After Changing The Plant Layout: Cycle time is reduced.  Movement of operator during assembly is minimized.  Effective control over process.

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PRODUCTS OF MAHINDRA & MAHINDRA COMPANY
Company Manufactures Mainly 3 Categories of Tractors, 1. ARJUN ULTRA-1 (445 DI, 555DI, 605DI)

2. SARPANCH (265DI, 275DI, 475 DI, 575DI, 595 DI)

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Thermax Limted, Pune

3. BHOOMIPUTRA (235DI, 245DI, 265 DI, 275 DI, 475 DI, 575DI)

4. GENSET

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CONCLUSION
Various Engine Models were studied in the Engine Assembling process and the enhancement of Teaching Techniques for the Employers. The assembly of engine is done by using continuous moving conveyor and various stations are maid for assembly of engine. There are 14 M-stations & 6 D-stations situated in the assembly line. The material handling devices used in this industry is Trolley. For material storage in the station Trolleys are used. My project for training is “Pre-Modification Flow & Post Modification Flow”. During my training, I prepare a layout of engine assembly line and from that I concluded that the layout of engine assembly is process type means that all assembly

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Thermax Limted, Pune

process is interrelated to each other. The assembly time is become least by means effective control over the process.

REFRENCES

Books: Automobile Engineering, Vol.1 – Dr. Kirpal Singh.  Theory of Machines – R. S. Khurmi and J. K. Gupta.  Internal Combustions Engine – V. M. Domkundwar.

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Thermax Limted, Pune

 www.mahindra.com  www.scribd.com  www.vxb.com  www.google.com  www.autoindia.com

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