Report On Protec & Panchnath

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An industrial Report On

Protec

A Report

Submitted by:

JAY KACHA (17SDSME01004)

JAIKISHAN SINGH (17SDSME01024)

DIPLOMA

IN

MECHANICAL ENGINEERING

Under the Guidance of

PROF: NITIN JAYAKUMAR

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF DIPLOMA STUDIES,

R.K. UNIVERSITY,

RAJKOT, GUJARAT – 360020

Department of Mechanical Engineering School of Diploma Studies RK University Page 1


PREFACE
This industrial training report is based on, which we performed after completion of 16 weeks of
industrial training at PROTEC and PANCHNATH AUTO PVT LTD. It is a crucial requirement
to know the business in all respect for diploma students. It can be acquired after achieving
practical training in industries.

Being a student of Mechanical Engineering we wished to gain experience in the various aspects
of working in the industry. Our primary goal was to gain some insight into methods of assembly
and production and during our time at the industry, we have achieved it to some extent. It was a
good learning experience and will stand good in the future.

Practical study plays a vital role in the field of education. It has been introducing for us to get
practical knowledge along with the theoretical knowledge. How management principles are
implemented in business can only be known through practical study, through visit. We learnt
about the industrial environments like problems and opportunities.

Practical knowledge in the best experience was the key getaway and on that basis we can
comprehend all aspects of the business. Based on the theory, we got trained on how to perform
without practical knowledge outcome consequently.

The report covers the details of personal management, marketing management, financial
management, and other general information about the company.

Given above, we were placed for our industrial training purpose in PROTEC and PANCHNATH
AUTO PVT LTD, situated at shaper – Rajkot, which is a highly reputed manufacturing
company. The project report consists of the activity carried out by us, during the training period.
The objective for the industrial training was to gain practical experience by implementing
practically whatever we had learned during our academic year of the course.

Jay Kacha
Jaikishan Singh

Department of Mechanical Engineering School of Diploma Studies RK University Page 2


DECLARATION

I hereby declare that this submission is my own work and that, to the best of my knowledge and
belief, it contains no material previously published or written by another person, nor material
which to a substantial extent has been accepted for the award of any other degree or diploma of
the university or other institute of higher learning, except where due acknowledgement has been
made in the text.

Jay Kacha
Jaikishan Singh

Department of Mechanical Engineering School of Diploma Studies RK University Page 3


CERTIFICATE

This is to certify that the industrial training report in PROTEC AND PANCHANATH AUTO
Pvt. Ltd. submitted to the Mechanical Engineering School of Diploma Studies, RK University.
This is a record of the work carried out by them under our supervision and guidance and is to the
satisfaction of department.

Date:

Place: Rajkot

Signature of Internal Guide: Prof. Nitin Jayakumar

Signature of External Guide: Prof. Deepak Somaiya & Prof. Vipul Tajpara

Signature of Head of Dept.: Dr. Marmik Dave

Department of Mechanical Engineering School of Diploma Studies RK University Page 4


ACKNOWLEDGEMENT
We express our sincere gratitude to our respected guide Prof. NITIN JAYAKUMAR,
Department of Mechanical Engineering, School of Diploma Studies, RK University for his
guidance throughout the course.

We also thank Mr. ALOK MEHTA (Managing Director), Protec, GIDC Metoda, Rajkot and
Mr. VIPUL TAJPARA (Head Supervisor), Panchnath Auto PVT LTD who has supported us
throughout our industrial training with his patience and knowledge while allowing us the room to
work in our way. We attribute the level of our diploma to his encouragement and effort &
without him this report and industrial training, would not have been written or completed. One
simply could not wish for better or friendlier guidance.

As a part of the study and being a student of semester 6th diploma studies, we had visited the
“PANCHNATH AUTO PVT LTD.” A group company of field marshal diesel Pvt. Ltd For
industrial training. It was a very good learning experience for us to have worked in this industry.
Our heartiest thanks to PROF. MARMIK DAVE, Head of the Department, Department of
Mechanical Engineering, School of Diploma Studies, RK University, Rajkot who has always
shown kind concern and consideration regarding our academic requirements, we wish to express
our deep gratitude to Dr. NILESH KALANI for providing us with all facilities and opportunities
to complete this industrial training.

We would like to thank the Management and Employees of PROTEC and PANCHNATH
AUTO PVT LTD for providing us the practical guidance and adequate support whenever
required.

Our sincere most thanks to the administration and management of RK University for their effort
in encouraging us to pursue academic growth.

Thanks to our Parents, for their continuous support and encouragement to strive for our goals.
We are indebted to all staff, colleagues, and friends who have directly or indirectly helped us
towards the achievement of this task.

Department of Mechanical Engineering School of Diploma Studies RK University Page 5


ABSTRACT
Industrial internship/training organized by the department is a part of the 6th Semester gives
exposure to students knows about the real-life application of various subjects in the industry,
which we get a chance to work with industries and get practical knowledge of working in
industries as an employee. In daily life, all the companies thrive to improve performance and
their reputation.

This industrial experience motivates and guides students to get adopted as a professional in the
workforce. In every industry assembly line layout design is an important task which affects the
production of the company. In this training, we learn about how to assemble the tractor and the
process & system of manufacturing of the part, testing of the product. We work in a practical
view.

All the departments and their respective workers work together as united to carry the company
forward in the future. The employees gave some brief information on management and gave
guidelines on safety rules & regulation for industrial training and how to behave in the areas
where engine testing and maintenance is going on. We also learn about how to manage the
relationship between the workers and the supervisor. It’s wonderful that we got a chance to work
among such kind of workers and got practical knowledge. This project addresses the productivity
improvement of the manual assembly line by making the use of operation analysis in the
assembly line for the tractor manufacturing company.

A methodology is proposed that help to improve the productivity by the implementation of


various techniques such as task-based techniques, product based techniques, material based
techniques, lean production, etc. such approaches help in redesigning of the assembly line can
help in proper space utilization, reducing of the assembly transportation and also reduce time.

The required data can be obtained from the company such as various charts for study, assembly
line layout; Etc. This Company is in collaboration with Mahindra and Mahindra Ltd. They
assemble tractors under the name Mahindra. By application of such things in the automotive
company, we can get much-improved production which can increase the productivity of the
company.

Department of Mechanical Engineering School of Diploma Studies RK University Page 6


Table of Contents
Chapter Particulars Page
No No.
Preface I
Declaration Ii
Certificate Iii
Acknowledgement Iv
Abstract V
List of Figure Vi

1 Introduction 1-12

1.1 Establishment 9
1.2 Layout Of Industry 10
1.3 Name of Departments 11
1.4 Manufacturing Product Details 12
1.5 Manufacturing Process 19

Conclusion 22

References 23

Department of Mechanical Engineering School of Diploma Studies RK University Page 7


List of Figure
Figure No Name Page No
1.1 Layout of industry 10
1.2 Taper roller geometry 13
1.3 Dial indicator 14
1.4 Dial indicator with L.C. 10um 14
1.5 Dial indicator with magnetic stand 15
1.6 Dial indicator with V-block 15
1.7 Vernier callipers 16
1.8 Digital Vernier callipers 16
1.9 Rock well hardness testing machine 17

1.10 Mahr MMQ 100 18

2.1 Mahr XC 20 18

2.2 material flow chart 21

Department of Mechanical Engineering School of Diploma Studies RK University Page 8


Chapter-1 Introduction
1.1 Establishment

 The company was basically established in the year of 2012-13 under the guidance of existing
director, Mr. Alok Mehta, the technical supervisor, Mr. Deepak Somaiya, head of
maintenance department, Mr. D.P. Singh, head of inspection department, Mr. Brijesh Patel
and other helping hands.
 After Orbit, a famous company in grinding of tapper rollers, Protec is the only company
which is leading the business of grinding of tapper rollers. However, due to some lacking
factors and late establishment as compared to Orbit, Protec is on 2nd rank in this business.
 Although, Protec is upgrading every day and implementing new technologies and processes,
within next 10-15 years, according to the director, Protec will overtake Orbit.
 The company is located at Plot no. G-2219, GIDC Gate no.-1 (Kranti Gate), Kalawad road,
Rajkot-
 However, for further contact a personal may contact at [email protected].

Department of Mechanical Engineering School of Diploma Studies RK University Page 9


1.2 Layout of Industries

Figure 1.1: Layout of industry

Department of Mechanical Engineering School of Diploma Studies RK University Page 10


1.2 Departments

1. Inspection department: its work is to inspect the raw material before grinding and after
grinding. The purpose of doing inspection of raw material before grinding is to check the
quality of raw material.
2. Maintenance department: as the name itself suggest about the work done by this
department, generally all type of maintenance is done by this department. However, the
machine maintenance like preventive maintenance, daily maintenance, weekly maintenance,
monthly maintenance and yearly maintenance is done by machine operator.
3. Production department: it is also known as grinding zone. It grinds the raw material into
desired form once it gets inspected by the inspection team. However, after grinding, the
rollers are again inspected by inspection team as well as by QC department so that the quality
of products in maintained.
4. QC/standard room: This department handles those parameters of tapper rollers which can’t
me measured directly by any meter. So they use their own built software in order to check the
production.
5. Admin department: The admin department takes care of all the paper work done in the
industry. It is their responsibility to gather all the data and keep it safe. They keep data in
hard copy for three months. Then they make soft copies of data and save it to different
storages devices. The data which is more than three months older and is in hard copy is
thrown away.
6. Raw material department: This department checks whether the raw material came from
other industries is free from defects or not. They also decide the ranges of different
parameters of the tapper roller in which it is to be grinded. If the raw material is having
defects in it then during grinding also these defects will be visible and the buyers will reject
the grinded material.
7. Dispatch department (Logistics): This department handles the selling of production done
by the production department. The material which is QC passed is weighed by the dispatch
department and loaded to the trucks coming from buyer industries.

Department of Mechanical Engineering School of Diploma Studies RK University Page 11


1.2 Manufacturing of product details:

 The main process carrying out in the factory is grinding. The tapper rollers (raw material)
generally comes from two industries named, Ravi PVT.LTD and Apple PVT.LMD.
 Tapper rollers have some parameters. The grinding should be done within the range of these
parameters. The range is decided as per the series number of the rollers by the inspection
team. It is the duty of production unit that these ranges of different parameters should not
get violated while grinding.
 Tapper rollers have different parameters that are described below, even the meters that are
used to measure them are shown with them.
1. Outer diameter (Big OD): it is the outer diameter of the roller.
2. Tapper (Small OD): it is the ovality of the surface of the roller.
3. Ovality: it is the deviation in ovality of the outer diameter of the roller.
4. Length: it the height of the roller from big OD to small OD or vice versa.
5. Face: it the upper surface of roller from big OD.
6. Run out: it is the deviation in surface of the face.
7. Indent: it is the inner part of the face.
8. Indent diameter: it is the diameter of the indent. It is always less than the big OD.
9. Indent depth: it is the depth of the indent from the face’s surface.
10. Radius: it the imaginary line that starts from big OD and ends on small OD but can be
made to meet at single point which is center for both the OD’s.

Department of Mechanical Engineering School of Diploma Studies RK University Page 12


Figure 1.2: Taper roller geometry

 List of measuring instruments available


 Dial Indicators with L.c. of – 0.5μm, 0.01 μm,1 μm
 Dial Indicator with Magnetic Stand
 Length checking Comparator
 V-Block with Dial
 All 3 type Vernier Caliper
 Feeler Gauge
 Mahr XC20 ( for Profile )
 Mahr XR20 ( for RA-Roughness Average )
 Mahr MMQ 100 ( for 3-Point Ovality )
 Rockwell Hardness Testing Machine

Department of Mechanical Engineering School of Diploma Studies RK University Page 13


Fig.1.3: Dial indicator

Fig.1.4: Dial indicator with L.C. 10um

Department of Mechanical Engineering School of Diploma Studies RK University Page 14


Fig.1.5: Dial indicator with magnetic stand

Fig.1.6: Dial indicator with V-block

Department of Mechanical Engineering School of Diploma Studies RK University Page 15


Fig.1.7: Dial indicator with standard V-block

Fig.1.8: Vernier calipers

Fig.1.9: Digital Vernier calipers

Department of Mechanical Engineering School of Diploma Studies RK University Page 16


Fig.1.10: Rock well hardness testing machine

Department of Mechanical Engineering School of Diploma Studies RK University Page 17


Fig.2.1: Mahr MMQ 100

Fig.2.2: Mahr XC 20

Department of Mechanical Engineering School of Diploma Studies RK University Page 18


1.5 Manufacturing process:
 Manufacturing process is divided into eight different processes mentioned below:
1. Shot blasting
2. Oiling
3. Rough grinding
4. Semi-finish grinding
5. End face grinding
6. Finish grinding
7. Online visual inspection
8. oiling

 Shot blasting: the raw material/tapper rollers that come for grinding are so rough that they
damage the grinding tools a lot if they are directly sent for grinding. Hence, the raw material
is first sent to shot blasting machine in which they are forced to strike with the small
spherical metal balls. These balls when strike with rollers at high speed, they remove the
roughness present on the surface of tapper rollers making them somewhat smoother for
grinding.

 Oiling: it is the process in which the shot blasted tapper rollers (forging rollers) are oiled in
order to protect them from corrosion.

 Rough grinding: it is the first step of grinding process of forging rollers. The machine used
to carry the process is named as “Centerless grinding machine”. The range in which the
forging rollers are to be grinded is from 130um to 140um and the ovality should be from 0 to
4um. The size of forging rollers depends on the series and type of the roller. However,
normally the size of the forging rollers varies from 230um to 250um.

 Semi finish grinding: it is as same as rough grinding process but the range of grinding
decreases to 50um to 55um and the ovality should be from 0 to 3um.

Department of Mechanical Engineering School of Diploma Studies RK University Page 19


 End face grinding: it is totally different from the above two processes. This process is
carried by the machine named, end face grinding machine in which the upper face of the
roller is grinded. In this machine, some different parameters of the rollers are to be taken
cared like length should be from 27.950mm to 28.050mm and the face runout should be less
than 12um. These parameters are measurable by the machine operator with the help of dial.
Radius should be from 127mm to 140mm. Roughness average should be less than 2um.
However, these parameters can’t be measured from any instrument directly by the machine
operator. Therefore, samples from the production line are taken by the machine operator and
sent to standard room for checking of these parameters. However, different rollers have
different ranges of same parameters.

 Finish grinding: it is as same as rough and semi finish grinding but here the size decreases
to 1um-4um.

 Online visual inspection: after completing all four processes, the rollers are passed through
a channel for visual inspection in which rollers having dent marks on dimple as well as on
surface, blind rollers, corroded, etc. are taken out from the channel.

 Oiling: the grinded rollers are oiled in order to protect them from corrosion.

Department of Mechanical Engineering School of Diploma Studies RK University Page 20


Fig.2.3: material flow chart

Department of Mechanical Engineering School of Diploma Studies RK University Page 21


Conclusion
 PROTEC is a wonderful place for learning new things. Specially, the grinding process of
tapper rollers.
 However, the tapper rollers have many difficulties in grinding, but once the process is
known, anybody can control the parameters of the tapper rollers.
 After implementation of 5S Manufacturing System working environment is became clean
and systematic.
 Concluding the experience of working in Protec is very good. The employees and
management are connected with each other in the company premises.
 All the employees including worker, Supervisor & Management persons are helping hands
that are always Ready & Happy to Help.
 Technically and practically implementations of new ideas are very useful for increasing
interest towards workers.
 To increase Work Ethics, Quality, Efficiency and Reputation towards the society and
competitor companies.
 The task and targets to be completed were discussed on every Thursday including training
of newer documents and maintenance method.
 As experience is getting more and more there are lots of knowledge that we got rather that
before few time.
 After implementation of 5S Manufacturing System working environment is became clean
and systematic.
 Contribution of all of the other departments the concept of Model Machine is became
successful.
 As the skill and Knowledge is getting more and more Supervisors gives some
responsibility for running the production line in our way.
 Implementation of various type of manufacturing system with the advancement in machine
maintenance procedures.

Department of Mechanical Engineering School of Diploma Studies RK University Page 22


References
1. https://www.mikrosa.com/en/centerless-grinding-machines/grinding-knowledge-
centerless-grinding/fundamentals-of-centreless-grinding/

2. https://www.ctemag.com/news/articles/basics-centerless-grinding
3. https://www.mahr.com/en/Services/Production-metrology/Products/MarForm---Table-
Formtesters/MarForm-MMQ-100/
4. https://www.globalspec.com/SpecSearch/SearchForm/manufacturing_process_equipment
/abrasives_grinding_finishing/grinding_machines_finishing_equipment/grinders_grindin
g_machines
5. https://www.mahr.com/en/Services/Production-metrology/Products/MarForm---Table-
Formtesters/MarForm-MMQ-100/

Department of Mechanical Engineering School of Diploma Studies RK University Page 23


An industrial Report On

Panchnath Auto PVT LTD

A Report

Submitted by:

JAY KACHA (17SDSME01004)

JAIKISHAN SINGH (17SDSME01024)

DIPLOMA

IN

MECHANICAL ENGINEERING

Under the Guidance of

PROF: NITIN JAYAKUMAR

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF DIPLOMA STUDIES,

R.K. UNIVERSITY,

RAJKOT, GUJARAT – 360020

Department of Mechanical Engineering School of Diploma Studies RK University Page 24


PREFACE

This industrial training report is based on, which we performed after completion of 16 weeks of
industrial training at PROTEC and PANCHNATH AUTO PVT LTD. It is a crucial requirement
to know the business in all respect for diploma students. It can be acquired after achieving
practical training in industries.

Being a student of Mechanical Engineering we wished to gain experience in the various aspects
of working in the industry. Our primary goal was to gain some insight into methods of assembly
and production and during our time at the industry, we have achieved it to some extent. It was a
good learning experience and will stand good in the future.

Practical study plays a vital role in the field of education. It has been introducing for us to get
practical knowledge along with the theoretical knowledge. How management principles are
implemented in business can only be known through practical study, through visit. We learnt
about the industrial environments like problems and opportunities.

Practical knowledge in the best experience was the key getaway and on that basis we can
comprehend all aspects of the business. Based on the theory, we got trained on how to perform
without practical knowledge outcome consequently.

The report covers the details of personal management, marketing management, financial
management, and other general information about the company.

Given above, we were placed for our industrial training purpose in PROTEC and PANCHNATH
AUTO PVT LTD, situated at shaper – Rajkot, which is a highly reputed manufacturing
company. The project report consists of the activity carried out by us, during the training period.
The objective for the industrial training was to gain practical experience by implementing
practically whatever we had learned during our academic year of the course.

Jay Kacha
Jaikishan Singh

Department of Mechanical Engineering School of Diploma Studies RK University Page 25


DECLARATION

I hereby declare that this submission is my own work and that, to the best of my knowledge and
belief, it contains no material previously published or written by another person, nor material
which to a substantial extent has been accepted for the award of any other degree or diploma of
the university or other institute of higher learning, except where due acknowledgement has been
made in the text.

Jay Kacha
Jaikishan Singh

Department of Mechanical Engineering School of Diploma Studies RK University Page 26


CERTIFICATE

This is to certify that the industrial training report in PROTEC AND PANCHANATH AUTO
Pvt. Ltd. submitted to the Mechanical Engineering School of Diploma Studies, RK University.
This is a record of the work carried out by them under our supervision and guidance and is to the
satisfaction of department.

Date:

Place: Rajkot

Signature of Internal Guide: Prof. Nitin Jayakumar

Signature of External Guide: Prof. Deepak Somaiya & Prof. Vipul Tajpara

Signature of Head of Dept.: Dr. Marmik Dave

Department of Mechanical Engineering School of Diploma Studies RK University Page 27


ACKNOWLEDGEMENT
We express our sincere gratitude to our respected guide Prof. NITIN JAYAKUMAR,
Department of Mechanical Engineering, School of Diploma Studies, RK University for his
guidance throughout the course.

We also thank Mr. ALOK MEHTA (Managing Director), Protec, GIDC Metoda, Rajkot and
Mr. VIPUL TAJPARA (Head Supervisor), Panchnath Auto PVT LTD who has supported us
throughout our industrial training with his patience and knowledge while allowing us the room to
work in our way. We attribute the level of our diploma to his encouragement and effort &
without him this report and industrial training, would not have been written or completed. One
simply could not wish for better or friendlier guidance.

As a part of the study and being a student of semester 6th diploma studies, we had visited the
“PANCHNATH AUTO PVT LTD.” A group company of field marshal diesel Pvt. Ltd For
industrial training. It was a very good learning experience for us to have worked in this industry.
Our heartiest thanks to PROF. MARMIK DAVE, Head of the Department, Department of
Mechanical Engineering, School of Diploma Studies, RK University, Rajkot who has always
shown kind concern and consideration regarding our academic requirements, we wish to express
our deep gratitude to Dr. NILESH KALANI for providing us with all facilities and opportunities
to complete this industrial training.

We would like to thank the Management and Employees of PROTEC and PANCHNATH
AUTO PVT LTD for providing us the practical guidance and adequate support whenever
required.

Our sincere most thanks to the administration and management of RK University for their effort
in encouraging us to pursue academic growth.

Thanks to our Parents, for their continuous support and encouragement to strive for our goals.
We are indebted to all staff, colleagues, and friends who have directly or indirectly helped us
towards the achievement of this task.

Department of Mechanical Engineering School of Diploma Studies RK University Page 28


ABSTRACT
Industrial internship/training organized by the department is a part of the 6th Semester gives
exposure to students knows about the real-life application of various subjects in the industry,
which we get a chance to work with industries and get practical knowledge of working in
industries as an employee. In daily life, all the companies thrive to improve performance and
their reputation.

This industrial experience motivates and guides students to get adopted as a professional in the
workforce. In every industry assembly line layout design is an important task which affects the
production of the company. In this training, we learn about how to assemble the tractor and the
process & system of manufacturing of the part, testing of the product. We work in a practical
view.

All the departments and their respective workers work together as united to carry the company
forward in the future. The employees gave some brief information on management and gave
guidelines on safety rules & regulation for industrial training and how to behave in the areas
where engine testing and maintenance is going on. We also learn about how to manage the
relationship between the workers and the supervisor. It’s wonderful that we got a chance to work
among such kind of workers and got practical knowledge. This project addresses the productivity
improvement of the manual assembly line by making the use of operation analysis in the
assembly line for the tractor manufacturing company.

A methodology is proposed that help to improve the productivity by the implementation of


various techniques such as task-based techniques, product based techniques, material based
techniques, lean production, etc. such approaches help in redesigning of the assembly line can
help in proper space utilization, reducing of the assembly transportation and also reduce time.

The required data can be obtained from the company such as various charts for study, assembly
line layout; Etc. This Company is in collaboration with Mahindra and Mahindra Ltd. They
assemble tractors under the name Mahindra. By application of such things in the automotive
company, we can get much-improved production which can increase the productivity of the
company.

Department of Mechanical Engineering School of Diploma Studies RK University Page 29


Table of Contents
Chapter Particulars Page No.
No
Preface 25
Declaration 26
Certificate 27
Acknowledgement 28
Abstract 29
List of Figure

1 Introduction 33-35

1.1 Establishment 33
Product overview 34
1.2
Layout Of Industry 35
1.3
36-48
2 Engine Department

Cleaning Machine 36-37


2.1
Station1 38
2.2
Station2 39
2.3
Station3 40
2.4
Sub-Assembly-1 41
2.5
Sub-Assembly-1 42
2.6
Station4 43
2.7
Station5 44
2.8
Station6 45
2.9
Station7 45
2.10
Station8 46
2.11
Station9 47
2.12
Station10 48
2.13

3 VTU and Hydraulic 49-55

What is Hydraulic? 49
3.1
Sub-assembly -1 50
3.2
Station1 51
3.3
Station2 52
3.4
Sub-assembly -2 53
3.5

Department of Mechanical Engineering School of Diploma Studies RK University Page 30


3.6 Station3 54
3.7 Station4 54
3.8 Station5 55

4 Pre Paint Assembly 56

5 Paint Shop 57

6 Transmission 58-62

6.1 Introduction to transmission department 59


6.2 Information about gear box 59
6.3 Transmission Assembly 60
6.4 Bevel Pinion and spline shaft fitment 60
6.5 Reverse idler gear 61
6.6 Flow chart diagram 62

Conclusion 63

References 64

Department of Mechanical Engineering School of Diploma Studies RK University Page 31


List of Figure
Figure No Name Page No
1.1 Layout of industry 36
2.1 Cleaning Machine 37
2.2 Cleaning Machine 38
2.3 Crank Case 39
2.4 Bearing Flange 40
2.5 Cam Follower 41
2.6 Flywheel & Flywheel Housing 42
2.7 Cylinder Head 43
2.8 Cylinder Block 43

2.9 Piston & Connecting Rod Assembly 44

2.10 Fuel Pump 44

2.11 Cylinder Head, High Pressure Pipe 45

2.12 Fuel Filter 45

2.13 Water Pump 46

2.14 Main Pulley 46

2.15 PTO Shaft 47

2.16 Alternator 48

2.17 Hydraulic Pump Bracket 48

2.18 Cap 49

2.19 Dip Stick 49

3.1 Very Touch Unit 50

3.2 Rocker Arm 51

3.3 Rocker Shaft Assembly 51

3.4 Rocker Shaft Assembly 52

Department of Mechanical Engineering School of Diploma Studies RK University Page 32


3.5 VTU Body 53

3.6 Rocker Shaft 53

3.7 Top Link 54

3.8 Draft Sensing 54

3.9 Draft Control Link 55

3.10 Passion Control Link 55

3.11 Control Valve 56

3.12 VTU Testing Machine 56

4.1 Docking Process 57

6.1 Gear box 59

6.2 Bevel pin and Spline Shaft 60

6.3 Reverse idler gear 61

6.4 Flow chart diagram 62

Department of Mechanical Engineering School of Diploma Studies RK University Page 33


CHAPTER 1: INTRODUCTION

1.1 Establishment

1. About Mahindra,
Mumbai, August 1, 2012: Mahindra & Mahindra’s Farm Equipment Sector (FES), a part of
the U.S. $15.4billion Mahindra Group, Maintained its leadership position in the tractor
industry in July 2012.

Domestic sales in July 2012 stood at 15495 units during July 2011. Total Tractor sales
(domestic export) in July 2012 stood at 16521 units, as against 16692 units for the same
period last year. Exports for the month of July 2012 stood at 1026 Units, as against 993
units in July 2011.

2. About The Mahindra Group,


The Mahindra Group focuses on enabling people to rise. Mahindra operates in the key
industries that drive economic growth, enjoying a leadership position in tractor, Utility
vehicles, and information technology and vacation ownership. Mahindra has a presence in
the automotive industry, agribusiness, aerospace, logistic, real estate, retail, steel and two
wheelers.

Department of Mechanical Engineering School of Diploma Studies RK University Page 34


1.2 Product overview

The Yuvraj 215’s low cost of ownership and best-in-class fuel efficiency is bringing
mechanization opportunities to farmers with small landholdings across India and
revolutionizing earnings capabilities.

Yuvraj 215 designed for small farm operations. With one cylinder and 15 HP, the Yuvraj
215 is compact and easy to operate. We built it for long life and low maintenance,
durability and dependability. It offers the first water-cooled single cylinder engine in the 15
HP segment, and its side shift gear is easy and comfortable to use.

The Yuvraj 215 achieves a top speed of 25 Km/ph the highest in its class. It can haul up to
1.5 tons. It’s ideal for farmers ready to upgrade from bullocks or power tillers, or for
farmers who need an additional machine for specific applications like inter-culture, power
generation, or water pumping. Farmers, who cultivate vegetables, tend orchards, or raise
cash crops can all benefit from the Yuvraj 215’s strong value proposition of affordability,
power, and performance. Yuvraj is used popularly in Cultivator, Rotator, Boom spray,
Blow sprayer, water pump, Trolley, Special attachment for Garbage handling across the
state. Yuvraj enables the small farmer to own a tractor and benefit from mechanization,
thus helping him boost his productivity.

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1.3 Panchnath Auto PVT LTD

Figure 1.1: Layout of industry

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CHAPTER 2: ENGINE DEPARTMENT

1. There are total ten stages in engine department including two sub-assemblies and
cleaning machine.
2. Each engine is probably completed in 10 minutes.
3. 28 worker work in this department.
4. Around 200 components are fixed or assembled to shape an engine.

2.1 Cleaning Machine


1. Load parts on cleaning tray are lifted to required position by using lifter truckle as per
requirement.
2. Input cleaning tray machine is used to lock it. And then press cycle button is started.
3. After cycle is complete parts are properly cleaned and drying is done by using Air
pressure.

Fig 2.1 & 2.2 Cleaning Machine

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 Following parts are cleaned in cleaning machine :
1. Crank case: It is the main cover of engine also called body of engine, made of Cast Iron.
2. Cylinder block: It is the block with internal cylindrical hole, made with Cast Iron and
place up on the crank case. It is to provide support to the piston and it also provide
cooling.
3. Crank shaft: It is output rotating part made with steel forging. It receives the efforts
supplied by the piston to connecting rod.
4. Cylinder head: It is placed on cylinder block.
5. Counter balance: Counter is used to remove the vibration in engine.
6. Timing cover: Timing cover is used to close the crank case and support the cam follower
& LOP gear.
7. Bearing flange mounting: Bearing flange is used to maintain steady position of crank
shaft.
8. Cover for cylinder head: Reduce atmosphere noise.
9. Connecting road: It is the rigid part which is used to connect piston and crank shaft.

2.2 Sub-Assembly-1

Fig 2.3 Crank Case

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1. Crank Case: It is the main cover of engine also called body of engine, made of Cast Iron.
2. Initially crank case is loaded on to line and Lubricating Oil Pump (LOP) gear sub
assembly is mounted onto the crankcase.
3. Ball bearing and main bearing fitment for crank case.
4. Grub screw is used for lubricating oil gallery.
5. Bearing flange sub-assembly is attached with flywheel to support movement of
Crankshaft.
6. Crankshaft assembly
7. During this stage sub assembly of counter balance, cam follower and crank shaft is done.

2.3 Stage 1

Fig 2.4 Bearing Flange


1. Bearing flange fitment
 Bearing flange is used to maintain steady position of crank shaft
2. Stamp engine number
 Engine number is stamped by using pouch and hammer.
3. Crank shaft
 It is output rotating part made with steel forging. It receives the efforts supplied by the
piston to connecting rod.
 Crank shaft working & not working check and crank shaft is play.
4. Engine mounting bracket
 Then bracket mounting on the crank case is done and is moved in for next process on the
assembly line of engine.

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2.4 Stage 2

Fig 2.5 Cam Follower


1. Cam follower
 Cam follower on force is applied from follower to cam and by using this force cam is
rotated. Follower comes down for helping cam to rotate particular circumference
length.
2. Crankshaft gear
 Crank shaft gear heating is done at 250° for the purpose of fitment.
3. Counter
 Counter is used to remove the vibration in engine.
4. Hand lever assembly
 Hand lever is used to increase the speed and engine is highly work
5. Extra fuel device
 If engine is stopped or not in working position than extra fuel device is used to run
the stopped engine and maintain the smoke.
6. Spacer for LOP
 Spacer for LOP is connect the LOP pump and LOP gear

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2.5 Stage 3

Fig 2.6 Flywheel & Flywheel Housing


1. Flywheel
 Flywheel is the element which is made up with CI, alloy of steel and having good
weight. It is placed on the crank shaft and it is used to store the mechanical energy
during the power stroke and it will release remaining three stroke also it is maintain
the fluctuation of speed of engine.
2. Flywheel is mounted taking the dowel pin as reference and the flywheel is locked using 6
Allen nuts and later the dowel pin is removed.
3. Weight of flywheel is nearly 25 kg.
4. Silicone gel (acts as a gum) is added on the outer ring and on the fly wheel.
5. The mounting flanges are bolted and the Manual inspection of bolts is done by yellow
Color marking.
6. Dowel pin is inserted on the crank shaft.
7. Starter motor is AC motor which is made to mesh with the flywheel.
8. Oil filter bracket is inserted.
9. Starter motor
 As its name indicates it starts working when engine is on.
 Starter motors have a pinion gear which is contact with the flywheel for starting
engine and engine stops when pinion is disengaged from flywheel.

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2.6 Sub-assembly-2

Fig 2.7 Cylinder Head


1. Cylinder block fitment:
 Water inlet flange stud.
 Inlet stud & nut (T : 12 – 15 Nm)
 Outlet dummy plate (T : 25 – 30 Nm)
2. Cylinder head assembly
 Expansion plug is inserted at the bottom of the cylinder head. Exhaust and inlet valve
spools are inserted; the diameter of inlet valve is greater than that of exhaust valve.
 Rocker arms are fixed in the cylinder head and springs are also placed on the inlet and
exhaust valve rods.
 Push rod tube, Rocker arm cover, High pressure pipe are also added in the same
stage.
3. Gasket for cylinder head is put on in between the case to the cylinder head. It is helpful in
preventing the leakage of air during compression stroke.
4. High pressure pipe is inserted between fuel injector and fuel injector pump.
5. Push rods connect cam to the rocker assembly for opening and closing of the valves.
6. Fitment acts as a temperature sensor.

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2.7 Stage 4

Fig 2.8 Cylinder Block


1. Cylinder block fitment
 It is the block with internal cylindrical hole, made with CI and place up on the crank
case.
 It is provide a support to the piston and it is also provide cooling.
2. Piston and piston rings
 It is cylindrical part fitted in the cylinder with rings and it other end connecting rod
 Piston made with aluminum Alloys.
 Piston is reciprocating part which receives the gas pressure and transmits to the
connecting rod.
 Piston ring provide a good sealing fit between piston and cylinder piston are equipped
with the piston ring
3. Connecting rod

Fig 2.9 Piston & Connecting Rod Assembly


 It is the rigid part which is used to connect piston and crank shaft.
 It is transmit the piston load to the crank shaft, thus it is used to convert reciprocating
motion of piston to the rotary motion of connecting rod.

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4. Piston & Connecting rod fitment
 Piston
 Connecting rod
 Brass
 Gudgeon pin
 Sairclip
 1st-Compression ring
 2nd-Scraper ring
 3rd- Oil ring
5. Check connecting rod
6. Strainer fitment
7. Drain plug fitment
8. Shim thickness and bumping
9. Bumping clearance measure

2.8 Stage 5
1. LOP gear fitment
 LOP gear is fitment on lop spacer through lop pump. It’s connecting with timing gear.
2. Timing covers sub-assembly and fitment
 Timing cover is used to close the crank cash and support the cam follower & LOP
gear
3. FIP fitment
 Fuel injection pump (FIP) is inserted near the cam shaft bearing.
 It supplies fuel from fuel filter to fuel injector with high pressure nearly 250 bars.

Fig 2.10 Fuel Pump

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2.9 Stage 6

Fig 2.11 Cylinder Head, High Pressure Pipe, Push Rods & Tube, Air & Exhaust out let

1. Air inlet
 Air is inserted inside the engine by an air inlet pipe and air inlet pipe is connected
with the air filter using the spacer.
2. Exhaust outlet
 Exhaust goes out through the exhaust pipe and exhaust pipe is connected with
silencer using the spacer.
3. High pressure pipe
 High pressure pipe is high pressure fuel is transferred between fuel injection pump
into fuel injector.
 Nearly 250 bar pressure which is inserted inside the high pressure pipe.
4. Push rods
 Push rod connect cam to rocker assembly for opening and closing of the valve.
5. Push road tube
 Push rod tube is used to protect push rod.
6. Rocker arm cover
 Rocker arm cover is to reduce atmosphere noise transmission.
7. Fuel injector
 It is used to inject fuel in a combustion chamber of diesel engine.

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2.10 Stage 7

Fig 2.12 Fuel Filter


1. Fuel filter fitment
 Unfiltered fuel may contain several kinds of contamination, for example paint chips
and dirt that has been knocked into the tank while filling, or rust caused by moisture
in a steel tank. If these substances are not removed before the fuel enters the system,
they will cause rapid wear and failure of the fuel pump and injectors. Fuel filters also
improve performance of engine.
 Fuel filter is mounting is done on flywheel housing with mounting bracket.
2. Lever is used to Pull stop lever assembly

2.11 Stage 8

Fig 2.13 Water Pump

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1. Water pump sub-assembly and fitment
 Water pump is mounted on the opposite side of the flywheel. It supplies water to the
water jacket surrounding the engine and other essential parts. It is connected to the
main inlet of the water jacket through a hose.
2. Main drive pulley mounting

Fig 2.14 Main Pulley


 Main drive pulley is mounted on PTO shaft
 Main pulley is used to transmit the power to water pump, Alternator.
3. P.T.O shaft fitment

Fig 2.15 PTO Shaft


 PTO (power track off) pulley is added. It is then mounted on the crank shaft.
4. Fan adaptor fitment
 It’s mounted on water pump and provides the support to fan.

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2.12 Stage 9

Fig 2.16 Alternator


1. Alternator, pulley & belt fitment
 Alternator is an electrical generator that converts mechanical energy to electrical
energy in the form of alternating current. Any AC electrical generator can be called
an alternator.
 Alternator is attached on a mounting, top of the crank case. Timing belt is added and
runs over alternator, water pump and PTO pulley.
2. Hydraulic pump bracket

Fig 2.17 Hydraulic Pump Bracket


 Hydraulic pump mounting bracket holder is added on timing cover

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2.13 Stage 10

Fig 2.18 Cap

Fig 2.19 Dip Stick


 Fill the 2.6 liter engine oil in engine(15w40)
 Dip stick fitment
 Tapper cover cap tighten with dolly tool

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CHAPTER 3: VTU AND HYDRAULIC

3.1 What is Hydraulic?

 It is a pneumatic device which is controlled by liquid pressure. In compression


pneumatic device oil pressure is employed and hence it is called as hydraulic.
 It is used in heavy lift the load.
 VTU-(very touch unit)

Fig 3.1 Very Touch unit

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1. VTU AND HYDRAULICS
 VTU stands for Very Touch Unit and it is usually employed in trucks to lift heavy
weights. It is based on the principles of hydraulics. It has 2 sub-assembly and 5
main stage in complete
3.2 Sub-assembly -1

Fig 3.2 Rocker Arm


 This is the simple sub-assembly and starting point is in the VTU assembly. The
rocker arm and connecting rod are taken. The connecting rod is fitted into the
rocker arm using the fixture provided. Proper movement of connecting rod is
checked. Also the PC and DC linkage assembly is done.
3.3 Stage - 1

Fig 3.3 Rocker Shaft Assembly Fig 3.4 Rocker Shaft Assembly

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 In this stage the rocker arm and connecting rod assembly, which was made in the
previous stage, is taken. The rockshaft is inserted into the VTU housing and the
rocker arm is pivoted. C-clip is used to ensure the proper locking of the shaft and
prevent disengagement. Also the hydraulic lift arm is fitted with proper
orientation.
1. VTU body
 Rocker arm is mounted on rock shaft after which the rock shaft is then mounted
on VTU body.
 Cam PC is added. It is used to bring back the spool valve in required position.
 Rock shaft bush is added. Washer is added on one side and oil seal on both sides
are added in order to prevent oil leakage.
 Lift arm is inserted on both the side and locked with a C-clip.
 Crank toppling is locked with draft sensing element.
 PC roller, PC link, DC link are mounted on the quadrant shaft. These three are
interconnected.
 DC bush lock with DC outer.
 DC outer is cabled with crank toppling.

Fig 3.5 VTU Body

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2. Rock shaft
 Rock shaft is used to transmit the power to lift arm. Rockshaft is also used to
lift Load.

Fig 3.6 Rocker Shaft

3.4 Stage – 2

 In this stage die bell crank assembly is fitted. Bell crank top link is pivoted
onto the bell crank assembly pin. After this the draft-sensing spindle is
inserted using the flanged nut. Draft sensing sleeve is mounted onto the draft
mounting assembly using outer draft sensing spring in between after this the
outer draft sensing link is inserted which supports outer draft sensing rocker.

Fig 3.7 Top Link Fig 3.8 Draft Sensing

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3.5 Sub-assembly – 2

 In this stage the hydraulic cylinder head assembly, quadrant bracket assembly
and valve control assembly is done. First of all orifice assembly is mounted on
to the cylinder head housing.
 After this isolator valve, valve shaft and isolating valve know is fitted into the
housing. For control valve assembly the hydraulic lift cylinder is mounted on
to the housing. Then piston assembly with RV rings is inserted into the lift
cylinder. After thin bore assembly control valve and control valve sleeve are
fitted on to the other side of the housing.
 After this the relief valve bore assembly is fitted into the housing. For
quadrant bracket assembly position control lever assembly and the quadrant
support bracket are mounted onto the quadrant position control plate. Now
draft control lever assembly and retainer are mounted on the quadrant strip
and the assembly is completed
3.6 Stage – 3
 PC link: -Position control link
 DC link:-Draft control link
 In this stage all the three sub-assemblies i.e. PC & DC linkages, hydraulic lift and
quadrant assembly fitment which has already been sub-assembled in the previous
stage arc fitted on to the VTU housing making it sure that the hydraulic cylinder
lift fits properly.

Fig 3.9 Draft Control Link Fig 3.10 Position Control Link

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3.7 Stage – 4
 In this stage the control valve, which was assembled in the previous subassembly
section, is fitted into the housing ensuring proper movement of the connecting rod
inside the valve. This is the final stage in the assembly after which the testing of
VTU is done which includes leakage, angle setting and load lifting capacity.
1. Control valve
 It comprises of spool valve, pressure valve, relief valve.
 When isolation valve is closed, piston stops the entry of oil and entry of oil is not
permitted further
 It goes to relief valve and then goes out. From this maximum pressure of relief
valve is measured.
 When spool valve is pressed inside, the oil flows into the piston continuously.
 In order to avoid this DC cable which is attached with the PC roller, pulls back
the spool valve and oil entry to the piston is stopped.

Fig 3.11 Control Valve

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3.8 Stage – 5
 In this stage the VTU leakage test and lifting tests are done. First, the VTU is
covered from the bottom and oil is filled and checked if there is any leakage.
After this the 450 kg weight is connected lifting arms and it is lifted and hold at
its maximum inclination so as to check the lifting and holding action.

Fig 3.12 VTU Testing Machine

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CHAPTER 4: PRE-PAINT ASSEMBLY
4.1 In Pre-paint assembly there are 6 stations

1. The Pre-paint assembly line is beside paint shop and Post paint assembly.
2. In station 1, the docking process is done in which the engine is connected with the
transmission.
3. There is a hydraulic machine in station 1, which is manually operated by a panel for docking
process.
4. The engine is first mounted on the machine and the transmission is mounted on a rail in
front of it. The docking process is done by operating the panel backward, forward, up 7
down.

Fig 4.1 Docking process

5. After that in station 2, hand lever, lever, foot base and battery tray is assembled.
6. In station 3, Brake and clutch is assembled. Brake is needed to be settled by putting a weight
of 7 Kg.
7. In station 4, Front axle is assembled.
8. In station 5, different pipes are assembled in the assembly, which are of oil filter and fuel
tank and etc.
9. In station 6, some other required assemblies are done after which the assembly is been sent
to the Paint Shop.

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CHAPTER 5: PAINT SHOP

5.1 Introduction

1. After pre-Paint the assembly of tractor goes to paint shop. In paint Shop the tractor is
washed with a high pressure of hot water. After washing the tractor it goes to clean with a
high pressure of air. After cleaning with air the tractor goes for paint, there it paints the
color with a color sprinkler. After having color the tractor goes to oven for 15 minute after
15 minute it automatically comes out of oven.

5.2 Station 1 - Paint Shop

1. After pre-paint the tractor goes for washing. The assembly of tractor gets washed with hot
water. After washing the pressurized air is flow on the assembly and cleans them. It cleans
all the minute parts as well big parts so that the color gets fixed well.

5.3 Station 2- Oven

1. In Paint shop color is spread through the nozzle on assembly of tractor. Then after tractor
assembly is gone to the oven. The oven is designed automatic open and closes the door in 15
minute. Tractor assembly are comes out automatically. Then after tractor assembly is gone in
post paint department.

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CHAPTER 6: TRANSMISSION

6.1 Introduction to transmission department


1. Transmission is the one department of our company where the assembly of gear system,
assembly of brake and assembly of rear axle is done for tractor.
2. We are working in this department. So we can learn about gear transmission system,
brake system, etc.
3. In this stage, we understood below points:
 How the tractor is running in variation speed.
 Which types of gears are used in gear box.
 How the fitting of different types of gears in trams cage.
 Types of liquid sealant tube.
 Fitting of brakes of tractor.
 Fitting of VTU (very touch unit).
 Fitting of clutch.
 Fitting of RAC (rear axle carriage sub assembly).
 Different range of torque and Size of bolts, studs and nuts, etc.

6.2 Information about gear box

Fig 6.1 Gear box

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 It is gear box. In this different gears are assemble in the body.
 It is connected with each other for transmission the motion to the wheel.
 This photo shows the different gears which are bevel and helical gears used in the
assembly of trance cage.
 In these stage spur gears, helical gears are used.

6.3 Transmission Assembly


 Transmission assembly deals with assembling of all the sub-assemblies into the
transmission case. The rack of cleaned transmission case are brought and first of
all magnetic drain plug is mounted on it
.
6.4 Bevel Pinion and spline shaft fitment

Fig 6.2 Bevel pin and Spline Shaft

 At first, the bearings for the spline shaft and lay shaft are hammered into the
transmission case. After this the spline shaft is hammered through the bearing-
Next step is to insert the bevel pinion shaft into the transmission case and the
cluster gear is mounted onto the spline shaft. This can get attached into the
sprockets of spline shaft and transmits the power.

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6.5 Reverse idler gear
 Reverse idler gear is used to reverse the direction of rotation of the output shaft.
In this the reverse idler shaft is inserted into the reverse idler gear, which is
supported by the Needle Reverse Bearing (NRB). After this the reverse idler gear
is mounted onto the transmission case and the reverse idler shaft hangs it.

Fig 6.3 Reverse Idler Gear

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6.6 Post-Paint Flow Chart Diagram

Wiring assembly Seat assembly Battery assembly

Fuel indicator Rear and front


Fender assembly
assembly wheel assembly

Air cleaner Air filter assembly


Silencer assembly
assembly

Radiator and coolant Hood, steering


assembly wheel and
Cooling fan assembly
dashboard
assembly

Fig 6.4 Post-Paint Flow Chart Diagram

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CONCLUSION

The next 8 weeks we took training in Panchnath Auto Pvt. Ltd. which makes many models of
Mahindra tractors , like JIVO , NXT , JIVO 4WD & 2WD etc.

In eight weeks we came to following conclusion which are Assembly of various parts used in
tractor, Problem occurring which doing assembly of tractor, Various stage are engine, engine
testing, VTU, transmission, Quality for manufacturing of tractor.

During one semester training period, a lot of experience, knowledge and exposure that we have
handy, All disclosures were awaken myself in a boost of self-confidence to face life more
challenging now.

Practical is a complement to the science or theory learned. This is clearly the concept of science,
where they have learned without practice will be lost and will not give anything - what effect. So
if we do without the knowledge of course there will be problems in terms of grip and stance ever
- changing.

During our industrial training, there are many changes from the point of learning environments
and discussion among supervisors. It can directly increase the dedication and rational attitude
toward us.

However, there are still some weaknesses that can be improved in the future. Therefore we
conclude that the industrial training program has provided many benefits to us even if there are
minor flaws that are somewhat disfiguring condition , so that this weakness can be rectified in
the future.

We can conclude that this industry is through training we received a lot of exposure in the
computing world. We would like to thank also the R K University giving students - students find
their own experience with having Industrial Training like this.

And we had all the important and necessary points and also we had taken visit the good and nice
company and also much known and honestly staff member.

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REFERENCES

1. https://www.mahindratractor.com/jivo-245-di.aspx
2. https://whatis.techtarget.com/definition
3. https://www.mahindratractor.com/tractor-mechanisation-solutions/tractor/yuvraj-215-nxt
4. https://www.mahindratractor.com/jivo-245-di.aspx
5. https://www.tradeindia.com/Seller-1141719-Panchnath-Auto-Pvt-Ltd-/
6. https://www.mahindratractor.com/jivo-245-di.aspx
7. https://www.mahindratractor.com/tractor-mechanisation-solutions/tractor/mahindra-265-
di

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