Ashish Training
Ashish Training
Ashish Training
PREPARED BY: -
NAME: - ASHISH
ROLL NO.: - 200161620045
BRANCH: - MECHANICAL ENGINEERING
COURCE: - B.TECH
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LIST OF CONTENTS
1 Training letter 03
2 Declaration by Student 04
3 Acknowledgement 05
4 Preface 06
10 CONCLUSION 31
11 REFERENCES 32
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lOMoARcPSD|34119814
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DECLARATION BY STUDENT
an
outcome of my research work. I further certify that.
2.The work contained in the report is original and has been
done by
me under the general supervision of my supervisor.
3.We have followed the guidelines provided by the
university in
writing the report.
4.Whenever I have used materials (data, theoretical
analysis, and
text) from other sources, I have given due credit to them in
the
text of the report and giving their details in the references.
4
ACKNOWLEDGEMENT
5
PREFACE
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CHAPTER-1
Overview:
Founder and Foundation:
It’s visionary Mr. HP NANDA, from a small Agency house in 1944 to one of the
largest engineering conglomerates in India, the saga of our ascent is Entwined in the
evolving dynamics of India’s economic progress. In a journey of seven pioneering
decades, we have reshaped, redefined and reinvented, the way India lives, works and
travels.
Vision & Values:
Escorts’ vision is to be among the top engineering companies in India. We shall
achieve this goal by being the preferred solution provider to the needs of our
customers, by practicing respectful and ethical business practices, by being the
employer of choice within the engineering industry, and by providing superior returns
to our investors.
Escorts Tractor Price starts from Rs. 2.75 to 5.20 Lakh in 2022. Escorts Offers a wide
range of 8 tractor models in India, and HP range starts from 12 ehp to 35 hp.
Their primary objective for setting up this in-house R&D unit was to have a centre
of excellence with global perspective to develop comprehensive technology plans
for innovations. And to optimize the product cost through continuous VEVA (Value
Engineering & Value Analysis) and Standardization Program.
The facilities include a high-technology engine laboratory featuring fully
computerized test beds with online control, data acquisition and analysis.
Escorts limited founded in 1948 have played a prime role in farm
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mechanization. Escorts tractors are sold fewer than 3 brands Farmtrac,
Powertrac and Digitrac, each unique. The company incorporates values of
collaboration, empowerment, transparency and respect. Its vision is to become
India's leading engineering company by all ethical and fair means.
Businesses:
Motorcycles:
The motorcycle division of Escorts group used to manufacture Polish SHL M11 175
cc (10.7 cu in) motorcycles under the brand name Rajpoot from the early 1960s until
2005.
In the early 1980s, Escorts started making Yamaha motorcycles in India. Rajpoot 350
was launched in 1981, which was later followed by the Yamaha RX 100 in 1984. The
motorcycle manufacturing unit in Faridabad, India, was sold to Yamaha in the late
1990s when Escorts decided to quit the motorcycle business to concentrate on tractors
and auto components.
Knowledge Management Centre:
The Escorts Knowledge Management Centre (KMC) was created in 1976 and is
spread over 100,000 square meters (0.039 sq. mi) in Faridabad. The center
designs tractors. It has facilities such as an engine laboratory that has
computerized test beds with online control, data acquisition, and analysis; an
advanced vehicle testing 8
laboratory; a noise vibration and harshness lab; a metrology lab; and a materials
engineering lab.
.
About the company:
From breaking fresh ground for Indian Infrastructure to nurturing the earth with
harvests of prosperity - From mobilizing the economy on the rail-tracks of progress
to being its driving force on the highways of the nation we at Escorts are
transforming lives, with the power of technology and imagination.
Committed to engineer a better world, we combine endless possibilities of human
caliber with innovative engineering solutions. Today, and every day, we help fulfill
aspirations of every life we touch. Our foray into farm mechanization has helped
transform the farm and challenges of rural India, into yields of opportunity.
We are helping India strengthen its presence in the Agri sector and make this core
segment one of the strongest contributors to the national economy. By customizing our
products around specific farmer needs, we are not only enhancing their productivity,
but also bringing happiness and prosperity to their doorstep.
Committed to engineer a better world, we combine endless possibilities of human
caliber with innovative engineering solutions. Today, and every day, we help
fulfill aspirations of every life we touch. We believe in sustaining our growth
curve, both organically and through astute product definitions. Consequently, with
a seamless weave of experience, engineering and excellence, we stand in the
vanguard of progress, among the industry leaders in our chosen sphere.
History:
Escorts Limited was originally founded as Escorts Agents Ltd. in 1944 by brothers
Har Prasad Nanda and Yudi Nanda. They started a family-owned business, Nanda
Bus Company, in Jammu. Escorts Limited was founded in 1944, and company
headquarters are in Faridabad, Haryana. The organization did a fantastic job of
producing considerably superior results in terms of Escorts tractors promotion and
sales. This tractor brand is well-known in the agricultural machinery.
industry. Material handling, construction equipment, and automotive machinery are
all examples of this. The company has now established itself in the tractor market
as well. Escorts tractor models feature high engine capacity and long-lasting
efficiency, never letting a farmer's or other user's expectations fall short. Escorts
tractors have established an incredible and mind-boggling example for other tractor
companies in India.
These tractors have engines that range from 12 to 35 horsepower. Escorts tractors
have received a positive market response, and these tractors have outperformed the
industry norm for producing a desirable tractor for farmers. Escorts tractor prices in
India start from Rs 2.60 and Rs 2.90 lakhs. In India, the Escorts tractors brand has
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introduced 3+ tractor types that are high-performing and well-equipped with
technologically advanced features.
CHAPTER-2
•The student learns about components that fitted in tractors (engine, transmission,
differential housing).
•The student learns about Hydraulic system used in tractors and its working
(hydraulic lift and power steering).
•The student learns some skills such as problem-solving, team management, team
building, time management, presentation skills and communication skills.
•The student can get opportunities to face real-world problems and provide the
effective solution for them.
•The student also gains technical knowledge related to actual working of machine
as compared to virtual.
•The student learns various industrial techniques (like six sigma, assembly line
processes) in order to produce products that will defects free.
DESCRIPTION OF THE WORK DONE
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Learning outcomes
By this Internship I learnt to solve real-world problems coming during the
production and inspection of tractors.
I had learnt proper development of corporate skills and also time organizing
and management.
I had learnt about the tractors components and various system used in it.
I had learnt the various processes that used while manufacturing the
tractors and develop some technical skills.
I had learnt good team building activities, and communication and
presentation skills.
I had learnt how production lines run.
CHAPTER-3
Agricultural tractors are used as a power source for various field operations such as
planting, harvesting, tillage, transportation, through driving axles, and PTO
devices. The tractor consists of assembly of different parts like clutch housing, gear
box housing, rear differential housing, brake housing and axle tube housing.
Escorts Tractor Price starts from Rs. 2.75 to 5.20 Lakh in 2022. Escorts offer a wide
range of 8 tractor models in India, and HP range starts from 12 hp to 35 hp.
Their primary objective for setting up this in-house R&D unit was to have a centre
of excellence with global perspective to develop comprehensive technology plans
for innovations. And to optimize the product cost through continuous VEVA (Value
Engineering & Value Analysis) and Standardization Program.
The facilities include a high-technology engine laboratory featuring fully
computerized test beds with online control, data acquisition and analysis. Escorts
limited founded in 1948 have played a prime role in farm mechanization. Escorts
tractors are sold under 3 brands Farmtrac, Powertrac and Digitrac, each unique.
The company incorporates values of collaboration, empowerment, transparency and
respect. Its vision is to become India's leading engineering company by all ethical
and fair means.
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.
Fig. 1
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PTO UNIT
PULLEY
GEAR BOX
A Gearbox is a mechanism that changes the input drive speed to a lower or higher
output speed or reverses the direction of rotation. Tractor gear boxes are usually
multi-ratio, with modern ones being of a continuously variable design (CVT). Also
referred to as the Transmission, as it transmits power from the Engine to the
It is directly connected
to the engine and top FOURTH GEAR GTD
gear which provides
high power
SECOND GEAR
Z-33
FIRST GEAR
Z-38
SQUARE FACE
Wheels or other Mechanism’s is being driven. (Note: Transmission can also refer
to the whole drive train of gearbox.
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TRACTOR POWER OUTLETS {PTO}
Power take-off shaft is used to take power from the tractor engine, to run different
implements and separate machine-like rotator, thrasher, grass cutter and other
implements. The differential housing provides support to the end of PTO shaft. All
forces transmitted by PTO directly comes on rear differential housing. The PTO of
the tractor under consideration has two speeds 540 and 1000 rpm.
A tractor in used for not only pulling the implements for tillage operations, sowing
of various crops, but also used to power stationary equipment for doing operations
such as threshing, pumping water from tube wells. A power outlet is generally
provided at the rear of the tractors.
PTO
1.Power comes from the gearbox.
2.Counter shaft of the gear box is extended out to the rear side, act as PTO outlet.
Speed:
1. 540 rpm - 6 splines
2. 1000 rpm – 21
splines
Setting of speed
:Setting of rpm speed is generally for 3/4 setting of the hand accelerator of the
tractor.
CHAPTER-4
Quality and Production are two important pillars of industry. Improving productivity
and ensuring quality is the main objective of the company. Providing customers with
the best quality is the target of the company while keeping in mind about the
production control as well. In Escorts Ltd Farmtrac division these were the main
objectives.
To achieve these objectives assembly line, consist of 3 main departments: -
Fig. 2
This stage starts with the fitment of sheet metal and electrical parts, moving to
next stages includes fitment of tyres, oil filing, coolant filing, diesel filing
followed by fastening of parts like driver seat, steering wheel, etc.
Clearing all after paint stages the tractor’s engine is started for the very first time and
then moved to the FINAL INSPECTION AREA before rolling out the assembly line.
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Fig. 3 Fig. 4
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PRE-DELIVERY INSPECTION (PDI):
After finalizing the tractors from the FTA stage, it travelled to PDI department, where it
undergoes various inspections area like:
• The importance of PDI cannot be minimized. A quality department should ensure that
each technician that performs these inspections has full knowledge of what to
examine, how to examine, and the integrity to do it on every vehicle, every time, no
matter what.
• At first it may look like wastage of time, but this process will create a status for
customer satisfaction. This status will increase sales and trust among the end
customers.
Fig. 5
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Fig. 6
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CHAPTER-5
LEAD TIME:
Lead-time as the amount of time it takes you to receive stock or materials from your
supplier. It can also cover the amount of time from when a customer places an order
for a product you sell until they receive it. Manufacturing lead-time is best described
as the time it takes to create a product and deliver it to the consumer. It may feel like
manufacturing lead-time is something beyond your control if you’re relying on
outsourced products or materials. However, even if you can’t make your supply chain
work faster to suit your needs, you can control how lead-times affect your business
once you understand how long it will take on average to complete the manufacturing
process.
WIP stands for work in progress, and it’s a way to measure all of your products
that are currently in manufacturing but aren’t ready to move on to being part of
your for sale inventory. To calculate your production lead-time using this formula:
WORKING AREA:
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In order to achieve lead-time, it's mandatory that all the tractors that are rolled
down should complete all the PDI processes within 4 hours.
Various stages from assembly line to the PDI department as follows-
Fig. 7
Fig. 8
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RT (ROAD TEST)
1 30 min for road test.
. Inspector takes it for manual check
2 on field and there, defects will be
. noted down for repairing purpose.
3 Leakage and lose parts also counted.
. Check points are:
4 Running board mtg.
. Driver seat mtg.
Rear axle
Plough light
Stay bar check nut
Hand break
Clutch & brake rod
Fuel filter
Fig. 9
Fig. 10
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RTV (ROAD TEST VERIFICATION)
1. Now at this stage, the tractors which are
having defects that cannot be cured
from DT mechanic, will work upon.
2. Defects like: Engine noise
Brake jam
Engine smoke
Transmission noise
Greasing not done in any part.
Tyre wobbling
Mismatch lower links
3. If the problem is not in control of RTV
inspector than it will go to major
rework. (this will affect the lead time)
Fig. 11
ULTRA-VOILETTEST
1 This stage was just after the DT.
. If the tractor is OK from the DT inspector,
2 it will directly come to UV test.
. Check for leakage present in any part
3. and tractor is clean or not.
Parts like:
4. FIP (fuel injection pump)
Engine filter
Hydraulic filter
Hyd. Pressure pipe Steering flexible
pipe Spool valve.
Fig. 12
PT (PAINT TOUCH UP)
1. At this stage, all the masking on the
tractors will remove.
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2 Scratch detection and paint defects will nullify here.
. Marking of scratches and touching up the defects generates through the PDI and
3 assembly line processes.
.
Fig. 13
Fig. 14
OF (OIL FLASHING)
1. This is the final stage for PDI and after that
tractor will register inside the feeding room.
2. Oil flashing stage, lead time also stops and
PDI ok slip will generate from it.
3. This stage function, Is to check the level of
oil present inside tractor (transmission oil,
gear oil) is OK or low. If low than it will be
refill by the person.
4. This was the last stage, after this the
tractor
move to shipping department where it will
ready to deliver the customer.
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Fig. 15
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5.Top link paint uncover / overflow Top defects of After-paint:
Major defects:
1.Engine Overheating in field resulting into engine seizure
2.Main gear fouls with fender
3.Transmission noise
4.Fuel tank dent
5.Rear/Front tyres mismatch
6.Spindle & hub not greased
7.Fender tilted
8.Engine smoke
9.Brakes jam
10.RPM not set
11.Hydraulic pressure pipe clamp loose/miss
12.Alignment not set which includes:
13.Bonnet gap not set
14.Center-panel gap not set
15.Top hood gap not set/overlap
16.TO shaft cap loose
17.ender paint uncover/overflow/dusty/poor
18.Cluster meter beading not set
19.Lower link height uneven
20.Running board harness w/o clamp
These were the top defects that were coming continuously from the assembly line and
due to which tractor is taking more time to complete the stages of PDI which includes.
Road Test
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•Hydraulic dropping test
•UV test
•Road Test verification
CONCLUSION
Training at Escorts Ltd has helped me to learn about "the basics of tractor and its
components.
This internship served as an excellent medium to increase my knowledge.
This internship provides an excellent medium to increase the knowledge of solving
real world problems.
The internship was two-dimensional, Understanding the industry operations related to
the assembly line of tractors was also part of my internship.
This internship involved helping me identify problems and gain an understanding of
how to analyze that problem. It also included methodology, isolating possible causes,
reaching the root cause and proposing solutions to deal with it.
Going through the process of analysis and reporting, it helped me understand how
industries function.
This internship gave me an opportunity to learn the working model of the organization
and helped me bridge the gap between the student and the associates of the
company. I am grateful to everyone who helped me through this internship; My
learning and understanding has increased a lot.
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Downloaded by Vikash 0033 {Mechanical Engineering} ([email protected])