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CHAPTER I
INTRODUCTION
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REPORT ON ORGANISATION STUDY AT
TAFE GEAR DIVISION
CHAPTER I - INTRODUCTION
ABOUT THE COMPANY
Tractors and Farm Equipment Limited (TAFE) is an Indian manufacturer
of tractors and other farm equipment with its corporate
headquarters in Chennai. The company was established in 1960and has reported annual revenue of $ 1 billion and a sales volume
of over 100,000 tractors annually. Tractors and Farm Equipment
Limited (TAFE) is a member of the $1.6 billion Amalgamations
Group. TAFE has collaboration with Massey Ferguson (now owned
by AGCO Corporation, USA). TAFE is a renowned manufacturer of
tractors and a variety of farm equipment under the TAFE Massey
Ferguson and Eicher brands. TAFE acquired Eicher tractors in
2005 through a special purpose vehicle, TAFE Motors and Tractors
Limited. It is a unit company of the Amalgamations Group, which
is a wholly owned subsidiary. It has major presence in a number
of Indian states like Rajasthan, Gujarat, Andhra Pradesh,
Karnataka, Madhya pradesh and Uttar pradesh. It is one of India's
largest Light Engineering Groups with diverse interests in Diesel
Engines , Automobile components , Tractors and related farm
machinery, lubricants, panel instruments, hydraulic pumps,
Engineering Tools, Storage Batteries, Paints , Engineering
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http://en.wikipedia.org/wiki/Tractorhttp://en.wikipedia.org/wiki/Farm_equipmenthttp://en.wikipedia.org/wiki/Chennaihttp://en.wikipedia.org/wiki/Massey_Fergusonhttp://en.wikipedia.org/wiki/Massey_Fergusonhttp://en.wikipedia.org/wiki/Eicherhttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://en.wikipedia.org/wiki/Tractorhttp://en.wikipedia.org/wiki/Farm_equipmenthttp://en.wikipedia.org/wiki/Chennaihttp://en.wikipedia.org/wiki/Massey_Fergusonhttp://en.wikipedia.org/wiki/Massey_Fergusonhttp://en.wikipedia.org/wiki/Eicherhttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsphttp://203.199.238.221/cgi-bin/inetcgi/tafechannel/common/aboutus.jsp -
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Plastics , Automobile franchises and Printing apart from interests
in Agribusiness , book selling and publishing. The group's
leadership technology, built on foreign know how has been
nurtured through indigenous efforts.
TAFE was established in 1961 in collaboration with
Massey Ferguson, UK to manufacture and market a range of
tractors and related farm equipment in India. One of the largest
tractor manufactures of tractors in India, TAFE's vision is to be the
first choice of customers in India and to also move towards a
growing presence in the international markets.
With a network of more than 500 dealers, branches,
service outlets as well as its own sales offices and depots
covering the entire width and breadth of India, TAFE is committed
to providing complete farming solutions to its customers and
empowering them to work towards increased farm productivity,
prosperity and profits.
TAFE started its production of the popular tractor
model, Massey Ferguson 1035 in 1961. Now they manufacture
tractors under three brand names, TAFE, Eicher and Massey
Ferguson. TAFE has a five decade old collaboration with MasseyFerguson (now a part of AGCO Corporation, USA), which is one of
the leading manufacturer of tractors in the world. The company is
currently investing in a Greenfield project at Manisa Industrial
Estate in Turkey with a capacity to manufacture about 15000
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tractors.TAFE has been a pioneer in the mechanization of theIndian farms. Beginning with the popularizing of tractors in
agriculture in the early 60s, TAFE has many firsts to its credit. TAFE
was the first company to market a total package of Tractors and
farm equipment to not only provides farm power but also
interfaces to transform the farm power to increased farm
productivity. TAFE was also the first to introduce the Direct Injection
technology in India, thereby intiating considerable fuel saving and
the resulting economies in tractor operations cost to its
customers. TAFE was also the first Indian manufacturer to launch a75 HP tractor to cater to the emerging needs of very large farms
and agri-businesses. With four manufacturing locations at
Chennai(Sembiam), Madurai (Kallidaipatti),
Bangalore(Doddaballapur), and Mandidheep (Bhopal), TAFE has a
large manufacturing base. Its Madurai plant, the latest and
possibly the largest such plant in the country is specially tailored
to take on short run production batches to the exacting standards
demanded by advanced countries. TAFE is also involved in
making diesel engines, gears, panel instruments, engineering
plastics, hydraulic pumps, plantations and passenger car
distribution through other divisions and wholly owned
subsidiaries. TAFE Motors and Tractors Limited has, apart from
the tractor manufacturing plant at Mandideep mentioned above, a
Diesel Engine plant at Alwar, Rajasthan producing a range of air
cooled and water cooled diesel engines upto 80 HP with plans are
on to increase the product range up to 125 KVA. The
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Transmissions Division located at Parwanoo in Himachal Pradesh
produces a range of transmission components both for captive
use as well as for sale to OE manufacture and marketing of farm
implements, trailers and accessories, distribution of passenger
cars, manufacture of hydraulic pumps and panel instruments to
discerning customers both in India and overseas. All its plants and
sales offices are linked by VSAT links providing fast and efficient
communications and data linkage another first of its kind in India.
Apart from its core business of manufacturing and
marketing tractors, TAFE is also involved in the following related
and unrelated areas.
As a natural sequel to producing tractors, TAFE has
developed a range of matching trailers, implements and
accessories. These are marketed through TAFE's dealer network by
a totally owned subsidiary, TAFE Access Limited (TAL). As a natural corollary,
TAFE, through TAL is also involved in the marketing and distribution
of lubricants and greases for tractors through its dealer network.
TAFE is also involved in the packaged power industry
through its Power Source Division. At its fully automated modern
plant at Maraimalai Nagar, near Chennai, it produces a range of
automobile batteries, under the AMCO brand name, which find wide
OE application in the new generation two and four wheelers
manufactured in India as well as in the replacement market. The
batteries are marketed through another unit of the
Amalgamations group viz., AMCO Batteries Limited. As well as for
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sale directly through a dedicated distribution channel under the
brand name of Speed.
The tractor's hydraulics is an important part in the
transformation of power into farm productivity and the hydraulic
pump is a critical component of any tractor. The transmission of
power developed in the tractor's engine to the ground is also a
major part of the total design of the tractor. TAFE therefore has in-
house facilities for the manufacture of hydraulic pumps and also
gears for tractors. A related facility for the manufacture of panel
instruments, not only for captive use but also for sale to the
growing automobile industry in India is an integral part of the
company.
TAFE has also diversified into Engineering plastics and
production of tools and dies for this industry. Its Doddaballpur
plant has clamp capacities ranging upto 1300 tons and is a major
supplier of the needs for precision plastic components of the
white goods, IT, automobile industries. Its commercial tool room
produces tools and dies to international specifications demanded
by discerning buyers.
TAFE's vision of being the customer's first choice on
offering to the customers quality products engineered to
perfection using technology that is contemporary and relevant to
the market it serves. This approach to quality as being inherent to
its existence has obtained for TAFE certification under ISO 9002,
the quality movement permeates throughout the organization
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and is apparent from the various laurels won by quality circles
from the company in national and international arenas.
TAFE's vision is not just wishful thinking but based on
recognized engineering, marketing and financial strengths, built
up over the past four decades. In all that it does, TAFE pursues
excellence. That this is not a cliche is reflected in the words of
TAFE'schairman, "To us in TAFE, excellence is not something that we
engineer, input or inspect into our products. It is an innate desire
that inspires our hearts at work and at home and ripples out into
the world around us.
TAFE Gears Division (TGD) was established in 1996
which is located in Pudupakkam 5 kms from Kelambakkam
district. Gears division is a supplier machine shop which
manufactures Crown wheel and Pinion used in transmission
system. Parts manufactured in this division are supplied to the
assembling units in Kallidaipatti (Madurai), Doddabalbur
(Bangalore) and for spare parts. TGD has total area of 2.83
hectares and the plant is built in 1500 sqmts. TGD functions for 3
shifts in 24 hours. Sunday is holiday.
COMPANY LOGO:
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PRODUCT PROFILE
Crown Wheel & Pinion (CWP)
Product Portfolio :
6T x 37T CWP
7T x 39T CWP
11T x 38T CWP
The above mentioned are the 3 versions of Crown
Wheel & Pinion (CWP) manufactured in this TAFE Gear
Division
INTRODUCTION TO CROWN WHEEL AND PINION
The final drive components, which reduce the rotational
speed of the gearbox output shaft to that supplied to the wheels
sometimes abbreviated as CWP. The reduction ratio (commonly
called the final drive ratio) lies in most common automobile
applications between 3:1 and 5:1. In all front engines, rear-wheel
drive cars with the engine mounted longitudinally, the crown
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wheel and the pinion rotates the drive through 90 deg i.e. from
fore aft to transverse.
A crown wheel is a wheel with cogs or teeth set at right
angles to its plane and the pinion is a small cogwheel that meshes
with the crown wheel. The pinion thread is specially made on the
thread gringer to ensure proper fitting. Tooth contact of a crown
pinion is insected on a Gleason machine at regular intervals of
time for uniform and adequate case depth. They are checked
thoroughly for high spots because this ensures premature failureand noise-free operation.
FEATURES
Crown wheel and pinion usually have the following features:
Excellent heat distortion control
High strength
Wear resistance property and
Noiseless and vibration free operation.
In a machine, when any torque is applied to the drive unit, the
tendency is for the crown wheel and pinion to be forced into or
out of mesh by the sliding contact.
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APPLICATION
Crown wheel and pinion are used widely in automotive
industries. They are one of the most stress prone parts of a
vehicle. They are used in automobiles to maintain forward motion.
To maintain forward motion both output drive shaft sides covers
are removed and the pinion and crown wheel are swapped
completely with differential.
ORGANISATION CHART
Tractors and Farm Equipment Limited
(TAFE)
Senior management Team
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MANAGING
DIRECTOR
&
CHAIRMAN
ED TAFE Motors and
Tractors Ltd.
ED - TAFE Power
Source DivisionED - TAFE Hydraulic
Pump Division
ED TAFE Gears
Division
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ED - TAFE Access Ltd -
Instrument Division
ED - TAL Precision
Parts
ED - TAFE Reach
Ltd.
ED - TAFE Engineering
Plastics Division
ED - AMCO Batteries
Ltd.
Chart of TAFE - Gear division (TGD)
ED TAFE Gear
Division (TGD)
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Directors
President
Vice President
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Sr. GeneralManager
GeneralManager
Divisional
Manager
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Manager Manager Manager ManagerManager
Asst. Manager Asst. Manager Asst. Manager Asst.
Manager Asst. Manager
Supervisors Supervisors Supervisors SupervisorsSupervisors
Labours Assistants LaboursLabours
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Productio HR StoresFinance Maintena
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CHAPTER II
PRODUCTION DEPARTMENT
PRODUCTION DEPARTMENT
PLANT LOCATION
REGISTERED OFFICE - HEAD OFFICE &
MANAGING
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861,Anna Salai
Chennai-600 002.
GEAR DIVISION
51/1, Vandalur-Kelambakkam Road,
Pudupakkam, Kelambakkam,
Kancheepuram district, 603 103.
Phone: 0411474647, 74847
TAFE GEAR DIVISION PLANT
The Gears Division of TAFE manufactures BEVEL gears
for tractors. The factory which is located at Pudupakkam, 40 kms
from Chennai is equipped with Gleasan machinery and highly
advanced in-house heat treatment facility to ensure that the gear
systems that roll out from here meet international standards.
PRODUCTION PROCESS CHART
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Raw material semi
finished Pinion
Raw material semi
finished CrownWheel
Hobbing Straight
stains
12 - Hole Drilling
Teeth cutting
Roughing Machine
Teeth cutting
Roughing Machine
Finishing Operation
Convex & Concave
cutting
Finishing Operation
Convex & Concave
cutting
Heat Treatment
plant CGCF (or) SQF
Heat Treatment
plant CGCF (or) SQF
Straightening,
Diameter & PilotGrinding
Inner Diameter
Grinding by BoringMachine
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Testing & Pairing
Operations
Lapping Operations
Threading Operation
for Pinion
Quality, Diameter &
Dimension Inspection
Storing
Packing
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PRODUCTION PROCESS
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Inspection
Dispatch
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Raw materials:
Raw Materials for Crown wheel is called as blanks and
for Pinion is Steel pillars. These raw materials are semi finished
raw material. These semi finished raw material are produced by
vendors by forging the iron blocks for Crown Wheel and forging
iron pillars. These raw materials are purchased by TGD. These
purchased raw materials are stored in Stores and distributed to
machine shop.
Machine Shop Soft cell:
These raw materials are delivered to Pinion cell and
Crown Wheel cell.
Note: - In the following stages the COOLANT OIL &
SOLUTIONS are used to reduce the friction heat of the Crown
Wheel & Pinion while drilling, cutting & grinding.
STAGES PINION CELL STAGESCROWN WHEEL
CELL
HOBBING The raw materials
will be processed
in Hob Cutter to
create straight
strains in the
Pinion. These
cuttings of straight
DRILLING The raw materials
will be processed
for drilling 12 holes
in the Crown
Wheel. This drilling
process is made by
Counter Boring
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strains are done
by Hob Cutter
Machine and
moved it to soft
grinding stage.
Machine and
moved to Teeth
cutting process.
STAGES PINION CELL STAGESCROWN WHEEL
CELL
SOFT
GRINDING
In this raw
material is grinded
to bring it to fixed
outer diameter.
There is chance of
irregular diameter
shape in raw
material. To make
a regular shape,
the raw material is
grinded with fixed
outer diameter
and passed to
rough cutting
stage.
ROUGHING
MACHINE
In this raw material
is processed for
cutting teeth. In
this process the
teeth for the Crown
Wheel is formed by
Rough Teeth
Cutting. This
process is done by
Rough Teeth
Cutting Machine
and passed to the
next stage for
finishing operation
ROUGHING
MACHINE
In this raw
material is
processed for
cutting teeth. In
this process the
FINISHING
OPERTION
In this raw material
is processed for
Convex & Concave
cutting of teeth to
reduce the
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teeth for the
Pinion is formed
by Rough Teeth
Cutting. This
process is done by
Roughing Machine
and passed to the
next stage of
finishing operation
for Convex &Concave teeth
cutting.
sharpness of the
teeth and for
finishing touch for
the teeth. In this
the Convex &
Concave teeth
cutting is made by
a single machine
Simultaneously and
passed it to HeatTreatment Cell.
STAGES PINION CELL STAGESCROWN WHEEL
CELL
FINSHING
OPERATION
In this raw
material is
processed for
Convex & Concave
cutting of teeth to
reduce the
sharpness of the
teeth and for
finishing touch forthe teeth. In this
the Convex &
Concave teeth
cutting is made by
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2 different
machines
(separate machine
Convex & Concave
Teeth Cutting) and
passed it to Heat
Treatment Cell.
Heat Treatment Cell:
The Raw Materials of Crown Wheel and Pinion
processed in Machine Shop is brought to Heat Treatment Cell to
mold those Raw Materials for long life, increase the strength, to
withstand heavy load and avoid worning out. This Heat Treatment
Cell consists of 2 types of furnaces.
Continues Gas Carburizing Furnace (CGCF)
Sealed Quenching Furnace (SQF)
The Heat Treatment Cell will use any One or if needed use both
the above furnace.
Continues Gas Carburizing Furnace (CGCF)
This is big furnace for continuous operations includes
degreasing, carburizing operations, hardening operations,
heating, cooling, press quench operations, etc., This is a
continuous operation and takes 22 hours to complete its
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process. The Heat Treatment Cell mostly uses this furnace
for operation because of easy and less time consuming.
Sealed Quenching Furnace (SQF)
This is a collection of small furnaces and its not a
continuous process. Its operation are degreasing, carburizing
operation, hardening operation, washing, tempering, etc,. it
takes more than 23 hours to complete the process. It is time
consuming and more labour work compared to CGCF.
The process of both furnaces will be explained in detail in
machinery details of the furnaces. After processing the raw
materials in heat treatment it is passed to Shot Blasting.
Shot Blasting:
After tempering, the Pinion and Crown wheel are
subjected to Shot Blasting to give glossy appearance and to check
and impart strength of the Crown Wheel and Pinion. Shots are a
kind of small steel balls, having hardness of 30 to 35 HRC. This
process is for 10 to 15 minutes per batch. 1 batch contains 45 nos
of Crown Wheel or 90 nos of Pinion. After this process again the
processed raw materials are passed to Machine Shop Hard Cellfor further Finishing process.
Machine Shop Hard cell:
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STAGES PINION STAGES CROWN WHEEL
GRINDING
In this raw
material is
grinded by 3
grinding
machines to
bring it to
required
diameter. Those
3 grindingmachines are
used to process
the pinion for
grinding minor
diameter, major
diameter and
pilot grinding
and passed to
testing and
pairing process.
BORE
GRINDING
In this raw material
is processed for
bore grinding to
bring required &
fixed inner
diameter of the
Crown Wheel. Due
to Heat treatment
there is a chance ofchange in the
diameter. So to fix
the diameter this
bore grinding is
used and it is
passed to testing
and pairing
process.
TESTING &
PAIRING
In this the
processed Pinion
is tested toensure its
dense, required
dimensions and
finally Pinion will
TESTING
&
PAIRING
In this the
processed Crown
Wheel is tested toensure its dense,
required
dimensions and
finally Crown Wheel
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be Paired with
Crown Wheel
run together for
testing to match
each other and
passed it to
lapping process.
will be Paired with
Pinion run together
for testing to match
each other and
passed it to lapping
process.
STAGES PINION CROWN WHEEL
LAPPING
The Pinion is processed
in Lapping Machine for
the purpose of
polishing, clearing
carbon & grinding
particles, to improve
surface finish using
Coolant Oil and Lapping
powder by rubbing
action and final washing
in this process and
passed to threading
process.
The Crown Wheel is
processed in Lapping
Machine for the purpose
of polishing, clearing
carbon & grinding
particles, to improve
surface finish using
Coolant Oil and Lapping
powder by rubbing
action and final washing
in this process. This is
the last process for
Crown Wheel and it will
be moved to Quality
Inspection of Finishedgoods.
THREADING The Pinion is processed
in threading machine for
threading operation for
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required dimensions on
the middle of the Pinion.
This threading operation
will be a fixed for
required diameter. This
is the last process for
Pinion and it will be
moved to Quality
Inspection of Finished
goods.
Final Quality Inspection Finished Goods:
The finished goods Crown Wheel and Pinion will be
passed on to Final Quality Inspection. Here final inspection on the
quality of the Crown Wheel and Pinion will be inspected by
checking all dimensions and diameters of the Crown Wheel and
Pinion should be as per the requirements. The critical parameters
of the Crown Wheel and Pinion should be 100%. Then the
approved and qualified Crown Wheel and Pinion will be moved to
Stores for other process.
MACHINERY DETAILS
The general layout of the TAFE Gear division factory
consists of two main divisions viz:
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MACHINE SHOP
HEAT TREATMENT CELL
MACHINE SHOP:
The operation in machine shop includes both soft cell
and hard cell.
SOFT CELL
PINION CELL:
1) HOBBING MACHINE:
MACHINE MAKE : COOPER 010
OPERATION PERFORMED : SPLINE CUTTING
MACHINE PROCESS TIME : 332 sec
HANDLING TIME : 10 sec
TOTAL TIME : 342 sec
2) SOFT GRINDING MACHINE:
MACHINE MAKE : PARISHUDH
OPERATION PERFORMED : MAJOR DIAMETER
GRINDING
MACHINE PROCESS TIME : 110 sec
HANDLING TIME : 15 secTOTAL TIME : 125 sec
3) ROUGHING MACHINE:
MACHINE MAKE : GLEASON
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OPERATION PERFORMED : ROUGH CUTTING
MACHINE PROCESS TIME : 205 sec
HANDLING TIME : 10 sec
TOTAL TIME : 215 sec
FINISHING OPERATIONS:
4) CONCAVE MACHINING MACHINE:
MACHINE MAKE : GLEASON
OPERATION PERFORMED : CONCAVE CUTTING
METHOD USED : COMPARATIVEMETHOD
MACHINE PROCESS TIME : 207 sec
HANDLING TIME : 10 sec
TOTAL TIME : 217 sec
5) CONVEX MACHINING MACHINE:
MACHINE MAKE : GLEASON
OPERATION PERFORMED : CONVEX CUTTING
METHOD USED : COMPARATIVE
METHOD
MACHINE PROCESS TIME : 223 sec
HANDLING TIME : 10 sec
TOTAL TIME : 233 sec
CROWN WHELL CELL:
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1. VMC CNC MACHINE:
MACHINE MAKE : AMS
OPERATION PERFORMED : COUNTER BORING
MACHINE PROCESS TIME : 287 sec
HANDLING TIME : 37 sec
TOTAL TIME : 324 sec
2. ROUGHING MACHINE:
MACHINE MAKE : GLEASON 608
OPERATION PERFORMED : ROUGH CUTTINGMACHINE PROCESS TIME : 337 sec
HANDLING TIME : 33 sec
TOTAL TIME : 370 sec
3. FINISHING MACHINE:
MACHINE MAKE : GLEASON 610
OPERATION PERFORMED : FINE CUTTING
MACHINE PROCESS TIME : 280 sec
HANDLING TIME : 35 sec
TOTAL TIME : 315 sec
** The job from soft cell undergoes heattreatment before
it enters hard cell. **
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HARD CELL
1. STRAIGHTENING MACHINE:
MACHINE MAKE : BEMCO
OPERATION PERFORMED : STRAIGHTENING
TIME TAKEN : 61 sec
2. GRINDING MACHINE - I:
MACHINE MAKE : PARISHUDH
OPERATION PERFORMED : MAJOR DIAMETER
GRINDING
TIME TAKEN : 298 sec
3. GRINDING MACHINE - II:
MACHINE MAKE : PARISHUDH
OPERATION PERFORMED : MINOR DIAMETER
GRINDING
TIME TAKEN : 225 sec
4. GRINDING MACHINE - III:
MACHINE MAKE : KAIZON
OPERATION PERFORMED : PILOT GRINDING
TIME TAKEN : 211 sec
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5. BORING MACHINE :
MACHINE MAKE : GCI 300 CNC
OPERATION PERFORMED : INTERNAL DIA
GRINDING
(CROWN)
TIME TAKEN : 271 sec
6. TESTING AND PAIRING MACHINE:
MACHINE MAKE : GLEASON
OPERATION PERFORMED : PAIRING OF PINION
AND
CROWN WHEEL
TIME TAKEN : 173 sec
7. LAPPING MACHINE:
MACHINE MAKE : GLEASON
OPERATION PERFORMED : LAPPING
TIME TAKEN : 184 sec
8. THREAD CUTTING MACHINE:
MACHINE MAKE : SIEMENS
OPERATION PERFORMED : THREAD CUTTING
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TIME TAKEN : 346 sec
HEAT TREATMENT CELL:
In heat treatment cell the mechanical properties of the
job is improved by the application of heat. This is done in two
types of furnaces viz;
Continues Gas Carburizing Furnace (CGCF)
(Or)
Sealed Quenching Furnace (SQF)
Shot Blasting
CONTINUES GAS CARBURISING FURNACE :
a) Low carbon alloy steel is used in Heat treatment.
b) Sulphur based cutting oil is used in machine shop.
c) Endothermic gas is used as a carrier gas in the Heat
treatment process.
PHASES:
1)Degreasing furnace is operated at 250 Deg C (1
tray)
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Degreasing is used to restrict sulphur oil by
being combining with CO & CO2.
Duration for waiting degreasing is
approximately 8 mins.
Duration for Degreasing is approximately 40
mins.
Operating pushing cycle time is approximately
48 mins for every tray.
2)Main furnace has 18 separate trays at various
zones.
ZONENO.OF
TRAYS
TEMPERATU
RE Deg C
CARBON
POTENTIA
LPre heat
zone 2 930 0.92 %
Carburizi
ng zone
1
4 930 0.92 %
Carburizi
ng zone
2
4 930 0.92 %
Diffusion
zone 14 930 0.90 %
Diffusin
zone 24 930 0.90 %
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The main furnace and reheating zone are operated
with a carrier gas (Endothermic gas) and LPG for
enrichment of C potential.
3)Air cooling chamber - 1 tray (no heating)
Duration for cooling is approximately 7 mins to
refine the core grains.
4)Reheating - 4 trays. Reheating is operated at 820 to 800 Deg C & Cp-
0.70%
5)Quenching
Quenching makes the steel to reach from
(Austenite)FCC to BCT structure (Martensite)
BCT - Body Centered Tetrahedron.
Quenching process is carried out with Quenching
oil
(Savsol 001). Quenching process is carried out with Press
Quench machine to minimize Gear teeth distortion
and accurate flatness.
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After quenching process, the components are sent
for washing through alkali bath and water bath.
At Alkali washing bath, oil from the work piece will
be removed.
At Water washing both, alkali from the work piece
will be removed.
Finally it is sent through Tempering furnace to
relive the stress.
6)Tempering
It can accommodate three separate trays (150
celsius for 90 mins).
7)Endothermic gas generator
LPG and Air are mixed in the ratio of 1:9.5 to 10.5
and pass through a stainless steel retort at 1070Deg C. The gas will pass through a Nickel coated
Ceramic catalyst in a Stainless steel retort to
produce Endothermic gas. The carrier gas
(Endothermic gas) will have approximately 23% of
CO and 0.3% of CO2.
SEALED QUENCHING FURNACE :
PHASES:
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1)Degreasing furnace is operated at 150 Deg C. It is
operated to remove Sulphur based cutting oil, which is
used in machine shop.
Duration for Degreasing is approximately 120
mins.
2)Main furnace is a single chamber and the process is
divided into 4 segments.
SEGMEN
T
TEMPERATU
RE Deg C
CARBONPOTENTIA
L
TIME
TAKEN
FUEL
USED
Segment
1930 1.20% 5 min
LPG +
CO2Segment
2930 1.20% 450 min
LPG +
CO2Segment
3930 1.10% 360 min LPG
Segment
4820 0.92% 20 min LPG
After the process, the load is pushed from the
furnace into the elevator (above quenching tank)
and the load is quenched in oil below the elevator.
3)Hardening
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Quenching process is carried out with Quenching
oil (savsol 001).
For Pinion, the load is quenched along with the
fixture.
4)Washing:
After quenching process, the components (pinion)
are sent for washing through water bath along
with the fixture.
At Water washing bath, oil and other
contaminations from the Pinions will be removed
along with the fixture.
5)Tempering
Pinions are sent through tempering furnace along
with the fixture to relive the stress at (150 Deg C
for 120 min).
SHOT BLASTING :
After tempering, the Pinion and Crown wheel are
subjected to Shot Blasting to give glossy
appearance and to impart strength. Shots are a
kind of small steel balls, having hardness of 30 to
35 HRC.
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CHAPTER III
STORES DEPARTMENT
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STORES DEPARTMENT
PROCESS OF PURCHASING & STORING
Purchasing of Raw Materials, spares, equipments,
accessories, etc., Is a process of Stores department. The following
flow chart will explain the process of purchasing.
Flow Chart of Purchasing, Storing & Issuing
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Requirements
Purchase Requisition
QuotationPurchase Order (P.O)
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Approval
Material Receiving
Checking &
Inspection
Material Tagging
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Racking
Storing
Coding the Material
through SAP
Stock (Material)
Issue
Entering (Posting)
Issues in SAP
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ACTIVITIES
Raw Materials:
Raw Materials for Production purpose will be
stored by Store Department in Stores. The Stores will be
having 3 months Stock of Raw Materials for Reserves. The
Stores will place order on Raw Materials once in 3 months as
a cycle.
Materials Rejection:
Some Raw Materials may be rejected after
Checking & Inspection due to damage or low quality. Those
rejected materials will be returned to vendors who supplied
and payment will not be paid for the rejected materials.
Goods Receipt Note (GRN):
GRN is prepared by Stores department for the
materials received after Checking & Inspection. This GRN will
be forwarded to Finance Department for payment process.
Material Tagging:
The received material will tagged according to theusage and will be placed according to the respective bin by
Racking the material tagged in the racks of the stores. This
tagging helps to issue the materials easily and can find the
shortages easily.
System Analysis and Program Development (SAP):
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The Stores department will enter the coding of the
materials received in SAP. It also updates the issue of
materials in SAP. Stores department will also maintain the
entries of delivered finished goods in SAP. The delivered
finished goods will be given a code by SAP. SAP is softwareinterlinked with all departments.
Storing:
The materials received by the Stores department
from Vendors will be stored in Stores and issued for
production at the time of need. The Finished Goods will also
be packed stored in Stores. The Stores department also
stores materials like spares, accessories, new machinery,etc,.
Packing & Delivering:
After Checking & Inspection of Crown Wheel and
Pinion (CWP), the Stores department will pack the CWP in a
pair as matched by production Department. If CWP is for
dispatch for Tractor manufacturing units, 2 pairs of CWP is
packed in a plastic box and if CWP is dispatch for Spare
Parts, 1 pair of CWP is packed in a Card board. These packed
boxes will be delivered to necessary place by chartered
carrier Tractor manufacturing units or Spare Parts.
Delivery Note:
Delivery Note will be prepared by the Stores
department as per the delivery of Crown Wheel & Pinion
(CWP) to the Tractor manufacturing units or to Spare Parts.
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The prepared Delivery Note will be forwarded to the Finance
department for accounting.
Chart of Packing & delivery of CWP
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Receiving of CWP
(Finished Goods) from
Production
Packing & Storing
Delivering to Tractor
manufacturing units
or Spare Parts
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CHAPTER IV
MAINTANENCE DEPARTMENT
MAINTANENCE DEPARTMENT
Maintenance department is an essential department in
this unit which follows the 4 major activities. They are,
Preventive Maintenance
Actual Maintenance
Planned Maintenance
Special Projects & Developments
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ACTIVITIES
Preventive Maintenance:
Preventive maintenance can be described as
maintenance of equipment or systems before fault occurs. It
is also called as Planned maintenance. This Preventive
maintenance activity helps the manufacturing unit to
function without any disturbances or problems. By predicting
the future problems for production and taking necessary
steps to overcome and being ready to act on the problemimmediately and solve the problem. For example: - Taking
necessary steps to overcome the Electricity problems during
summer season.
Actual Maintenance:
Actual Maintenance is another major activity of theMaintenance department. In this the Maintenance
department will be always ready any time to solve the
unexpected problems while running of machines while
production. Solving of the unexpected problems on the day
to day process of production is called Actual Maintenance.
For example: - Solving the failures of machinery while
production.
Planned Maintenance:
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Planned Maintenance is the major activity of the
Maintenance department. The Maintenance department will
prepare plan and follow the plan to maintain and develop the
production process. Planned Maintenance is a regular
activity followed by the Maintenance department. For
example:- Regular service for machineries, Changing
machinery oil periodically, etc,.
Special Projects & Developments:
Special Projects & Developments is the major activity ofMaintenance department to support the production process
and develop the manufacturing unit. Special Projects &
Developments are the activities like installing new machinery,
upgrading the existing machinery, making add-ons for the
machinery to make the production process easy and fast.
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CHAPTER - V
FINANCE DEPARTMENT
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FINANCE DEPARTMENT
ACTIVITIES
Powers:
Finance department of TAFE Gear Division (TGD) is under
control of Finance department of TAFE Head Office in Anna
Salai, Chennai. Finance department of TGD will be reporting to
TAFE Head Office. Finance department of TGD is restricted
limited powers.
Impressed amount:
TAFE Gear Division (TGD) is allocated with an Impressed
amount (Reserves) minimum of Rs. 30,000 for operations of
Finance department for production purpose. Finance
department of TGD will maintain this Impressed amount. If the
Impressed amount decreases to Rs. 10,000, the Manager of
Finance department will make requisition to Head Office for
shortage of Impressed amount, immediately Head Office will
issue a cheque for the requested amount to Finance
department of TGD.
Funding Operations:
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Finance department of TGD is operated with Current A/C
in Central Bank of India in Kelambakkam. For withdrawal of
Impressed amount or other Sanctioned amount from Head
Office for Production purposes and deposits of cash by Finance
department of TGD by the Scrap sales is transacted through
this bank.
Petty Cash Accounting:
Finance department of TGD follows the Petty Cash
Accounting. It follows Petty Cash Accounting because it
transacts with only small value of money. Large transactions
for TGD production process are made by TAFE Head Office.
Petty Cash Accounting is recorded and filed through System
Analysis and Program Development (SAP) by verifying and
approving Petty Cash Receipt. This process is called as RealTime Accounting. Real Time Accounting is financial reporting
provides financial information on a daily basis.
Credit:
Finance department of TGD avails credit from the
government for Excise duty for purchasing Raw Materials and
will be adjusted with the Dispatch of Finished Goods to the
TAFE Manufacturing unit and to Spare Parts.
Salary & Wages:
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Salary for the Management Staff is paid directly by TAFE
Head Office by crediting the salary to the individuals bank A/C.
The Wages for the Contract Labours are paid by the Finance
department of TGD which will be sanctioned and given by TAFE
Head Office.
Tax:
Finance department of TGD will be paying certain taxes
like TDS (Tax Deducted at Source) 2% of Contract Labour
Wages, Scrap Sales tax 1%. These taxes are unavoidable andFinance department of TGD is liable to pay the taxes.
Focus Cost:
Focus Cost means Budget. Focus Cost is prepared by the
Finance department for future Production process. Focus Costwill be estimated by Divisional Manager of TGD unit and
Manager of Finance department of TGD. This Focus Cost will be
sent for approval to TAFE Head Office by Finance department
of TGD. TAFE Head Office will discuss with Divisional Manager
of TGD make some adjustments in Focus Cost if necessary and
approve for sanction.
CHART PROCESS OF PURCHASE & PAYMENTS
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Delivery of purchase
Requisition
Purchase Order (P.O)
Goods Receipt Note(GRN) from Stores
Invoice Verification
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CHAPTER VI
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Payment
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HUMAN RESOURCE DEPARTMENT
HUMAN RESOURCE DEPARTMENT (HRD)
ACTIVITIES
Recruitment and Selection:
The candidate will be sent from TAFE Head Office to
Production unit for Selection & Recruitment process. The
candidate will be first screened by Personnel officer and Head
of the Department, and then screened by Divisional Manager.
After Divisional Managers screening, the candidate will be
interviewed by Senior General Manager in TAFE Head Office
and a final interview by Divisional Manager of HRD in TAFE
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Head Office. If the candidate passes the above process, the
candidate will selected and employment offer will be given.
CHART PROCESS OF RECRUITMENT & SELECTION
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Candidate
Screening byPersonnel officer &
Head of the
Department in TGD
Screening by
Divisional Manager -
TGD
Interview by Sen.Gen. Manager of TAFE
Head Office
Final Interview by
Divisional Manager of
HRD TAFE Head
Office
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Wages & Salary Administration:
Wage Administration for Contract Labour for
Production Operations will be under the control of
Human Resource Department of TGD.
Salary Administration for Management staffs of
TGD will be under the control of Centralized Payroll
Department of TAFE Head Office.
Performance Appraisal:
Performance Appraisal is the major activity of the Human
Resource Department. The following is Performance Appraisal
Process followed by HRD of TGD.
Performance Appraisal is the activity of HRD of TGD for
every Six months.
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Candidate is
Selected & offered
Employment
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Performance Appraisal is made by rating every
employee of TAFE Gear Division (TGD)
Performance Appraisal is processed by Performance
Appraisal Team which consists of Personnel Officer,
Superior of Appraisee & Divisional Manager TGD.
Attendance of employee is also taken for consideration
for Performance Appraisal.
Based on the Performance Appraisal employees &
labours, Salaries and wages will be increased andpromotion is given if necessary.
Employee Welfare:
Many welfare activities are undertaken and followed by
Human Resource department of TGD like,
Canteen facility is availed for Management staffs &
Contract Labour, where free healthy lunch is
provided for them.
Uniform & Shoes are provided to Management Staffs
at free of cost.
Safety equipments are provided to Contract Labours
for their safety.
Transportation facility is availed for Employees of
TGD.
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Medical facilities & Allowances are provided for the
employees of TGD.
Training & Development:
Training on new machinery or to new production
process is provided for existing employees
Training for new employees is provided.
Training calendar is scheduled by Human
Resource Department (HRD) of TAFE Head Office
and followed by HRD of TGD.
Divisional Manager of TGD will give suggestions in
framing the training calendar.
Induction & On the Job trainings are 2 types of
training provided for new employees of TGD.
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CHAPTER VII
CONCLUSION
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CONCLUSION
FINDINGS & INTERPRETATION:
TAFE Gear Division (TGD) is a sister concern of
Tractors Farms &Equipments (TAFE).TGD is under
control of TAFE.
TGD does not have separate department for
Marketing activities, because it supplies is
produced CWP to TAFE Tractor Manufacturing
units in Madurai (Kallidaipatti), Bangalore
(Doddaballapur) and to TAFE Spare Parts.
TAFE is operating separate divisions like TGD, TAL,
etc., to avoid the labour unions, strikes, etc,.
In TGD many innovative production process are
made as proto type, tested and implemented.
TGD is fully interlinked with System Analysis and
Program Development (SAP).
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Labours were employed through Contract Labour
Agencies for contract in production unit.
TGD concentrates more on Production Department
compared to other department.
TGD strictly follows 5- S principle.
SUGESSTIONS:
TGD can sell the CWP to third party also by setting
up Marketing Department to increase the revenue.
TGD can increase Production by extending the
Production Plant. TGD has all facilities to extend its
Production Plant.
Separate Packing Cell can be setup for the
purpose of Packing Finished Goods.
REFERENCES
http://www.tafe.com/
http://www.tafechannel.com/
http://www.frontpoint.com/tafe/green/htm/areaoffice.
htm
http://en.wikipedia.org/wiki/TAFE_Tractors
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