INDUSTRIAL TRAINING REPORT

CONTENTSINTRODUCTION TO TRACTORSTRACTOR DESIGN, POWER AND TRANSMISSION.INDIAN TRACTOR INDUSTRY.THE MATURING YEARS I N INDIAN TRACTOR INDUSTRY.HISTORY OF SWARAJ.MILESTONES.TECHNICAL COLLABORATIONS AND PRODUCTS & SERVICESWEEK # 1WEEK # 2WEEK # 3WEEK # 4SPECIFICATIONS OF THE PRODUCTS.

INTRODUCTION TO TRACTORS

A tractor is a vehicle specifically designed to deliver a high tractate effort (ortorque) at slow speeds, for the purposes of hauling a trailer or machinery used in agriculture or construction. Most commonly, the term is used to describe the distinctive farm vehicle: agricultural implements may be towed behind or mounted on the tractor, and the tractor may also provide a source of power if the implement is mechanized. Another common use of the term, "tractor unit", describes thepower unit of a semi-trailer truck (articulated lorry).

The word Tractorwas taken from Latin, being the agent noun oftraverse to pull. The first recordeduseofthewordmeaning"anengineorvehicleforpullingwagonsorploughs"occurredin1901, displacement Traction engineThe first powered farm implements in the early 1800s were portable engines steam engines on wheels that could be used to drive mechanical farm machinery byway of a flexible belt. Around 1850, the first traction engines were developed from these, and were widely adopted for agricultural use. The first tractors were steam-powered plowing engines. They were used in pairs, placed on either side of a field to haul a plow back and forth between them using a wire cable. Where soil conditions permitted (as in the United States) steam tractors were used to direct-haul plows, but in the UK and elsewhere plowing engines were used for cable-hauled plowing instead. Steam-powered agricultural engines remained in use well into the 20th century until reliable internal combustion engines had been developed.

In 1892, John Froehlich invented and built the first gasoline/petrol-powered tractorin Clayton County, Iowa, USA. After receiving a patent Froehlich started up the Waterloo Gasoline Engine Company, investing all of his assets which by 1895, all would be lost and his business resigned to become a failure.

After graduating from the University of Wisconsin, Charles W. Hart and Churlish. Parr developed a two-cylinder gasoline engine and set up their business in Charles City, Iowa. In 1903 the firm built fifteen "tractors". A term with Latin roots coined by Hart and Parr and a combination of the words traction and power. The 14,000 pound #3 is the oldest surviving internal combustion engine tractor in the United States and is on display at the Smithsonian National Museum ofAmerican History in Washington D.C. The two-cylinder engine has a unique hit-and-miss firing cycle that produced 30 horsepower at the belt and 18 at the drawbar.

In Britain, the first recorded tractor sale was the oil-burning Hornsby-Ackroyd Patent Safety Oil Traction engine, in 1897. However, the first commercially successful design was Dan Alboins three-wheel Ive tractor of 1902. In 1908, the Saunderson Tractor and Implement Co. of Bedford introduced a four-wheel design, and went on to become the largest tractor manufacturer outside the U.S. at that time.

While unpopular at first, these gasoline-powered machines began to catch on in the1910s when they became smaller and more affordable.

Henry Ford introduced the Fordson, the first mass-produced tractor in 1917. They were built in the U.S.,Ireland, England and Russia and by 1923; Fordson had 77% of the U.S. market. The Fordson dispensed with a frame, using the strength of the engine block to hold the machine together. By the 1920s, tractors with a gasoline-powered internal combustion engine had become the norm.

Tractor design, power and transmission

Tractor configurations

Tractors can be generally classified as two-wheel drive, two-wheel drive with front wheel assist, four-wheel drive (often with articulated steering), or track tractors(with either two or four powered rubber tracks).

The classic farm tractor is a simple open vehicle, with two very large driving wheels on an axle below and slightly behind a single seat (the seat and steering wheel consequently are in the centre), and the engine in front of the driver, with two steerable wheels below the engine compartment. This basic design has remained unchanged for a number of years, but enclosed cabs are fitted on almost all modern models, for reasons of operator safety and comfort. In some localities with heavy or wet soils, notably in the Central Valley ofCalifornia, the "Caterpillar" or "crawler" type of tracked tractor became popular in the 1930s, due to superior traction and floatation. These were usually manoeuvred through the use of turning brake pedals and separate track clutches operated by levers rather than a steering wheel.A modern 4-wheel drive farm tractorFour-wheel drive tractors began to appear in the 1960s. Some four-wheel drive tractors have the standard "two large, two small" configuration typical of smallertractors, while some have four large powered wheels. The larger tractors are typically an articulated centre-hinged design steered by hydraulic cylinders that move the forward power unit while the trailing unit is not steered separately. In the early 21st century, articulated or non-articulated, steerable multi-track"tractors" have largely supplanted the "Caterpillar" type for farm use. Larger types of modern farm tractors include articulated four wheel or eight wheel drive units with one or two power units which are hinged in the middle and steered by hydraulic clutches or pumps. A relatively recent development is the replacement ofwheels or steel crawler-type tracks with flexible steel-reinforced rubber tracks, usually powered by hydrostatic or completely hydraulic driving mechanisms. The configuration of these tractors bears little resemblance to the classic farm tractordesign.

Engine and fuels

The predecessors of modern tractors, traction engines, used steam engines forpower. Since the turn of the 20th century, internal combustion engines have been the power source of choice. Between 1900 and 1960, gasoline was the predominant fuel, with kerosene and ethanol being common alternatives. Generally one engine could burn any of those, although cold starting was easiest on gasoline. Often as mall auxiliary fuel tank was available to hold gasoline for cold starting and warm-up, while the main fuel tank held whatever fuel was most convenient or least expensive for the particular farmer. Dieselization gained momentum starting in the1960s, and modern farm tractors usually employ diesel engines, which range inpower output from 18 to 575 horsepower (15 to 480 kW). Size and output are dependent on application, with smaller tractors for lawn mowing, landscaping, orchard work, and truck farming, and larger tractors for vast fields of wheat, maize, soy, and other bulk crops. Liquefied petroleum gas (LPG) or propane also havebeen used as tractor fuels, but require special pressurized fuel tanks and filling equipment so are less prevalent in most markets.

Transmission

Older farm tractors use a manual transmission. They have several gear ratios, typically 3 to 6, sometimes multiplied into 2 or 3 ranges. This arrangementprovides a set of discrete ratios that, combined with the varying of the throttle, allow final-drive speeds from less than one mile per hour up to about 25 miles per

hour (40 km/h), with the lower speeds used for working the land and the highest speeds used on the road. Slow, controllable speeds are necessary for most operations that are performed with a tractor. They help give the farmer a larger degree of control in certain situations, such as field work. However, when travelling on public roads, the slow operating speeds can cause problems, such as long queues or tailbacks, which can delay or annoy motorists in cars and trucks. These motorists are responsible forbeing duly careful around farm tractors and sharing the road with them, but many shirk this responsibility, so various ways to minimize the interaction or minimize the speed differential are employed where feasible. Some countries (for example the Netherlands) employ a road sign on some roads that means "no farm tractors. Some modern tractors, such as the JCBFastrac, are now capable of much higherroad speeds of around 50 mph (80 km/h).

An older model European farm tractor. Older tractors usually have unsynchronized transmission design, which often requires that the operator stop the tractor in order to shift between gears. This mode of use is inherently unsuited to some of the work that tractors do, and has been circumvented in various ways over the years. For existing unsynchronized tractors, the methods of circumvention are double clutching or power-shifting, both ofwhich require the operator to rely on skill to speed-match the gears while shifting. Both of these solutions are undesirable from a risk-mitigation standpoint because of what can go wrong if the operator makes mistake transmission damage ispossible, and loss of vehicle control can occur if the tractor is towing a heavy load11

Either uphill or downhill something that tractors often do. Therefore, operators manuals for most of these tractors state that one must always stop the tractor before shifting, and they do not even mention the alternatives. As already said, that mode of use is inherently unsuited to some of the work that tractors do, so better options were pursued for newer tractor designs.Cutaway of modern tractor

Hitches and power applications

The power produced by the engine must be transmitted to the implement orequipment in order to do the actual work intended for the equipment. This may be accomplished via a drawbar or hitch system if the implement is to be towed orotherwise pulled through the tractive power of the engine, or via a pulley or powertakeoff system if the implement is stationery, or a combination of the two.Drawbars

Until the 1950s, plows and other tillage equipment usually were connected to the tractor via a drawbar, or a proprietary connecting system. The classic drawbar is simply a steel bar attached to the tractor (or in some cases, as in the early Fordsons,cast as part of the rear transmission housing) to which the hitch of the implement was attached with a pin or by a loop and clevis. The implement could be readily attached and removed, allowing the tractor to be used for other purposes on a dailybasis. If the tractor was equipped with a swinging drawbar, the drawbar could be set at the centre or offset from centre to allow the tractor to run outside the path ofthe implement. The drawbar system necessitated that the implement have its own running gear(usually wheels) and in the case of a plow, chisel cultivator or harrow, some sort oflift mechanism to raise it out of the ground at turns or for transport. Drawbars necessarily posed a rollover risk depending on how the tractive torque was applied. The Fordson tractors (of which more units were produced and placed in service than any other farm tractor) was extremely prone to roll over backwards due to an excessively short wheelbase. The linkage between the implement and the tractorusually had some slack which could lead to jerky starts and greater wear and tearon the tractorAnd the equipment.A large modern John Deeremodel 9400 four wheel drive tractorwith tripled wheels and a drawbar-towed tool chain including one-pass tillageequipment, planter and fertilizer applicatorwith tanksDrawbars were appropriate to the dawn of mechanization, because they were very simple in concept and because as the tractor replaced the horse, existing horse-drawn implements usually already had running gear. As the history ofmechanization progressed, however, the advantages of other hitching systemsbecame apparent, leading to new developments. Depending on the function forwhich a tractor is used, however, the drawbar is still one of the usual means ofattaching an implement to a tractor.

Fixed mounts

Some tractor manufacturers produced matching equipment that could be directly mounted on the tractor. Examples included front-end loaders, belly mowers, row crop cultivators, corn pickers and corn planters. In most cases, these fixed mounts were proprietary and unique to each make of tractor, so that an implementproduced by John Deere, for example, could not be attached to a Minneapolis Moline tractor. Another disadvantage was that mounting usually required sometime and labour, resulting in the implement being semi-permanently attached withbolts or other mounting hardware. Usually it was impractical to remove the implement and reinstall it on a day-to-day basis. As a result, the tractor was unavailable for other uses and dedicated to a single use for an appreciable period oftime. An implement generally would be mounted at the beginning of its season ofuse (such as tillage, planting or harvesting) and removed only when the likely use season had ended.

Three-point hitches and quick hitches

The drawbar system was virtually the exclusive method of attaching implements(other than direct attachment to the tractor) before Harry Ferguson developed the three-point hitch. Equipment attached to the three-point hitch can be raised orlowered hydraulically with a control lever. The equipment attached to the three-point hitch is usually completely supported by the tractor. Another way to attach an implement is via a Quick Hitch, which is attached to the three-point hitch. This enables a single person to attach an implement quicker and put the person in less danger when attaching the implement. A modern three point hitch

The three-point hitch revolutionized farm tractors and their implements. Almost every tractor today features Ferguson's 3 point linkage or a derivative of it. The three-point hitch allows for easy attachment and detachment of implements while allowing the implement to function as a part of the tractor almost as if it were attached by a fixed amount. Previously, when the implement hit an obstacle the towing link would break or the tractor could flip over. Ferguson's genius was to combine a connection via two lower and one upper lift arms that were connected to a hydraulic lifting ram. The ram was in turn connected to the upper of the 3 links so that increased drag (as when a plough hits a rock) caused the hydraulics to lift the implement until the obstacle was passed.

Power take-off systems andhydraulics

In addition to towing an implement or supplying tractive power through the wheels, most tractors have a means to transfer power to another machine such as abaler, swather, or mower. Unless it functions solely by pulling it through or overthe ground, a towed implement needs its own power source (such as a baler orcombine with a separate engine) or else a means of transmitting power from the tractor to the mechanical operations of the equipment. Early tractors used belts or cables wrapped around the flywheel or a separate beltpulley to power stationary equipment, such as a threshing machine, buzz saw, silage blower, or stationary baler. In most cases, it was not practical for the tractorand equipment to move with a flexible belt or cable between them, so this system necessitated that the tractor remain in one location with the work brought to the equipment, or that the tractor be relocated at each turn and the power set-up reapplied (as in cable-drawn plowing systems used in early steam tractoroperations).

Modern tractors use a power take-off (PTO) shaft to provide rotary power to machinery that may be stationary or pulled. The PTO shaft generally is at the rearof the tractor, and can be connected to an implement that is either towed by a drawbar or a three-point hitch. This eliminates the need for a separate implement-mounted power source, which is almost never seen in modern farm equipment. Virtually all modern tractors can also provide external hydraulic fluid and electrical power to the equipment they are towing, either by hoses or wires.

INDIANTRACTOR INDUSTRYIntroductionAs commercialization of agriculture grew in intensity in the mid-to-late 19thcentury the British Raj and the local legislatures and provinces began investing agricultural development through support and establishment agricultural research farms and colleges and large scale irrigation schemes yet the level ofmechanization was low at the time of independence in 1947. The socialist oriented five year plans of the 1950s and 60s aggressively promoted rural mechanization via joint ventures and tie-ups between local industrialists and international tractormanufacturers. Despite this aggressiveness the first three decades afterindependence local production of 4-wheel tractors grew slowly. Yet, by the late1980s tractor production was nearly 140,000 units per year and by the late 1990swith production approaching 270,000 per year, India over-took the United States as the world's largest producer of four-wheel tractors with over 16 national and 4multi-national corporations producing tractors today. Despite these impressive numbers FAO statistics estimate that of total agricultural area in India, less than50% is under mechanized land preparation, indicating large opportunities still exist for agricultural mechanization. India is primarily an agrarian nation, with more than 50 percent of our GDPbeing contributed directly or indirectly byagriculture. No wonder, India is considered the largest tractor market in the world.If that sounds great, let us face hard facts.In terms of total tractors in use in the country, we are ranked adistant eighth.Intermsof penetration,Indiahasa tractor densityof 10.5tractorsperthousandhectaresofGrossCroppedArea(GCA)ascomparedto the international average of close to 30 tractors per thousand GCA. Figuratively speaking, Indians large gross cropped area (GCA) is next only to the big two USAand Russia. Thatand thehighly fragmentedlandholdings inIndiahave helpedourcountrytobecome thelargest tractormarket intheworld.Thus theIndiantractor market, perSe,hastobe viewed onlyafter consideringitsposition in the world.Despite a phenomenal increase in tractor population in the country, the tractor density is very low at about 10.5 tractors per thousand hectares of GCA in comparisonto theinternationalaverageof about28 tractors.Also,thesmallsize of land holding inIndia, haveled tolow averagepoweroftractorsat35Horse Power (HP), which is far lower than the global average of above 80HP. With the successful introduction and acceptance of the high yielding seeds, however, there was a sudden upsurge in the demand for tractors after 1967 and the demandstarted multiplying atan annualrate ofapproximately50% (1967:18,000;1970:33,000).TheGovernmentsdecisiontofreelyinvitenewentrepreneursto manufacture tractorin 1968and sudden upsurge indemand, withthe greenrevolution,ledtoascrambleofnewentrepreneursfornewcollaborators.6unitseventually, established the actual manufacturing facilities.They were as follows: THE MATURING YEARS IN INDIAN TRACTOR INDUSTRY

With theentry of new units in1970 and increasingGovernmentpressure towards indigenization picked up substantially after 1970 and by 1978 almost allthetractorsmanufacturedwerenearlyindigenous.Afilliptoindigenizationwasalso given bythe overallindustrialization ofthe country, whena largenumberofancillarymanufactureshad also established themand werein apositionto supply wide variety of components tothe tractor industry.

1945 to1960War surplus tractors and bulldozers were imported for land reclamation and cultivation in mid 1940's. In 1947 central and state tractor organizations were setup to develop and promote the supply and use of tractors in agriculture and up to1960, the demand was met entirely through imports. There were 8,500 tractors in use in 1951, 20,000 in 1955 and 37,000 by 1960.

1961to1970Local production began in 1961 with five manufacturers producing a total of 880units per year. By 1965 this had increased to over 5000 units per year and the totalin use had risen to over 52,000. By 1970 annual production had exceeded 20,000units with over 146,000 units working in the country.1971to1980Six new manufacturers were established during this period although three companies (Kirloskar Tractors, Harsha Tractors and Pittie Tractors) did not survive. Escorts Ltd. began local manufacture of Ford tractors in 1971 in collaboration with Ford, UK and total production climbed steadily to 33,000 in1975 reaching 71,000 by 1980. Credit facilities for farmers continued to improve and the tractor market expanded rapidly with the total in use passing the halfmillion mark by 1980.

1981to1990A further five manufacturers began production during this period but only one ofthese survived in the increasingly competitive market place. Annual production exceeded 75,000 units by 1985 and reached 140,000 in 1990 when the total in use was about 1.2 million. Then India - a net importer up to the mid-seventies - became an exporter in the 1980s mainly to countries in Africa.

1991to1997Since 1992, it has not been necessary to obtain an industrial license for tractormanufacture in India. By 1997 annual production exceeded 255,000 units and the national tractor population had passed the two million mark. India now emerged as one of the world leaders in wheeled tractor production.

1997to1999Five new manufacturers have started production since 1997. In 1998 Bajaj Tempo, already well established in the motor industry, began tractor production in Pune. In April of the same year New Holland Tractor (India) Ltd launched production of70 hp tractors with matching equipment. The company is making a $US 75 million initial investment in a state of the art plant at Greater Noida in Uttar Pradesh state with an initial capacity of 35000 units per year. Larsen and Toubro have established a joint venture with John Deere, USA for the manufacture of 35-65 hp tractors at a plant in Pune, Maharashtra and Greeves Ltd will produce Same tractors under similar arrangements with Same Deutz-Fahr of Italy. Looking to South American export markets Mahindra and Mahindra are also developing ajoint venture with Case for tractors in the 60-200 hp range. Total annual production was forecast to reach 300,000 during the following year.1999toPresent

Facing market saturation in the traditional markets of the north west (Punjab, Haryana, eastern Uttar Pradesh) tractors sales began a slow and slight decline. By2002 sales went below 200,000. Manufacturers scrambled to push into eastern and southern India markets in an attempt to reverse the decline, and began exploring the potential for overseas markets. Sales remained in a slump, and added to the market saturation problems also came increased problems of "prestige" loan defaults, where farmers who were not financially able took tractors in moves to increase their families prestige. There are also reported increased misuse of these loans for buying either lifestyle goods, or for social functions. Government andprivate banks have both tightened their lending for this sector adding to the industry and farmers woes. By 2004 a slight uptick in sales once again due to stronger and national and to some extent international markets. But by 2006 sales once again were down to 216,000 and now in 2007-08 have slid further to just over200,000.

Tractor Manufacturers Association

The Tractor Manufacturers' Association of India (TMA) is housed under The Confederation of Indian Industry (CII), New Delhi. Though not all manufacturers are members TMA is recognized as the main trade group representing the agricultural tractor industry in India. Mallika Srinivasan, Economic Times Businesswoman of the year 2006, and CEO of TAFE Limited, is currently serving as president.

Current Manufacturers of Tractors in India

Angad Tractors, SAS Motors Limited

Balwan Tractors, Force Motors Ltd

Captain Tractors Pvt. Ltd

Crossword Agro Industries

Eicher

Escorts (Escort, Power trac. and Farmtrac)

HMT Tractors

Indo Farm

John Deere

Mahindra Gujarat Tractor Limited

Mahindra & Mahindra

MARS Farm Equipments Ltd.

New Holland Prt Tractors Mahindra & Mahindra TractorSwaraj Division Same Deutz-Fahr Ltd.Sonalika (International Tractors Ltd.)Standard TractorTAFEVST TillersAsian Tractors Ltd Ford Tractors Harsha Tractors Haryana Tractors Ltd Kirloskar Tractors Pittie Tractors United Auto Tractors Ltd.

Future potentialWithatotalof140millionhectaresandwiththeperformanceofaround3.18lactractorsintheyear2008-2009,Indiatodaystandsasthelargestmanufacturer of tractors in the world. With the average number of tractors inIndiaper hectare wellbelow theworld average, the Indianmarketisamarketwithahugeuntappedpotential.Indiaisthelargestmarketforthebelow50HPtractorsintheworld.Ininternationalmarkets,theaverageHPoftractorsusedisaround 80 -100 HP.At present the Indian tractor industry is among the select few in the world that is growing.

HISTORY OF SWARAJ

In the mid-sixties, with the Green Revolution triggering large-scale tractor usage, there was a need for the country to build sufficient indigenous capacity to meth is growing demand In 1965, the Central Mechanical Engineering Research Institute (CMERI),Durgapur initiated design and development of Swaraj Tractor based on indigenous know how. That is how the idea for development of what was to become Swaraj was initiated. The first prototype was ready in May 1967 and by April 1970, field experience of over 1,500 hours had been gained. At that point, it was decided to christen a name for the product signifying Indian, easy to pronounce and signifying power and grace. The name `Swaraj', was approved by the then Prime Minister ,Mrs Indira Gandhi.In 1970, the Government of Punjab acquired the Swaraj tractor's design and established Punjab Tractors Limited (PTL). The tractors were produced and sold under the brand name of Swaraj. In 2007, Mahindra & Mahindra Ltd. acquired majority stake in PTL, and in Feb 2009, it was merged into M&M as the Swaraj Division of Mahindra & Mahindra.

Origin of the word SWARAJThe word SWARAJ, in Hindi, means freedom from bondage.Since, P.T.L.wasthefirstlargesttractorprojectinIndia,moreoverfullybaseduponIndiantechnology.So SWARAJ wasappropriately chosenasits brandname.

Growth ofPTLPunjabTractorsLimitedstartedwithanannualcapacityof5000tractorsandwithacapitalofRs.3.7crores.Itwentintocommercialproductionintheyear 1974; its first production of 26.6BHP tractors was given the nameSWARAJ720.EversincethenP.T.L.hasnotlookedback.Inthefirsttwentyyearofitsexistenceitscapacityhasbeenincreasedto24000perannum whichisaconsiderableachievement byanystandards.PTLisconsideredasahighlyreputatedandimpressivecompanyinIndia.Itmanufactures many products and is helping in to develop India and improving its farming techniques .Swaraj has become synonymous with tractors that are powerful and reliablebecause of their long term expertise in delivering such products consistently. Weve been manufacturing tractors that serve the need of our buyers in agricultural as well as commercial operations. Our product range starting from a 22 HP category tractor to a 72 HP category tractor straddles every HP category requirement of our customers. The brand enjoys a strong equity in the market and commands a market share ofclose to 12%. The brand is known for producing tractors that are powerful and reliable. Presently, there are more than 7,00,000 satisfied customers of Swaraj in the country. Swaraj tractors are also exported to various countries including Bangladesh, Nepal, Sri Lanka, Nigeria, Ghana, Gambia, Zimbabwe, Zambia, Tanzania and the USA

.MILESTONES

1970Establishment of PTL for making Swaraj brand of tractors

1974Commercial production started with 2 models: 724 FE & 735 FE

1980Swaraj 8100, Indias first self-propelled combine harvester launched

1983Swaraj 855 launched in the 50 hp category1995Establish of the 2nd plant for manufacturing Swaraj tractors in Chhaparchhedi

1999Launch of Swaraj 744

2002Cumulative sales of Swaraj tractors (till date) touches 5,00,000

2007Swaraj 724 FE Orchard and Swaraj 978 launched

2007M&M (the leaders in domestic tractor industry) acquires majority stake in PTL

2009Merger of PTL into M&M and subsequent transformation as the Swaraj Division of Mahindra& Mahindra Ltd.

2009 Launch of 735 XM the first of the XM series of models

Financial Information:

AnnualTurnoverforthefinancialyear2003-04=Rs.641.44crores

NetProfit=Rs.43.11crores

%ageturnoverspentonResearchanddevelopment=1.28%

MarketShare=15%

Earningspershare=Rs.7.10

Inputs:1. Raw Materials: The following table shows a detailed analysis of raw material consumption during the financial year 2008-20092. Power Consumption: The total power consumption last year was 117.83lakh units.

3. Water consumption:No records were kept for water consumption as the net amount spent on water resources was negligible.

4. Diesel Consumption: The average amount of diesel consumed per tractorlast year was 619.11 Rupees. This includes consumption in both assembly andpaint shop.

Technical Collaborations:For Light commercial Vehicles: P.T.L. entered into technical and financial collaboration with Mazda MotorCorporation of Japan in the year 1984 to set another company by the name ofSwaraj Mazda Limited. It was Rs. 50 crore projects with an installed capacity to manufacture 5000 LCVs of up to 3.5 tonnes payload capacity

For Forklifts: The Company entered into technical collaboration with KOMATSU FORKLIFTSCOMPANY of Japan in 1985 for the manufacture of high tech forklifts of both diesel and electric at its combine division.

For Diesel Engines: P.T.L. set up Swaraj Engines Ltd. (S.E.L.) in technical and financial collaboration with Kirloskar Oil Engines for the manufacture of diesel engines.

Competition within India: The major competitors for PTL in India are Mahindra & Mahindra Tractors, Massey, Escorts, Eicher and HMT. The trends of market shares for the last 30years are shown in the figure below. We can see that the market share of Swaraj tractors has increased from 9.1% in 1983 to 15% in 2003. Also the ranking has improved from 6 to3rd.This is the sign of growing organization well on track tobecome the largest producers of tractors in India. On the international scene, Swaraj is now a recognized name in the developing world. Swaraj Tractors find an important place in countries like Ghana, Zambia, Kenya, Sudan, Indonesia, and Malaysia etc.

MARKET SHAREPERCENTAGE AND VOLUME

Pollutants and Pollution control measures:1. Water Pollution: There aretwo kinds ofeffluent waste that pollutes water

Industrial effluent: Process water after use is discharged as effluent. Industrial effluent is contaminated with pH imbalance, sulphates, chlorides, dissolved solids, suspended solids, oil and grease.

Domestic effluent: Domestic use consists of drinking and canteen waterconsumption apart from toilets. Domestic effluent is discharged into public sewer directly.

2. Air Pollution: Major contributors to air pollution are:

Shot-blasting section

Painting booths

Baking oven

D.G. sets

Major air pollutants include SPM, NO, SO2.3. LandPollution:The following solid was8Pollution Control Measures:

Plantation of trees

Expenditure of 5 lakh rupees per year for environmental management and pollution control activities

Effluent Treatment Plant for Industrial Effluent Treatment

Bag House Filter for the Shot Blasting Sections

Fume Extraction System for the pre-treatment process

Filter press for the extraction of water contents from the effluent sludge

Hierarchy of the Organization:

1. Board of Directors (B.O.D)

2. Working Directors:Vice Chairman and Managing Director

3. Executive Directors: Finance, Human Resource and Development, Manufacturing, International Business Division, Material Services, Swaraj Automotive Limited, Swaraj Motors Limited, Senior Vice-President (Marketing)

4. Vice-presidents:3-4 under each Executive Director in level 3

5. Assistant Vice President

6. General Manager

7. Chief Manager8. Senior Manager9. Manager10. Assistant Manager11. Senior Engineer12. Engineer13. Assistant Engineer14. Junior Engineer015. Operating ClassThe level 5-15 are under each vice president of level 4.Employee Strength: The total numbers of employees currently under the Mohali division of PTL are around 1600. These comprise of 500 in management staff and rest is working staff.

Products: The major products of Punjab Tractors limited are divided into two categories i.e. for domestic consumption and overseas consumption. The domestic products include the following:

1. Swaraj855

2.Swaraj939FE

3.Swaraj834FE

4.Swaraj744FE

5.Swaraj735FE

6.Swaraj733FE

7.Swaraj724FE

8.Swaraj72219.Forklift15

10.Forklift20

11.Forklift30

12.ElectricForklift15

13.Swaraj8100-HarvesterCombine

The products for overseas consumption include:

1. Swaraj978FE,4Wheeldrive

2.Swaraj978FE,2Wheeldrive

3.Swaraj855FE,4Wheeldrive

4.Swaraj939FE,4Wheeldrive32WEEK # 1

I spent the first few days of my training period for observational part. I spent time at various shops and tried to understand the various aspects of manufacturing. The manufacturing includes the following departments:

1. Production

Light machine shop (LMS)

Heavy machine shop (HMS)

Assembly shop

Heat treatment shop

Paint shop

2. Product servicesTool room

Tool Design

Tool Control

Research & Development

Production planning & control (PPC)

Material Management & control (stores)

Quality Engineering

Maintenance

Industrial Engineering

3. Support Services Management systems

Finances.

Purchase

LIGHT MACHINE SHOP (LMS)INDRODUCTION

LMSisthelargestsectioninthefactory.Alltransmissioncomponentsviz.shafts and gearsused in Tractors are manufactured here. Ithasmore than120 machines;Facilities ofthisshop include Equipmentforblankoperation,boring, drilling etc. Except the bevel gear generator & gearshaver,which have been imported from WIv1W & Churchill of West Germany respectively, all other machines are from HMT Ltd. The rupees thirty one million plant and machineryof thisshop installedin anarea of33,000 sq.ft.and casting, forging and high standard of quality.

TYPES OF MACHINESCylindrical grinder, internal grinder, copying lathe, gear hobber, Radial drillingmachine, drumturretlathe, turretlathe, Honingmachine, Centre lathe, Capstan lathe, Capstan lathe, Vertical pull broaching machine, Chuckmatic, Fay Auto,Cantering&facing machine, Vertical Millingmachine,HorizontalMillingMachine.Deburringmachine,D/EboringmachineGearShaverGTRmachine,BevelGearGenerator,Gearshaper,CNCmachine,PowerHacksawSpecialpurposedrillingmachine,twinchucker,CentreHole grinding machine.

Function of the departmentGear manufacture and grinding, machining of bull gears, bevel gear cutting ofall rounds on powerhacksaws, facing and centering, all type of grinding innerand outer gears, hobbing and broachingmachine. Gear shaving gear d burring machine, drillingofallgearsreportingsystem,numberofworkmenshifts operations

Inter relations with other departmentsTool room:jigs, fixtures andcutting tools

Maintenance: attending breakdowns and carrying out preventive maintenance of machine tools etc.

Industrial engineering: provisionof processcharts formachining operations.

Assembly:ensuring properfitment ofcomponents

Production planning and co-ordination: Micro loadingof components on daily basis.

Quality control and inspection, storageand inspection R & D

Heat treatment- shot blastingoperations labtesting, inspection etc.

Different Manufacturing Operations in LMSFacing: Itistheoperationsoffinishingtheendsofthework,tomaketheends flat and smooth& to make the piece ofrequired length.

Under Cutting:It issimilarto groovingoperation butis performed inside hole.

Chamfering: It is the operation ofbevelling the extreme end of the workpiece. Chamfer is provided for better look/to rough turning: in this operations max. Metal is removed &very little oversize dimensions is left forfurther machining.

Finish Turning: Heremin.metalisremoved&veryfinefinishisobtainedon the work surface.

Grooving: It is the operationof turningthe groove or neck inordertoterminate athreadortoprovideadequateclearanceenablenuttopassfreelyonthreadedworkpiece,toremoveburs&toprotecttheworkpiece from being damaged.

Knurling: It is a proc of embossing a diamond shaped regular pattern on the surface of the work piece using aspecial knurling tool.

Broaching: Itisamethodofmetalremovalbyatoolthathassuccessivelyhigher cutting edges in a fixed path. Each tooth removes afixed amount ofmaterial.

Drilling: It is a process of making hole in an object by forcing a rotating tool called drill.

Boring: It is a process of enlarging a hole that has already been drilled. Grinding: To grindmeans to abradeto wear away by frictionor tosharpen

Ingrinding:Thematerialisremovedbyameansofarotatingabrasivewheel.Itisgenerallyusedforsharpeningthecutting tool,forgrinding threads, better surface finish etc.

Hobbing: It is theprocessof cutting teethon gear&shafts& isperformedby rotating tool called hob on the hobbingmachine

Shaping: The process of cutting gears on the shaper is known as shaping. The tool used in shaping for teeth cutting is a multipoint cutting tool.HEAVY MACHINE SHOPINTRODUCTION:

All heavycastingsof tractorsare machinedin this shop withthe helpofvariety of special machines (SPM).ThesemachinesaretailormadebyHMTtosuitcomponentrequirements.About 20 SPM and 30 GPM are installed ina covered area of47,000 sq.ft. at a cost of 20 million, 2600 tonnes of castings are machined every year on a two-shiftbasis.In addition to the machining ofcastingsforthe tractor,somejobsare also performed for SwarajMazda Limited.

COMPONENTS MACHINEDIN THE SHOP: Gearbox housing (MaterialR-33, Casting, 180-230 BHN, 76-kgwt.)

Differential Housing Rear Cover Trumpet Housing

FUNCTIONS OF THE DEPARTMENTMachining of heavy castings like differential housing, gear box housing, rearcover, trumpet housing,steering housing of tractors,machining of tractorsparts, machining of some components for Mazda

INTER-RELATION WITHOTHER DEPARTMENTSTool room- Requirement of jigs,fixtures and cutting tools.

Maintenance- Attending breakdown and carrying out preventive maintenance of machine tools.

Industrial engineering- Provide process charts for machining operations.

Assembly- Ensuring proper fitment of components, productionplanning and control, micro loading of components on day-to-day basis.

Quality control &inspection Storage and inspection.

R&D

Paint shop

TYPES OF MACHINESRadialdrillingmachine

Verticalmilling

Horizontalmilling

Simplexmilling

Duplexmilling

Lathe

Doubleend

T/Wboring

Automaticlathe

SPM(specialpurpose M/c

ASSEMBLY SHOP

The Assembly Shop is the production shop where assembly and sub-assembly of allthe parts takeplace. The final processed parts from the variousparts ofproduction shop such as HMS, LMS and Heat Treatment reach the assembly Shop. The various parts reach the assembly. shop only after being washed, cleansed and dried, which takes place when the different parts are on their way toassembly shop.Theabovewashingprocesstakesplaceautomaticallyi.e.themachinisthasto dropthe final Parton therollerconveyor, andtheparts reachthe assembly shop after being automatically washed anddried. The assembly shopcanbedivided intovariousgroupsdepending uponsub-parts being assembled.Thesegroups are:1. Differential assembly andsub-assembly.2. Differential Cover assembly.3. GearBox assembly and sub-assembly.4. Main assembly line

WEEK # 2

DIFFERNTIAL ASSEMBLY

Before the various differential parts such as BP shaft, differential cage etc.areassembled,thevarioussub-assemblyofpartsareperformedinthesubunits.Inthe firstunit,boththeBPshaftsarefittedwithvariouscomponentssuchascircularclips,needlebearingsetc.tobeabletobeassembledtothedifferentialCage.ThisconstitutestheassemblyofCrossBar,PlanetaryGear, PlanetaryGearCover,andCrownWheeletc.Thevariousboltsrequired making theassembly.ofaboutpartsandintegral one are bolted using a pneumatic bolter gun. After this, the differential cage is collected from the conveyor firstly fitted withthe necessary bearing races. Then the differential Cage unit and theBP shaftare assembled, making up acompleteone unit.The TrumpetHsg. and the Axles are assembled in a different assembly shop and there on thewholeunitalongwiththeBullGearsisassembledtothedifferentialCage.The Assembly ofDifferentialHsg.is completewiththeassemblyoflayshaftext., the oil filter and the brake mechanism

Flow chart for the differential assembly:

Section of differential

The differential has three jobs:

1. To aim the power to the engine wheels.

2. To act as the final gear reduction in the vehicle, slowing the rotational speed ofthe transmission one final time before it hits the wheel

3. To transmit power to the wheels allowing them to rotate at different speeds.

Differentialassemblywith cageassembly

Cageassemblyusedindifferential

Spidercross

Gear Box Assembly

The Gear Box Assembly is the third stage of the assembly unit in which the gear boxis assembled. Firstly,the gearboxcage iscollected fromtheconveyorrollerandsuccessivelypartssuchasthecountershafts,clutchshafts,main shaft along with theballbearingsareassembledtothe unit. There is separate sub unit assembling the planetary cage and gears, which is thenattachedtotheGearBoxoutputshafttoobtaintheduplexspeedratiosofthetractor.Thebox afterbeing tested foritsefficiency issent tothe5stages

Working on gearbox assembly

.

Steering Gear Box + Gear Shifting + Brake Assembly:

Thisunitconsistsof4stagesoftheassemblyunit.Inthisunitthesubassembly of the steering gear box, gear shift mechanism on gear cover + the brake mechanism is assembled of these mentioned sub assemblies, the brake assembly issenttothe1stageofassemblyandthesteeringgearboxandgearboxcoverassembly issent to the 3stageof assembly. Apart fromthesesubassembly unit also producesthe KPS assembly.Figure showing gear arrangementSliding mesh gear box with four gears1.1. Main drive gear2. Counter shaft3. Main shaft4. Gear I5. Gear II6. Gear III7. Gear IV

WEEK # 3Differential Cover Assembly

The second stage of Assembly shop isthe differentialcover assembly shop which incorporates the gear pump assembly. And the direction control valve. The DI coveriscollectedfromtheconveyorandthevariousattachmentssuchasPowerCylinder,Piston Assembly., OilPump, DCVValveetc.is made, andthe coveristestedforitsefficiencyonthetestingjig.AfterwhichitissenttothefirststagewherethewholeunitisassembledtotheDcassembly.Andfurthersenttothe 5 stages of the assembly.

Flow process chart of rear cover assembly

In this assembly

Control valve

control sector

Ram cylinder piston

Bracket and ram armREAR COVER TESTING MACHINE

In this testing rig all the rear covers are tested before applying them on differential. The rear cover is fixed to the machine temporarily and then the testing is done. All the oil levels are checked and then the movement of bracket arm and the rockerarm is checked. The pressure is checked abed it should be between 16-17 k pas. The defected cover is again checked and tested so that the customer should get the best machine possible.

Assembly of Engine + Clutch MechanismThis unitisseparate 6stage ofassembly inwhichthe engines arereceived from thestores andfitted with theclutch mechanism andlay beamalong with the counter weights.

Assembly of Engine with the rest transmission sectionThe assembly of the engine and rest of the transmission is done within the 7 stage. In this stage the whole of thechassis is formedas an integral unit. Thevarious linksand mechanismbetween theengine and the gearbox ordiff isfastenedtogetherandthewholeintegralunitischeckedforitscompleteaccessories etc. Inall theabove stagesof assembly, theskilledworkersare used to accomplish all the stagesof assembly. But theyare also held by thepneumaticboltgunsandtheoverheadautomaticconveyorsandthealarmconveyoretctomaketheirjobeasy.Alsothewholeoftheassemblyisdoneon theassembly jigsorstands whichis keptmoving ataspeedofabout 7cm/mm.Also it is to be made in mindthat anyspill ofthe sub partssuch asbolts, nuts etc. by mistake is not going to spoil the working space as all these spillsgetsunderneaththeworkingspaceandasaresulttheworkingspaceremainsclean and tidy.

Hydraulic pump alternator and self starter

KAIZEN

Kai+Zen

Change + Good

Kaizen means non-stop improving the quality and the process. With Kaizen, an involved leadership guides to continuously improve the ability to meet high quality, low cost and on-time delivery. Kaizen transforms companies into superior global competitors .Kaizen costing are a continuing reduction during the manufacturing phase of an existing product. The Japanese word Kaizen refers to continual & gradual improvement through small betterment activities, rather than large or radical improvement made through innovation or large investment in technology. Kaizen costing is most consistent with saying

slow & steady win the race.

There are two essential elements that make up KAIZEN:

*improvement/change for the better; and

*ongoing/continuity.KAIZEN achieves its effects by working through people. All are expected to be involved. Managers, for example, are expected to spend about half their time on improving what they - and those for whom they are responsible - do. KAIZEN recognizes that improvements can be small or large. Many small improvements can make a big change - so KAIZEN works at a detailed levelIt is adopted by swaraj tractors in order to improve the quality of the production. All the workers are involved in this process which lead to the changes in the root level

PAINT SHOPOperations performed in paint shop are:SurfacePreparation(PreTreatmentCell)-carriedoutforsheetsandrims

. Painting

Inspection

Rejection (Reprocessing)-for sheetsand rims

.PreTreatmentCell

Various procedures followed here are: Degreasing

WaterRinsing (partwhichisdegreasedisalkalineinnature sorinsed with water due to its being good solvent)

.De Rusting

Surfaceoxidation

Phosphating (done so as toform a thinlayer of coating onpart so that no surface remains unpainted)

Passination(doneso astoavoidpaint penetratingthroughcertain section of part bodys surface)

PaintingChassis Paint Line: Operations carried out here are:

Washing: Here chassis isfirst washedwith a chemical cleaner, concentration of which is 5% and auto sprayed in a chamber

.Drying:Thechassisisthendried byhotairwhose temperatureisup to 60 to 70C.

Primer Painting: A thinlayer of primer paint issprayed on the chassis so that the final paint is strongly fixed on.Flash Off: This is thedistance given so as to allow paint to dry

.FinalPainting

Flashoff.

Baking:Chassis is allowed to bake for around 30 minutes.

Sheet and rims Painting: After surface preparation in PTC,sheets and rims are first of all cleaned with ordinary cloth.

There after following operations are carried out:Primer painting (full primer in addition to single coating of paint)

Flashoff

.Baking(at temperature of around 120-130C)

Wet Rubbing and cleaning with tack rag.

WEEK # 4

QUALITY ENGINEERING DEPARTMENT

Discipline that deals with the analysis of a manufacturing system at all stages, to improve the quality of the production process and of its output. Quality engineering receipt (formally known as Quality Engineering Department) is divided into two fields at Swaraj division of Mahindra and Mahindra Ltd.1. Suppliers Quality

2. In-House Quality

SUPPLIERS QUALITY

Suppliers section consists of maintaining the quality of products that are being supplied by suppliers. It contains inspection of the raw materials being supplied by suppliers. It also includes discussion regarding delay of raw material and defectiveparts supplied. Subsequent actions are taken if the supplied products being supplied are found defective and inspectors from the industry are sent regularly to avoid such defects. This inspection is regularly done by the industry so maintain good quality supply and sound relationship with suppliers.

IN HOUSE QUALITY

In house quality is embedded into every department of the industry. As such there are five dept. that are:

Q.E.L.M.S (Light Machine Shop)

Q.E.H.M.S (Heavy Machine Shop)

Q.E.H.T (Heat Treatment)

Q.E.P.M (Plant maintenance)

Q.E.A (Assembly)

Quality Engineering Assembly

Quality Engineering Assembly consists of five quality posts. Each Quality Posts are situated at every intervals of the assembly line. Each Quality post has a certain responsibility of maintaining the quality of the Product being manufactured in the industry. And the final quality post is known as P.D.I (Pre Dispatch Inspection).

P.D.I.(Pre Dispatch Inspection)

P.D.I (Pre Dispatch Inspection) is the final quality post which carries a majorresponsibility of dispatching the tractors as manufactured by the assembly line ofphase IV. This is similar to giving final touches to the jewellery being sold. This department carries rigorous checks as per the pre-designed checklist prior to dispatch of machinery.

HOW DOES IT HOLD GOOD?

P.D.I acts as one of the major diagnosing centre for every daily to daily outgoing failure and scrutinizing them and hopefully trying to remove these failures. This way forthcoming problems reported by dealers are reduced. This helps to maintain healthy relationship with dealers and customers.

MEASURES UNDER P.D.I1. TRANSMISSION FLUID LEVEL

2. ENGINE OIL LEVEL

3. F.I.P OIL LEVEL

4. WATER LEVEL IN RADIATOR

5. ELECTRICAL FUCTIONING

6. COMPONENT STORAGE

7. CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER

8. PAINT DEFECTS AND OTHER VISUAL INSPECTIONS

9. WATER MIX IN ENGINE AND TRANSMISSION FLUIDTRANSMISSION FLUID LEVEL

To check the transmission fluid level, the dipstick from tractor is removed using/E spanner (24*27). The oil level is checked by using the gauge. If the oil is overor under the required quantity, oil is added or drained respectively to adjust the oil level and it is brought up to the required level.

ENGINE OIL LEVELTo check the engine oil level, a pull out dipstick is used which is pulled out from the engine block by hand. To check the oil level correctly, the oil is wiped off the dip-stick with a clean cloth. The dip-stick is reinserted and then again taken out. The oil level is again checked using the mark built on the dip-stick. If the oil is above or below the required level, it is added or drained respectively.

F.I.P OIL LEVEL

To check the oil level of the Fuel Injection Pump oil level, we loosen the inspection screw by D/E spanner (14*17) and check the oil in the F.I.P(Fuel Injection Pump). Oil is added in case the oil is not coming out.WATER LEVEL IN RADIATOR

The water level in the radiator has a very essential role. Without the water the radiator cannot work efficiently. Before the tractors are dispatched, the water/coolant level is checked and filled if the level is not unto the full mark. To check it, radiator cap is opened and so is the cap of the water/ reservoir tank. The level of water/coolant in the reservoir tank can be checked by visual inspection. To check the water levels in the radiator, finger is immersed inside it after removing the cap. If the water level is not fine it is filled up to the required level. This test also checks the seals on the radiator cap.

Level of water in the Reservoir tank

ELECTRICALFUCTIONING1) Operation of Brake Switch

Brake switch is a small, brake pedal operated spring loaded switch used to light up the rear stop light (red light) on the application of the brakes. It can have very serious affects if the tractor is on a heavy traffic road. To check if its workingproperly or not, the electrical switch of thebattery is put on the level and then the brakes are applied. If the stop lights, light up, then the switch is working fine otherwise it is replaced.

2) Battery

The battery of the tractor is a very costly and an essential part. The customershould not get a de-charged battery. The battery of the Swaraj 735 FE and above models has a battery with a magic eye. The magic eye has a colour indicator forthe indication of the condition of the battery. If the battery is OK - then the colourshows Green If the battery needs charging then it shows a white indicator Ifdistilled water needs to be added to the battery It shows a red indicator

3) Fuse box

The fuse box of the tractor is also checked before it is rolled out. To check if any fuse has been broken, the tractor is started and all the electrical functions like the head and the rear lamps, the turn-indicators and the horn is checked. If any component does not seem to work, the first check is to check the fuse connectionism the fuse box.

COMPONENT STORAGE

Visually inspect the tractor is done. All the nuts and bolts are checked, the logos and stickers are observed and checked so that they are correctly placed and are appropriate to the product. If the components are missing, deteriorated or wrongly fitted, the needful is done. For example, all the 4 tyres of the tractor are required tobe of the same brand. This helps in the proper control of the tractor while in motion.

CHECKING OFAIR LEAKAGEFROM THE AIRINTAKEFILTER

The air intake by the engine is done through the air filter. If the air does not goes through the air filter the engine will choke destroying the piston linings and hence causing a massive damage to the engine. The intake of air through the air filter is even more important in case of tractors as they work in dusty environments full ofsand and other materials. The air filter is located above the level of the engine on the left side, as seen by the driver. To check if there is any air leakage in theSuction tube, the air filter cap is removed and the tractor is started. Hand is placed on top of the air inlet pipe, properly covering it. If the engine stops on doing this, the tractor passes the test.When the hand is placed and the entry of the air is blocked, the engine stops

PAINT DEFECTS AND OTHER VISUALINSPECTIONS

A variety of paint defects occur while the tractor is being assembled. These defects are inspected at the IQS (Internal quality study). The IQS area at Swaraj tractorsplant has been set up by Mahindra and Mahindra Limited. It involves a thorough check on tractors finish i.e. Buff marks, etc. It involves a very thorough check in very good illumination from each side. They select five random tractors from the assembly line and inspect them thoroughly. Various paint defects that are found at IQS are:1. Dust in paint2. Excessive buff marks3. Metal scratches4. Paint scratches5. Paint run-down6. Poor touch up/ overspray7. Dent / ding

WATER MIXIN ENGINE AND TRANSMISSION FLUID

Due to various leakage points, water seepage occurs and water seeps into the engine oil and transmission fluid compartments. The water mix levels of engine oil and transmission fluid is checked by two methods:1. Visual inspection of the Dip-sticks of both the engine oil and the transmission fluid compartments can easily tell if water is present or not. If water is not mixed,both the engine oil and the transmission fluid are transparent. If water is present in the engine oil compartment, the drop of the oil which comes out with the dip-stickwill be hazy. The same is the case of transmission fluid. If water is present it will turn translucent.2. Water mix paste is used to check if water is present in the engine oil ortransmission fluid. The Water mix paste (green in colour) is put on the tip of the dip-stick and inserted back into the respective compartments. If water is present, it reacts with the green coloured water mix paste and turns it pink in colour. This gives a proof of the presence of water. Various others tests are performed before the tractors are finally dispatched, which are performed as the need arisesMAINTENANCE DEPARTMENTINTRODUCTION

Many changes have taken place in the maintenance system and practice used in the industries with the progress made by technology. Along withproduction, maintenance plays vital role. In fact production and maintenance go side by side If a machine is under breakdown, it cannot be subjected to theproductionprocesswiththeadventofnewandmoderntechnology,theentireconceptof maintenance haschanged. Earlier maintenance practiceswereonly confined tothe breakdown maintenance, butnow differenttypes of maintenancepractices are followed like:

1. Scheduledmaintenance

2. Break downmaintenance

3. Preventivemaintenance

4. Predictive maintenance

The following are the main objectives of maintenance:

to achieve theminimum break downlevel and to achieve theproduction target at low cost

.to keep the plantin proper working condition

Machineandotherfacilitiesshouldbearrangedsothattheycanbeused to their max. capacity.

The Maintenance division of the factory ensures the availability of all the facilities necessary for the performance of functions at optimum return ofinvestment

IMPORTANCE OFMAINTENANCE1. Equipmentbreakdown leadsto inevitableloss ofproduction time,which isprevented bymaintenance department.

2. Plantmaintenanceplaysan importantrole inproduction

3. managementbypreventingbreakdownswhichcavesinevitableshortfalloftarget,needsOf sub-contracting work, rescheduling of production, need of over time etc.4. Routine check-up of facilities ensure safe and efficient operation ofmachinery.

5. Maintains optimum production efficiency ofmachinery

5. Helpsinmaintainingtheoperationalaccuracyandreducestheworkcontent.

6. Reduce breakdowns and concerned downtimes thus achieving the target ofmax. Production atmin .cost

.7. Ensure safety of life and limbs of workersand machine operators.

With rise inthe technology,not onlypredictive andpreventive actionbusthe concept ofcost cutting, properutilization of resources,better sparepartsplanning, training have also become important now.

Thiscan bemadepossibleto centpercentby systematic maintenance.In swaraj tractorslimited systematic maintenanceoperations arepracticedto improvetheplantavailabilityandtoachievethegoalatareasonablecost.i.e.toachieveavailabilityperformanceatthelowestcostandwithinthesafetyconstantsAt present themaintenance deptt. Of SWARAJ TRACTORS have five subsections.1Electrical maintenance cell

2. Engineering machine maintenance cell

3. Material handling equipmentmaintenance cell.

4. Spare part planning and control cell.5. Engineering utility maintenance

TQM (TOTALPRODUCTIVE MANAGEMENT)

They follow a policy of TPM-Total Productive Management. Total productive management contains following aspects:

1. Maximize reliability of plant and machinery by aiming above and eliminating the losses.

2. Nurture teamwork and continuous improvement through total employee involvement.

3. Promote healthy, clean and cheerful working environment

4. Cultivate

MY MACHINE, MY WORKPLACEconcept.5. Making available low cost, trouble free, accident free ,customer focused and attractive products.