Jigs and Fixtures: Mahindra & Mahindra Swaraj

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SIX MONTH INDUSTRIAL TRAINING REPORT

ON
JIGS AND FIXTURES
AT

MAHINDRA & MAHINDRA SWARAJ

SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DEGREE OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

BY
HARISH VIRDI
100311129872

DEPARTMENT OF MECHANICAL ENGINEERING
PTU GZS CAMPUS, BATHINDA
NOV, 2013

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Acknowledgement

Any endeavor cannot lead to success unless and until a proper platform
is provided for the same. This is reason I find myself very fortunate to have
undergone my industrial training of six months at MAHINDRA &
MAHINDRA SWARAJ.

I am very fortunate to have had a chance to feel the gravity of what role
Mechanical Engineering plays in the industry. It was a golden opportunity for
me to get a chance to experience what it feels to be in a company where
discipline, quality and hard work are the motto. This training helped me a lot
in bridging the gap between the theoretical and the practical aspects of my
knowledge.

First of all I would like to thank Prof. CHARANJIT SINGH and to all the
teachers of Mechanical Department for their valuable guidance &
encouragement as a teacher throughout my training period.

I am also thankful to Prof. SURINDER SINGH (HOD
MECHANICAL DEPARTMENT) for giving me an opportunity to undergo
training in such a renowned company.

I am sure that the knowledge & information that I have gained during
this period would be of immense value for my growth in the field of
Mechanical Engineering.
HARISH VIRDI
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INTRODUCTION

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 meet this 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.

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GROWTH OF COMPANY

PUNJAB TRACTOR LIMITED started with an annual capacity of five thousand tractors &
with a capital of Rs. 3.7 crores. It went into commercial production in the year 1974; its
first production was 26.6 BHP tractors given the name SWARAJ-720. Ever since then P.T.L.
has not looked back. In the first twenty years of existence its capacity has been increased
to 24,000 per annum, which is a considerable achievement by any standards. Besides
tractors, it has added a host of other products to its range, which includes:
Harvesting Combine.
Fork Lifters.
Agriculture implements.
Automotive casting.

Punjab Tractors Ltd (PTL) is one of the leading manufacturers of tractors in India. PTL
has been known as the industry out performer since inception. Even when the industry
grew at a CAGR of 6.1% during 1991-2000, PTL grew at the CAGR of 11.9%. In terms of
market share, PTL is the second largest player after M & M in FY2001 with a market share
of 18.1%. PTL tractors are sold under the Swaraj brand name. PTL has strong market
share of around 20% in the northern region with the highest share in Punjab and Haryana
and 16% in the western regions and southern regions of India. In the east the company
accounts for 11% market share. The tractor sales accounted for 83.3% of PTL's turnover in
FY2001 whereas the harvester-combines, forklifts and spare parts accounted for the
balance. Indsustry basic The Indian tractor market is dominated by low price, rugged,
versatile and low to medium powered tractors; the main reason being the inability of
farmers to invest in farm mechanization. Tractors are categorized on the basis of horse
power (HP) of the engine. In India, the popular range of tractors is 20-40 HP compared to
60 HP in Europe and 90 HP in the USA. Though large tractors were economically unviable
in India, there has been an increasing demand for high-powered tractors due to soil
conditions, particularly in states of MP, Gujarat and Maharashtra. But more recently,
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higher-powered tractors are also being sold in states like Punjab where it is considered as
a status symbol. Tractors available in India are 1/4th of the prices of similar powered
tractors internationally or in developed countries. Availability of credit is the most crucial
factor impacting tractor demand, as in India 90% of the tractors are financed by bank
credit at concessional rates. Increased use of irrigation facilities, shift towards multi-
cropping, consolidation of lands holdings, promotion of co-operatives and higher
investment in agriculture also contributes to higher tractor demand. The tractor segment
comprises players like Eicher, Escorts, HMT, Punjab Tractors, M&M, TAFE, Sonalika, which
control about 98% market share. India is the worlds largest market in tractors since 1996.
A few international players like Case New Holland, John Deere and Steyr have also set up
facilities in India. But these players have entered the higher-powered category and, thus,
pose little threat to the existing players who enjoy advantages of established
distribution/service network and strong brand equity. Punjab Tractors is promoted
mainly by Punjab State Industrial Development Corporation Limited and has acquired the
second highest market share in the tractor segment from 9.1% in 1975. In 1970, PTL had
major competition from other companies like Eicher, Tractors and Farm Equipment
(TAFE), Mahindra & Mahindra (M&M), Escorts and HMT. PTL is one of the leaders in its
business and has put up a heady performance in contrast to other private sector players.
As against other players, which report a ROCE of 15% on an average, PTL has consistently
remained at about 50% in the last few years though the industry is capital-intensive.
Punjab Tractor is the only major tractor company, which entered this business without
any foreign collaboration. The company has beefed up its R&D capabilities in the last two
to three years. PTLs Swaraj-735 is in a class of its own and has been benchmarked by its
competitors to which 16 new features have been added. PTL has single mindedly
focused on increasing its market share in tractors. Current Scenario During the first half
of 2001-02 PTL increased its market share from 18.5% to 21.4%. With the total industry
volumes plummeting by 16.6% the sales of PTL fell only a trifle 3.1%. Under these
circumstances, though the revenue has fallen by a 0.38% the operating profitability has
risen by 1.03%. PTL garnered the operating margins of 19.4% in the first half of FY2001-
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02, while the lead players like M&M Escorts and Eicher have reported operating margins
of 4.4%, 0.7% and 2.9% respectively. The Net Profit has increased by 1.4% to Rs.564
million and the contribution of 40-50HP tractors has increased by 30%, which indicates
higher margins from bigger tractors due to a strong foothold in Punjab and Haryana
markets.

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Companys
History

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Swarajs history

The Swaraj brand has a rich history emerging from the spike in the demand for tractors
during the Green Revolution of the mid-sixties. The Central Mechanical Engineering
Research Institute (CMERI), a government agency, initiated the project of creating an
indigenously built tractor. Punjab Tractors Ltd purchased the design in 1970, and we
inherited nearly forty years of experience when we acquired PTL in 2008.

The combination of Swarajs longstanding reputation with our cutting edge design and
manufacturing has made the name Swaraj synonymous with power, reliability, and
expertise. We enjoy a market share of nearly 12 percent and a community of more than
700,000 satisfied owners in India alone. We bring our customers excellent tractors and
product support at 600 dealerships across India. We are 2,100 dedicated, highly trained,
and customer-centric employees working to bring you the best in farming equipment and
customer support.

Our success lies in our commitment to fulfill a diverse set of customer needs. We have
models to suit small farms and large, first-time buyers and those seeking upgrades, and
agricultural as well as commercial operations. Our range of tractors starts from 22 HP to
72 HP, and we also offer compatible wheel-type and track-type harvesters.

In addition to our strong presence in India, Swaraj tractors are used across the world in the
US, Nigeria, Zimbabwe, Tanzania, Nepal, Sri Lanka, Bangladesh and Ghana. In each
region we enter, we seek to provide farmers with tractors and implements precisely suited
to their agricultural conditions, helping them maximize their prosperity.

Swaraj Engines Ltd., situated at Phase 9, Industrial Area Mohali was established in
technical and financial collaboration with Kirloskar oil Engines Ltd. For manufacturing
diesel engines for Swaraj Tractor Division Phase 4, Industrial Area, Mohali. During the
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few years of its existence, it has not only increased its product range but also increased its
production from 345 in the first year more than 18000 engines now. These engines are sent
to the Swaraj Tractor Division where they are fitted on various Tractors.
Swaraj group came into existence with the establishment of Punjab Tractor Limited on
27
th
June, 1974. The company was Indias first large scale based on totally indigenous design
& technology, was promoted by Punjab State Industrial Development Corporation (PSIDC)
with the help of Govt. of India & Public financial institutions.

INTERNATIONAL AND NATIONAL
COLLABORATION OF SWARAJ GROUP
Swaraj group has entered into technical and financial collaborations with various
national and international companies.
Swaraj Mazda Limited was set with technical and financial collaborations with
Mazda Motors Corporation of Japan.
Swaraj Combine Division was entered into with Komatsu Forklift Company of
Japan for manufacturing fork lifters.
Swaraj Engines Limited was set up in technical and financial collaboration with Kirloskar
Oil Engines Limited, Pune for manufacturing diesel engines.

VARIOUS DIVISIONS OF SWARAJ GROUP:-
Swaraj consists of SIX divisions:
1. Swaraj Tractors Division.
2. Swaraj Mazda Ltd.
3. Swaraj combine Ltd.
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4. Swaraj automotive Ltd.
5. Swaraj foundry division
6. Swaraj Engines Ltd.

Swaraj Tractors Mohali operations
Swaraj Division (Tractor plant 1 and Tractor & Harvester Plant 2)
Swaraj Foundry Division
Swaraj Engines Ltd.
Swaraj Automotive

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Mahindras history
On October 2nd, 1945, Mahindra & Mohammed was set up as a franchise for assembling
jeeps from Willys, USA.
Two years later, Mahindra & Mohammed changed its name to Mahindra & Mahindra.
Ghulam Mohammed migrated to Pakistan post-partition and became the first Finance
Minister of Pakistan.
Mahindra and Mahindra started trading steel on behalf of European suppliers. In 1955,
Mahindra and Mahindra was converted to a public limited company. Soon after that the
Mahindra tools division started. After the formation of Mahindra tools, Mahindra
Engineering and Chemical products was formed. In 1983, M&M led the Indian tractor
segment. Post that incident they formed a joined venture with British Telecommunications
to form Mahindra British Telecom.
Keshub Mahindra was made the Chairman of Mahindra in 2007 from the post of Vice-
Chairman and Managing Director. Mahindra has total revenues of US 12.5 billion dollars
and employs more than 1,19,900 people around the world. The company has coverage in
the vehicles market, the tractor market, information technology as well as significant
present in financial services, leisure and hospitality.

MANUFACTURING FACILITIES

Mahindra has seven auto manufacturing facilities
Igatpuri (Engine Plant)
Haridwar (3 wheeler / GiO plant)
Kandivli (utility vehicles)
Nasik (utility vehicles)
Chakan
Zaheerabad (LCVs & 3 wheelers)
Completely Knocked Down Unit Plants in Egypt and Brazil

It has the following tractor manufacturing facilities
Mahindra Tractors
Mumbai
Jaipur
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Rudrapur
Nagpur

Swaraj Tractors Mohali operations
Swaraj Division (Tractor plant 1 and Tractor & Harvester Plant 2)
Swaraj Foundry Division
Swaraj Engines Ltd.
Swaraj Automotive

Mahindra Powerol plants
Delhi
Chennai
Pune
Vasai

USA (3 Plants)
Houston, TX
Red Bluff, CA
Chattanooga, TN
China (3 Manufacturing plants)
MCTCL (Nanchang)
MYYTCL (2-Yangcheng)

ANZ (1 Assembly plant)
Brisbane, Queensland

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Collaboration

M&Ms president (farm equipment sector) Anjani kumar Choudhari, who took charge as
PTLs chairman , told ET: Swaraj has tremendous brand value in many northern markets
and we are going to exploit it fully. M&M bagged the bid at about Rs 360 per share, and
is acquiring about 43 per cent stake in the Chandigarh-based tractor firm for close to Rs
1,000 crore in an all-cash deal.
The 43 per cent stake includes 29 per cent owned by private equity firm
Actis and 14.2 per cent by the Delhi-based Burman family. It was the second largest tractor
company a few years ago and we would be promoting Swaraj aggressively to regain its lost
market share. Some price improvements in the product are also being planned, which would be
followed by a publicity campaign. While both the tractor brands would exist independently, a
synergy in production and other back-end operations has been planned. M&M would utilize
the low-cost vendors of PTL for its own tractors and eventually have a common vendor base
for both the products. We are planning major capital investment for modernization and
expansion of foundry operations. There is a huge shortage of casting capacity in the market, so
a major integration of the PTLs foundry business with M&M operations is being planned. The
company is also planning an expansion of PTLs combined harvester (mechanized harvesting
vehicle) manufacturing facility. Iran Tractor Manufacturing Company, our business partners
in Iran, has shown keen interest in the combined harvesting facility. Officials of the company
have visited the PTL factory and are looking for exports of these machines.

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Companys progress
1965:- Govt. of India's research institute (CMERI) at Durgapur initiates design and
development of SWARAJ tractor based on indigenous know-how.

1970:- Punjab Govt. through PSIDC acquires SWARAJ tractor's design from CMERI and
establishes Punjab Tractors Ltd. (PTL) for its commercialization.

1971-73:- PTL sets up SWARAJ Project for 5,000 tractors per annum at a capital outlay of
Rs. 37.0 million with an equity base of Rs 11.0 million.

1974:- Swaraj 724 (26.5 HP) tractor commercially introduced.

1975:- 2nd tractor model SWARAJ 735(39 HP) developed by own R&D, commercially
introduced.

1978:- 3rd Tractor model SWARAJ 720 (19.5 HP) developed by own R&D, commercially
introduced. Maiden equity divided declared.

1980:- Guided by social concerns and responsibility, PTL takes over PSIDC's scooters unit
- Punjab Scooters Ltd. (subsequently renamed as SWARAJ Automotives Ltd.) India's
first Self propelled Harvester Combine - SWARAJ 8100 developed by own R&D,
commercially introduced. SWARAJ Foundry Division set up in backward area.

1983:- 4th Tractor Model - SWARAJ 855 (55 HP) developed by own R&D, commercially
introduced. Expansion of annual capacity to 12,000 tractors per annum at Plant 1.

1984:- SWARAJ MAZDA Ltd. promoted in technical and financial collaboration with
Mazda Motor Corps. & Sumitomo Corp. Japan for manufacture of Light Commercial
Vehicles. PTL's equity participation is Rs. 30.4 million (29%) and that of Mazda and
Sumitomo's Rs. 27.0 million (26%).
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1985:- SWARAJ Industrial Forklift Trucks developed by own R&D, commercially
introduced.
1986:- SWARAJ ENGINES Ltd. promoted in technical and financial collaboration with
Kirloskar Oil Engines Ltd.(KOEL) for manufacture of diesel engines. PTL's equity
participation is Rs. 6.9 million (33%) and that of KOEL's Rs 3.6 million (17%).

1995:- Setup of tractor Plant II at Village Chappercheri with annual capacity of 12,000 per
annum.

1998:- Commencement of expansion to 60,000 tractors (30,000 at each plant). Capital
outlay of Rs 1000 million, funded mainly through internal accruals.

1999:- 5th and 6th tractor models - SWARAJ 733 (34 HP) & SWARAJ 744 (48 HP)
developed by own R&D, commercially introduced.

2000:- Expansion of annual tractor capacity to 60,000 completed.

2001:- PTL won National Championship trophy in competition organized by All India
Management Association (AIMA) for young managers. Economic times and Boston
Consulting Group selects PTL as one of the India's finest 10 companies out of Economic
times top 500 Companies.

2002:- Cumulative tractor sales crosses 5,00,000/-.

2003:- PSIDC's disinvestment of its entire Equity holding (23.49%) in PTL in favour of
CDC Financial Services (Mauritius) Ltd. With this, total holding of CDC & its associates
in PTL stands at 28.48%.

2004:- 7th & 8th tractor models - Swaraj 939 (41 HP) & Swarj 834 (34 HP) developed by
own R&D, commercially introduced.
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2005:- PTL disinvested 15,73,000 equity shares of Rs. 10/- each of Swaraj Mazda Ltd.
(constituting approx. 15% of SML's paid up capital) in favour of Sumitomo Corporation,
Japan, a joint venture partner in Swaraj Mazda Ltd. at a total consideration of Rs. 629.2
million.

2007:- CDC/Actis Group and Burman Family's disinvestment of their Equity holding in
PTL (43.3%) in favour of Mahindra Group (M&M).

2008:- Swaraj 3 Tonne Battery forklift, designed and developed by in-house R&D,
commercially launched

2009:- Launch of 735 XM the first of the XM series of models
Launch of 843XM building on the XM series

2011:- Rated Highest In Industry for Customer Satisfaction Index (CSI), Sales Satisfaction Index
(SSI) & CaPS.
Swaraj Division achieved Stage-5 in MQW Assessment.

2012:- Launch of 825XM, 841XM, 744XM, 855XM - strengthening the product portfolio with XM
Series.
Swaraj becomes the second tractor company in the world to win the prestigious DEMING
Prize.
Rated Highest In Industry for Customer Satisfaction Index (CSI)

2013:- Swaraj Division Plant 1 and Plant 2 Won TPM Excellence Award From JIP.
10,000 tractors sold.

MAHINDRA SWARAJ TRACTORS DIVISION:-
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It is located in Phase-IV, SAS Nagar. The construction work of PTL was started in
March 1972 and the first batch rolled out on 14
th
November 1973. It started
with an annual capacity of 5000 tractors with a capital of Rs. 37 million. In 1974
it went into commercial production with Swaraj 724 26.5 BHP tractors as its first
model. During its 22 year of production, it has not only expanded its
manufacturing capacity to more than 24000 tractors per annum but adds more
products into its manufacturing range. Its product range includes the following.
TRACTORS:-
Swaraj 724 XM 25-30 HP
Swaraj 724 XM orchid 25-30 HP
Swaraj 735 FE 35-40 HP
Swaraj 724 XM

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Engine Specifications:

Model : RV-2 XM + 3A

HP : 25-30 HP

Type : 4 - Stroke, Direct Injection, Diesel Engine

No. of Cylinders : 2

Bore and Stroke : 100 X 116 mm

Displacement : 1824 cc

Rated Engine
Speed :
1800 rev/min

Air Cleaner :
3- Stage Oil Bath Type

Cooling System : Water Cooled with No loss tank

Transmission
Clutch
standard Single dry disc friction plate
No. of
gears

8 Forward, 2 reverse speeds

Gear Speed (km/hr)

Forward 2.19 to 27.78
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Reverse 2.74 & 10.77

PTO Speed
Speed
standard 1000 rpm

Optional 540 rpm

Brakes
Brake
type
standard Dry disc type brakes

Optional NA

Steering Type
Type
Standard
Mechanical Steering with Heavy Duty single drop arm for
better manoeuvrability & comfort to operator

Optional NA

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Hydraulics
Hydraulics

Live Hydraulics
Position control: To hold lower links at any desired height
Automatic draft control:To maintain uniform draft
Mix Control: For optimum field output
Lifting
Capacity
Standard 1000 Kgf at lower link ends

Optional NA
Linkage

3 point linkage Category-I suitable for Category-II type
implement pins.

Tyres
Front
Standard 6.00x 16
Rear
Standard 12.4x 28
Rear/Front
Optional NA

Electricals
Electricals

12 V, 88 Ah. Battery
Starter Motor and alternator
Instruments

Engine rpm cum hour meter with direction indicators, Fuel
Gauge, Ammeter, and Water Temp. Gauge & Oil Pressure
Indicator

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Weight & Dimensions
O.A. Length

3320 mm
O.A. Width

1675 mm
O.A. Height

2270mm
Wheel Base

1935 mm
Min. ground
Clearance

375 mm
Weight of tractor

1750 kgs
Wheel Track
Front
Rear
1300 mm
1350 mm (with 12.4*28 tyre size)

Swaraj 724 XM orchid

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Model : RV-2 XM +3A

HP : 25-30 hp





Rated Engine
Speed :
1800 rev/min

Air Cleaner :
Dry type, Dual element with dust unloader

Cooling System : Water Cooled with no loss tank

Transmission
Clutch
No. of gears


Gear Speed (km/hr)

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Reverse 2.28 & 09.02

PTO Speed
Speed
standard 1000 rpm

Optional NA

Brakes
Brake
type
standard Oil Immersed Brakes

Optional NA

Steering Type
Type
Standard

Optional NA

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Hydraulics
Hydraulics

Live Hydraulics
Lifting
Capacity

Optional NA
Linkage

implement pins.

Tyres
Front
Standard 5.00x 15
Rear
Standard 11.2x 24
Rear/Front
Optional NA

Electricals
Electricals

Instruments

Indicator

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Weight & Dimensions
O.A. Length

2800 mm
O.A. Width

1440 mm
O.A. Height

1450mm
Wheel Base

1575 mm
Min. ground
Clearance

240 mm
Weight of tractor

1400 kgs
Wheel Track
Front
Rear
1060 mm

Swaraj 735 XM

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HP : 35-40 HP




Displacement : 2734cc

Rated Engine
Speed :
1800 rev/min

Air Cleaner :


Transmission
Clutch
standard Single dry disc friction plate - 280 mm dia. (11")
No. of
gears


Gear Speed (km/hr)
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Reverse 2.73 & 10.74

PTO Speed
Speed
standard 1000 rpm

Optional 540 rpm

Brakes
Brake
type

Optional Oil immersed Brakes

Steering Type
Type
Standard

Optional Power Steering

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Hydraulics
Hydraulics

Live Hydraulics
Lifting
Capacity

Optional NA
Linkage

implement pins.

Tyres
Front
Standard 6.00x 16
Rear
Standard 12.4x 28
Rear/Front
Optional 6.00 x 19/ 13.6 x 28

Electricals
Electricals

Instruments

Indicator

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Weight & Dimensions
O.A. Length

3470mm
O.A. Width

1695 mm
O.A. Height

2255mm
Wheel Base

1950 mm
Min. ground
Clearance

395mmm
Weight of tractor

1895 kgs
Wheel Track
Front
Rear
1300 mm

Swaraj 735 FE

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HP : 35-40 HP





Rated Engine
Speed :
1800 rev/min

Air Cleaner :

Transmission
Clutch
No. of
gears


Gear Speed (km/hr)


Reverse 2.73 & 10.74
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PTO Speed
Speed
standard 1000 rpm

Optional 540 rpm

Brakes
Brake
type


Steering Type
Type
Standard

Optional Power Steering

Hydraulics
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Hydraulics

Live Hydraulics
Lifting
Capacity

Optional NA
Linkage

implement pins.

Tyres
Front
Standard 6.00x 16
Rear
Standard 12.4x 28
Rear/Front
Optional 6.00 x 19/ 13.6 x 28

Electricals
Electricals

Instruments

Indicator

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Weight & Dimensions
O.A. Length

3470mm
O.A. Width

1695 mm
O.A. Height

2255mm
Wheel Base

1950 mm
Min. ground
Clearance

395mmm
Weight of tractor

1895 kgs
Wheel Track
Front
Rear
1300 mm

Swaraj 825 XM
.
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Model : S-15 XM

HP : 20-25 HP





Rated Engine Speed : 1650 rev/min

Air Cleaner :


Transmission
Clutch
No. of
gears


Gear Speed (km/hr)

Forward 3.3 to 30.4

Reverse 2.9 & 9.6

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PTO Speed
Speed
standard 1000 rpm

Optional 540 rpm

Brakes
Brake
type

Optional NA

Steering Type
Type
Standard

Optional NA

Hydraulics
Hydraulics

Live Hydraulics
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Lifting
Capacity

Optional NA
Linkage

implement pins.

Tyres
Front
Standard 6.00x 16
Rear
Standard 12.4x 28
Rear/Front
Optional NA

Electricals
Electricals

Instruments

Indicator

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Weight & Dimensions
O.A. Length

3260mm
O.A. Width

1690 mm
O.A. Height

2395mm
Wheel Base

1930 mm
Min. ground
Clearance

400mmm
Weight of tractor

1870 kgs
Wheel Track
Front
Rear
1300 mm

Swaraj 834 XM

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HP : 35-40 HP






Air Cleaner :

Transmission
Clutch
No. of
gears


Gear Speed (km/hr)

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Reverse 2.68 & 10.52

PTO Speed
Speed
standard 1000 rpm

Optional 540 rpm

Brakes
Brake
type


Steering Type
Type
Standard

Optional NA

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Hydraulics
Hydraulics

Live Hydraulics
Lifting
Capacity

Optional NA
Linkage

implement pins.

Tyres
Front
Standard 6.00x 16
Rear
Standard 12.4x 28
Rear/Front
Optional NA

Electricals
Electricals

Instruments

Indicator

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Weight & Dimensions
O.A. Length

3475mm
O.A. Width

1705 mm
O.A. Height

2250mm
Wheel Base

1930 mm
Min. ground
Clearance

380mmm
Weight of tractor

1845 kgs
Wheel Track
Front
Rear
1300 mm

Swaraj 841 XM

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Model : MDI 2385 S 3A

HP : 40-42 HP



Bore and Stroke : 88.9 X 110 mm


Rated Engine Speed
:
1900 rev/min

Air Cleaner :


Transmission
Clutch
No. of
gears


Gear Speed (km/hr)
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Forward 2.3 to 29.3

Reverse 2.8 & 10.9

PTO Speed
Speed
standard 540 rpm

Optional NA

Brakes
Brake
type
standard Oil immersed Brakes

Optional NA

Steering Type
Type
Standard

Optional NA

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Hydraulics
Hydraulics

Live Hydraulics - SENSILIFT Hydraulics for better
operations in Loose & Sandy Soil
Lifting
Capacity

Optional NA
Linkage

implement pins.

Tyres
Front
Standard 6.00x 16
Rear
Standard 12.4x 28
Rear/Front
Optional 6.00 x 16 / 13.6 x 28

Electricals
Electricals

Instruments

Indicator
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Weight & Dimensions
O.A. Length

3390mm
O.A. Width

1680 mm
O.A. Height

2200mm
Wheel Base

1935 mm
Min. ground
Clearance

370mmm
Weight of tractor

1820 kgs
Wheel Track
Front
Rear
1300 mm

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SWARAJ AUTOMOTIVE LIMITED
Swaraj AUTOMOTIVE limited are a part of Swaraj enterprise. Swaraj
automotive Ltd., situated at focal point, Industrial Area, Nabha.. The
Governor of Punjab S.S. Ray paid the foundation stone of the factory on 29
th
Dec. 1987. It started production from 28
th
Dec. 1988.
In other sideSEL plant, The Sel plant produces engines in the range
of 20hp to 50hp. This plant had produced 18000 engines in the first year of his
production. But now it is producing 50 engines averagely every day. There are
300,000 tractors working successfully in the fields which are having engines of
Swaraj engines limited .This plant is a bone for agricultural automotive industry.
The various engine models being produced at SEL are:-
1. RV2 ----------- two cylinders ; 24 B.H.P.
2. RV3 ----------- three cylinders ; 39.5 B.H.P.
3. S15 ----------- Single cylinder ; 25 B.H.P.
4. RB33 ----------- three cylinders ; 55 B.H.P.
5. RB30 ----------- three cylinders ; 44 B.H.P.

These engines are sent to the Swaraj tractor division where these
are fitted on various model tractors. The S-15 engines are manufactured in the
Swaraj combine division and are fitted on Swaraj 722 model tractors.

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SWARAJ ENGINES LIMITED

Swaraj Engines Ltd., situated at Phase 9, Industrial Area Mohali was established
in technical and financial collaboration with Kirloskar oil Engines Ltd. For manufacturing
diesel engines for Swaraj Tractor Division Phase 4, Industrial Area, Mohali. During the
few years of its existence, it has not only increased its product range but also increased its
production from 345 in the first year more than 18000 engines now. These engines are sent
to the Swaraj Tractor Division where they are fitted on various Tractors.
The foundation stone of the Swaraj Engine was laid by the governor of Punjab Mr. S. S.
Ray on 29
th
December, 1987 and the production started from 28
th
December, 1988
SEL is spread over an area of 12.72 acres. Having built covered area for
manufacturing block is 13500 sq.mtrs & administration block is 1600 sq.mtrs. & Canteen
blocks covers about 1300 sq.mtrs Investment on plant, machining, tooling etc 52 Crores.
Machine shop houses 151 machines out of 29 are computerized numerical control
machines.
All components, before assy. are thoroughly cleaned by special purpose
washing machines. Cleanliness level of components is regularly monitored. Great
emphasis is laid on general hygiene of the plant, machinery & components offered for
assy. The engines are assembled in air pressurized shops, where ambient temperature
during summer is maintained at 32C with 30 air changes per hour. Each test cell is sound
proof & air pressurized; where 130 air changes take place/ hr. Engines are tested as per the
latest norms laid out by ARAI. Tested engines are dispatched to tractor or Combine
Division the very next day.
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In addition to components for tractor engine we are having a dedicated machine
shop, which is manufacturing & supplying 100% Cylinder Blocks & Con Rods required by
SML, on day to day basis. Supply of SML cylinder head is also made from here.
The various engine models being produced at SEL are:

1. S-15, Single Cylinder:

2. RV-2, Two Cylinder:
Engine Specifications
Model : RV-2 xm KIRLOSKAR
HP : 26.5 S.A.E.
Tractor : SWARAJ 724 FE
Model : S-15 ; Swaraj
HP : 24.5 S.A.E.
Tractor : SWARAJ 722
Cooling System : Water Cooled
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Cooling System : Water Cooled

3. RV-3, Three Cylinder:
Model : RV-3 xm KIRLOSKAR
HP : 39 S.A.E.
Cooling System : Water Cooled.

4. RB-30, Three Cylinder:
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Model : RB-30 xm KIRLOSKAR
HP : 48 S.A.E.
Cooling System : Water Cooled with Oil Cooler for engine oil.

5, RB-33, Three Cylinder:
Model : RB-33 xm KIRLOSKAR
HP : 50 S.A.E.
Cooling System : Water Cooled with Oil Cooler for engine oil.

These engines are sent to the Swaraj Tractor Division where these are fitted on
various model tractors. The S-15 engines are manufactured in the Swaraj Combine
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Division and fitted on Swaraj 922 model tractors. But now S-15 engines are also
manufacture by Swaraj engines and soon its full production will started in Swaraj
engines.SEL manufactures diesel engines for Swaraj Tractor Division

SALE OF TRACTORS

TERRITORY

%age of Domestic Sales

North (Punjab, Haryana & Uttar Pradesh) 32%
Central (Madhya Pradesh & Rajasthan) 26%
East (Bihar, West Bengal, Orissa & Assam) 10%
West (Gujarat & Maharashtra) 12%
South (Andhra Pradesh, Tamil Nadu,
Karnataka & Kerala)

20%

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ABOUT
THE
INDUSTRY

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DEPARTMENTS
Department is the breaking down an enterprise into various departments. Grouping of
activities into department is very essential because it limits the number of subordinates to
supervise by a manager.The various departments are:
1. Assembly shop
2. Heat Treatment shop
3. Heavy Machine Shop
4. Light Machine Shop
5. Maintenance
6. Paint Shop
7. Production planning and control
8. Tool Room

Layout of Industtry

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ASSEMBLY SHOP
The Assembly at SWARAJ TRACTOR DIVISION deals with the assembly of
tractor models 724 xm, 724 xm orchid , 735 xm, 825 xm,834 xm and 841 xm . Assembly is
the joining of various constituents to form a final product. The assembly process is carried
out on the main line, which has various sub assemblies along its length. Assembly shop
can be divided in two main areas: -
1) Before paint area
2) After paint area.
BEFORE PAINT AREA: -
The area before painting can further be divided into sub assemblies/ loops namely
Differential loop.
Gearbox loop.
Rear cover loop.
Engine assembly loop.

DIFFERENTIAL LOOP:-
Differential casting mounted on trolley after washing.
Bull pinion Shaft left and right fitted.
Cage assembly fitted.

It consists of:
1. Crown wheel.
2. Tail pinion assembly.
3. Roller bearing.
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4. Bevel wheels.
5. PTO shaft fitted.
6. Rear axle/trumpet is fitted.
7. PTO shifter assembly fitted.
8. Gearbox assembly is lifted.
9. Rear cover assembly fitted.
10. Brakes are fitted.
11.Parking brake.
12.Suction pipe
13.PTO cover
14. Trailer hook is fitted.
15. Angle bracket is fitted.
16. Rocket link is fitted.
17. Footboard is fitted.
18. Clutch pedal is fitted.

GEAR BOX LOOP:-
Gearbox housing mounted on trolley.
Drive shaft & input shaft assembly.
Output shaft assembly.
Lay shaft and connecting shaft assembly.
Shifter rod assembly.
Steering assembly.
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REAR COVER LOOP:-
Rear cover mounted on trolley.
Control valve and response valve assembly.
Ram assembly. (This consists of cylinder, piston and piston rods.)
Testing of hydraulic lift.

ENGINE ASSEMBLY LOOP
Engine mounted on trolley
Dynamo is fitted.
Self-motor is fitted.
Oil pump is fitted.
Front axle beam and bracket is fitted.
Clutch plate is fitted.
After that the chassis is carried to the next level by the lift where the engine & the
3-point assembly of the tractor along with the other components are fixed. The parts fitted
here are:
3-point linkage which contains the following parts:
Bracket.
Lower link fitted at the left side.
Leveling rod fitted at the right side.
Stabilizer stainer.
Draw bar.
Top link.
Battery frame.
Front frame.
Tie rod attached with the drop arm of the steering system.
Accelerator link.
Delievery pipe.
Engine attachement
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The engine is attached with the chassis system in this level of assembly. The engine
is also carried to this level with the help of the lift crane, which lifts the engine assembly &
delievers it to this level. Shlug is applied at the corneror we can say at rhe circumference of
the gearbox where engine is attached with studs & bolts. Shlugs works as gaskets or seals
& avoid the oil leakage & water mixing in the engine. the engine, which is suplied to this
level of assemble where the engine is attached contain the following parts attached on it:
Front axle.
Extension in the front axle used for the setting of the wheels.
K.P.S.A. (King Pin Shaft Axle) with the wheel disc & nuts fitted in there for the
fitting of the wheels.
Drop arms.
Tie rods.
Bucket.
Clutch plates
Alternator.
Self starter.
Fuel pump.

The above parts are already fitted with the engine when it comes to the engine
chassis assembly. The make of the engine is KIRLOSKOR or SWARAJ KIRLOSKOR
depending upon the model as 3-cylinder, 2-cylinder or 1-cylinder. The engine was
imported from this company from Pune. SWARAJ also has its own engine plant where the
engines are assembled. After assembling the chassis & engine arrangement, the fitments
are checked by the workmen appointed there at this level & if there is some part missing, it
is attached here. Then the whole assembly is mounted over the conveyor, which takes that
piece to different chambers of washing, drying, primering, baking, painting & again
baking.

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After painting the conveyor takes the assembled piece to the dismounting stage
where different parts & components are fitted on the tractor & the tractor was completed.
After that the testing of the tractor is done. A tractor has to pass through different tests to
claim itselfs to be as perfect & if there is some problem coming out in this stage, the tractor
is send to the recovery shop, where the problem of the tractor is recovered. After the
recovery the tractor is again tested & after passing the test the tractor finally send to the
yard from where it is send to the R & D complex for further tests.

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CHECK POINTS AT ENGINE TESTING

1. Engine load at rated RPM
2. SFC at rated RPM
3. Oil Pressure at Idle RPM & NLFT
4. Engine Idle RPM & NLFT
5. FIP Hunting
6. FIP model
7. Engine Number & Code
8. Lubricating Oil Level
9. Check for Unusual noise of Compression Leakage
a. Tappet Noise
b. Gear Noise
c. Head Noise
d. Valve Touch Noise
e. Humming Noise
10. Water leakage Al. Bend / Adaptors / Water manifolds / Hose pipe
11. Water Leakage from water Pump mtg. / pump seal
12. Water leakage from Thermostat Assembly
13. Lubricating oil leakage LO. Filter / Pipes
14. Lubricating oil Leakage from Joint for Gov. hsg.
15. Lubricating oil Leakage from Joint for Oil sump
16. Lubricating oil Leakage from GES / FWES Seal / FAB Studs
17. Fuel Leakage from Fuel connections / Sed. Bowl
18. Fuel Leakage from Feed pump / Banjo
19. Water mixing in Engine oil
20. Fuel supply noise at 1400 RPM No Load (Any erratic noise)
21. Seating of rubber bush bottom (Push rod Tube) in RV Engines

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Leakage check points
1. Injector Leak off Pipe
2. Rocker Cover
3. Water Inlet Manifold
4. Water Hose Pipes
5. Lubricating Oil Cooler Pipe
6. Water Pump
7. Water Separator
8. Diesel Filter
9. Gear Casing Mounting Studs
10. Lubricating Oil Filter
11. Rocker Supply Pipe
12. Crank Case
13. Oil Seal Housing
14. Oil Sump
15. Cylinder Head
16. Cylinder Block

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HEAT TREATMENT SHOP

Heat treatment shop plays a very important role in every industry. In automobile industry
all the gear and shafts need to be heat treated to impart +desired strength and increase life
of the component. The H.T. shop at PTL is equipped with several gas carbonizing
furnaces, quenching tanks, induction hardening machines and shot blasting furnaces.
Heat Treatment is an operation or combination of operations involving heating and
cooling of metals and alloys in the solid state to produce certain desired properties. All the
heat treatment processes may be considered to consist of three main parts:

1. The heating of the metal to pre-determined temperature.
2. The soaking of the metal at that temperature until the structure becomes
uniform throughout the mass.
3. The cooling of the metal at some pre-determined rate to cause the formation of
desirable structures within the metal/alloy for the desired purposes.
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4.
H.M.S. (Heavy Machine Section)

In H.M.S. generally there are four major heavy parts that are given proper
machining operations. These include Gear Box Casing, Differential Housing, Trumpet
Housing and Rear Cover.
All heavy casting of tractors is machined in this shop with the help of variety of
special machine (SPM). These machines are tailors made by IIMT to suit component
requirements. In addition, facilities of this shop include general-purpose turning, drilling
and milling machines. About 20 SPM and 30 GPM are installed in a covered area of
47,000 sq. Ft. At a cost of 20 million, 2600 tones of castings are machined every year on a
two-shift basis. In addition to the machining of casting for the tractor, some jobs are also
performed for Swaraj Mazda Limited.

COMPONENTS MACHINED IN THE SHOP:

Gearbox housing (Material R-33, Casting, 180-230 BHN, 76-Kg wt.).
Differential housing.
Rear cover.
Trumpet housing

L.M.S. (LIGHT MACHINE SECTION)
In L.M.S. the light parts are given proper machining. These include
various parts such as Gears, Shafts, Cage Assembly casing etc.
Different operations performed in lms are:-

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Facing: It is the operation of finishing the ends of the work to make the ends
flat and smooth and to make the piece of required length.

Under cutting: It is similar to grooving operation but is performed inside a
hole.
Chamfering: It is operation of beveling the extreme end of the work pieces,
chamfer is provided for better look.

Rough turning: In this operation max Metal is removed and very little over
size dimensions are left for further machining.
Finish turning: Here minimum metal is removed and very fine finish is
obtained on the work surface.
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Grooving: It is operation of turning the groove or neck in order to terminate a
thread or to provide adequate clearance enable nut to pass freely on threaded
work piece to remove burs and to protect the work piece from being damaged.

Knurling: It is the process of embossing a diamond shaped regular pattern on
the surface of the work piece using a special knurling tool.
Broaching: It is the method of metal removal by a tool that has successively
higher cutting edges in a fixed path. Each tooth removes a fixed amount of
material.
Drilling: It is the process of making hole in an object by forcing a grind means
to abrade to wear away by abrasion or to sharpen. In grinding the metal is
removed by the means of rotating abrasive wheel it is rotating a rotating tool
called drill.
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Boring: It is the process of enlarging a hole that has already been drilled.

Grinding: It is generally used for sharpening the cutting tool, grinding threads
and better surface finish etc.
Hobbing:
Hob: - Hob is a cutting tool used for cutting gears or similar form gears by the
generating principle.
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A Hob resembles a worm in appearance its cutting teeth on the outside
of a cylindrical body following a helical path corresponding to the thread of a
worm. It is useful to think of a hob as a cylinder with a series of racks being
parallel to the hob axis or nearly so and each one slightly displaced axially with
respect to the preceding racks. As the hob rotates in fixed rotation with the
blank each row of teeth successively cuts the next portion of the gear tooth
spaces.

Hobs can be broadly classified as: -
Single start
Double start
Triple start.
Hob material: -
1. High speed steel (HSS) - M2
2. HSS with 8% cobalt (M35)
3. Power metallurgy (ASP 30)
4. Carbide.
5. Tool steel.

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Gear shaving: Gear shaving is a metal cutting operation for finishing the gear
cutting process.
Shaving is a low pressure, free cutting, finishing operation applied to a hobbed gear to
achieve the following:-
1. Correct eccentricity and errors in index, helix angle and tooth profile.
2. Improve tooth surface finishing.
3. Maintain tooth size.
4. Eliminate tooth-bearing conditions by producing a crowned tooth form.

MAINTENANCE DEPARTMENT

Maintenance is another very important factor, which influences the productivity; there are
different kinds of maintenance practices like:

1. Scheduled Maintenance.
2. Breakdown Maintenance.
3. Preventive Maintenance.
4. Predictive Maintenance.
Its importance is mainly due to the fact that it reduces breakdown time and health is
achieving production targets at low costs
It caters to repairing replacing, and adjustment or modification of parts used in various
machines.
Each machine has a symbol, which indicates whether maintenance has to be on daily
basis, weekly basis, quarterly basis or monthly basis. The maintenance scheduled is
maintained for each month after consultation with the shop in charge.
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PAINT SHOP
Paint Shop is the place where the different sheet metal components are painted. They are
made to pass through various chemicals before they are actually painted. The painting method
opted is that of Spray Painting.

NEED FOR PAINTING:-
Long life
Rust resistance
Better look (more appealing)
The various operations performed in paint shop are:
Surface Preparation (Pre Treatment Cell) - carried out for sheets and rims.
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Painting JOST 1(dash board, rear frame, front shield, top bonnet), JOST
2(fenders, side panel), CHASIS BOOTH (washing, primer, washing zones),
FINAL TOUCH UP.
Inspection
Rejection (Reprocessing)-for sheets and rims.

NEED FOR SURFACE PREPERATION:-
1. for removing
Organic compounds (oil, grease)
Inorganic compounds (oxides, peroxides)
2. Better paint adhesion
3. Eliminate chances of reoccurring of dust
METHODS OF SURFACE PREPERATION:-
Rubbing surface with sand paper
By shot blasting
By buffing
By chemical process

CHEMICAL PROCESS:-This process includes:
Degreasing
Rinsing (avoid transfer of caustic contents into next acidic process otherwise next
acidic process will get disturbed)
Derusting
Rinsing
Surface activation
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Phosphating (done so as to form a thin layer of coating on part so that no surface
remains unpainted)
Rinsing
Passivation (done so as to avoid paint penetrating through certain section of part
bodys surface)
Drying

PAINTING:-The process (sheet and rim painting) includes
Full Primer + one coat of paint (30-40 microns)
Flash off (This is the distance given so as to allow paint to dry)
Baking (120-130 degree centigrade)
Rubbing
Cleaning with tag rag
Final painting
Flash off
Baking
CHASIS PAINTING:-
Washing
Drying
Primer painting
Flash off
Final painting
Flash off
Baking
After painting inspection is carried out inspection is carried out and the product is
passed or rejected
Various parameters checked are:
Depth of penetration of paint
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Thickness of paint coating
Smoothness
Uniformity

Reasons for rejection:-
Flow
Less paint
Pin hole
Crow footing
Shade Variation
Dust
Vender fault

PRODUCTION PLANNING AND CONTROL
(PPC)
The PPC at SEL is in charge of maintaining the inventory status, of arranging receipt and
dispatch of components and of follow up. It also supervises transfer of components from the
machine shop and stores to the assembly area and maintains the shop floor status of the
components. PPC indicates two functions:
Production planning is the function concerned with the planning, Directing and controlling of
the methods to be used to make products and the way in which the production facilities etc.
should be laid out in the space available for production.
Production Control is the function of the management, which plans, directs and controls
the material supply and processing activities of an enterprise. So that specified products are
produced by specific methods to meet and approved sales program

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TOOL ROOM
In industry various types of tools are used. The tool room caters to the needs
for manufacturing of jigs, fixtures, gauges, dies, etc. During machining wear & tear of the
tool takes place. The tool room is provided in order to re-sharpen these tools.

FUNCTIONS OF TOOL ROOM
RE-SHARPENING OF THE TOOLS- whose wear & tear has taken place. This
ensures that there is no delay in production due to blunt tools.
NEW JIGS & FIXTURES- In order to improve the production rate & quality of the
work & to decrease the job setting time, new jigs & fixtures are developed in the
tool room.
MAINTENANCE OF OLD JIGS & FIXTURES- Old jigs & fixtures that lose their
accuracy due to breakage or wear & tear are repaired in the tool room.
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NEW DEVELOPMENT WORK- Any modification & development work is carried
out in tool room, for e.g. a new component is to be installed in a tractor, its die
assembly is developed in the tool room.
MANUFACTURING OF MEASURING TOOLS- Certain measuring tools used in
the metrology lab for quality check are manufactured in the tool room.

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Machines in Tool Room
1. Cutting Machine
Horizontal cutting
Vertical cutting

2. Milling Machine (CNC)
Vertical Milling Machine
Vertical Milling Machine(manual)

3. Lathe Machine (CNC & Manual)

4. Grinding Machine
Surface Grinding Machine
Cylindrical Grinding Machine

5. Drilling Machine (Radial arm)

6. Precision Grinding

7. Jig Boring

8. Vertical Machining Centre

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CUTTING MACHINE
Cutting Machines are used to cut raw mate rial. They are also used to cut and reshape
jobs that have already been made. There are two types of cutting machine in tool room:
1. Vertical Cutting Machine
2. Horizontal Cutting Machine
Purpose of both vertical and horizontal cutting machine is same.

Vertical cutting machine

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Milling Machine
Milling is the machining process of using rotary cutters to remove material from a work
piece advancing in a direction at an angle with the axis of the tool. It covers a wide variety
of different operations and machines, on scales from small individual parts to large, heavy-
duty gang milling operations. It is one of the most commonly used processes in industry
and machine shops today for machining parts to precise sizes and shapes.

Milling operates on the principle of rotary motion. A milling cutter is spun about an axis
while a workpiece is advanced through it in such a way that the blades of the cutter are
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able to shave chips of material with each pass. Milling processes are designed such that the
cutter makes many individual cuts on the material in a single run; this may be
accomplished by using a cutter with many teeth, spinning the cutter at high speed, or
advancing the material through the cutter slowly. Most often it is some combination of the
three. The speed at which the piece advances through the cutter is calledfeed rate, or
just feed; it is most often measured in length of material per full revolution of the cutter..

A diagram of revolution ridges, showing the position of the cutter for each revolution and
how it corresponds with the ridges
As material passes through the cutting area of a milling machine, the blades of the cutter
take swarfs of material at regular intervals. This non-continuous cutting operation means
that no surface cut by a milling machine will ever be completely smooth; at a very close
level (microscopic for very fine feed rates), it will always contain regular ridges. These
ridges are known as revolution marks, because rather than being caused by the individual
teeth of the cutter, they are caused by irregularities present in the cutter and milling
machine; these irregularities amount to the cutter being at effectively different heights
above the workpiece at each point in its rotation. The height and occurrence of these ridges
can be calculated from the diameter of the cutter and the feed.
[4]
These revolution ridges
create the roughness associated with surface finish.

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Lathe Machine

In a lathe, metal is removed from the workpiece using a hardened cutting tool, which is
usually fixed to a solid moveable mounting, either a tool-post or a turret, which is then
moved against the workpiece using handwheels and/or computer controlled motors. These
(cutting) tools come in a wide range of sizes and shapes depending upon their application.
Some common styles are diamond, round, square and triangular.
The tool-post is operated by lead-screws that can accurately position the tool in a variety of
planes. The tool-post may be driven manually or automatically to produce the roughing
and finishing cuts required to turn the workpiece to the desired shape and dimensions, or
for cutting threads,worm gears, etc. Cutting fluid may also be pumped to the cutting site to
provide cooling, lubrication and clearing of swarf from the workpiece. Somelathes may be
operated under control of a computer for mass production of parts (see "Computer
Numerical Control").
Manually controlled metalworking lathes are commonly provided with a variable ratio gear
train to drive the main lead-screw. This enables different thread pitches to be cut. On some
older lathes or more affordable new lathes, the gear trains are changed by swapping gears
with various numbers of teeth onto or off of the shafts, while more modern or expensive
manually controlled lathes have a quick change box to provide commonly used ratios by
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the operation of a lever. CNC lathes use computers and servomechanisms to regulate the
rates of movement.

Grinding Machine

Cylindrical Grinding Machine Surface Grinding Machine

The grinding machine consists of a bed with a fixture to guide and hold the work piece,
and a power-driven grinding wheel spinning at the required speed. The speed is determined
by the wheels diameter and manufacturers rating. The user can control the grinding head
to travel across a fixed work piece, or the work piece can be moved while the grind head
stays in a fixed position.
Fine control of the grinding head or tables position is possible using a vernier calibrated
hand wheel, or using the features of numerical controls.
Grinding machines remove material from the work piece by abrasion, which can generate
substantial amounts of heat. To cool the work piece so that it does not overheat and go
outside its tolerance, grinding machines incorporate a coolant. The coolant also benefits the
machinist as the heat generated may cause burns.

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Drilling Machines
A drill is a tool fitted with a cutting tool attachment or driving tool attachment, usually
a drill bit or driver bit, used for boring holes in various materials orfastening various
materials together with the use of fasteners. The attachment is gripped by a chuck at one
end of the drill and rotated while pressed against the target material.
Drill Press
A drill press (also known as pedestal drill, pillar drill, or bench drill) is a fixed style of drill
that may be mounted on a stand or bolted to the floor orworkbench. Portable models with
a magnetic base grip the steel workpieces they drill. A drill press consists of a base,
column , table, spindle and drill head, usually driven by an induction motor. The head has
a set of handles radiating from a central hub that, when turned, move the spindle and
chuck vertically, parallel to the axis of the column. The table can be adjusted vertically and
is generally moved by a rack and pinion; however, some older models rely on the operator
to lift and reclamp the table in position. The table may also be offset from the spindle's axis
and in some cases rotated to a position perpendicular to the column.

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Radial Arm
A radial arm drill press is a large geared head drill press in which the head can be moved
along an arm that radiates from the machine's column. As it is possible to swing the arm
relative to the machine's base, a radial arm drill press is able to operate over a large area
without having to reposition the workpiece. This saves considerable time because it is
much faster to reposition the drill head than it is to unclamp, move, and then re-clamp the
workpiece to the table. The size of work that can be handled may be considerable, as the
arm can swing out of the way of the table, allowing an overhead crane or derrick to place a
bulky workpiece on the table or base. A vise may be used with a radial arm drill press, but
more often the workpiece is secured directly to the table or base, or is held in a fixture.
Power spindle feed is nearly universal with these machines and coolant systems are
common. Larger size machines often have power feed motors for elevating or moving the
arm. The biggest radial arm drill presses are able to drill holes as large as four inches
diameter in solid steel or cast iron. Radial arm drills are specified by the diameter of the
column and the length of the arm. The length of the arm is usually the same as the
maximum throat distance

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Precision Grinding
Function of precision grinding is similar to that of other grinding machine. It differs from
them in terms of accuracy. The accuracy of work done by this machine is in microns. Since
the work has to be done with such precision, therefore, the room is temperature controlled
all the time. Here is the image of precision grinding working in Mahindra n Mahindra
Swaraj Division.

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Jig Boring
The jig borer is a type of machine tool invented at the end of World War I to make possible
the quick-yet-very-precise location of hole centers. It was invented independently in
Switzerland and the United States.
[1]
It can be viewed as a specialized species of milling
machine that provided tool and die makers with a higher degree of positioning precision
(repeatability) and accuracy than those general machines had previously provided.

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Vertical Machining Centre
Vertical Machining Centre or VMC machine is cnc machine. Different operation can be
done on this machine such as milling, boring etc. The machine works on 3 axis. It has
numbers tools , and tools can be selected according to the requirement .The VMC room is
temperature controlled room to perform work with high accuracy.

. V.M.C. in Tool Room
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Some instruments used in Tool Room
Micrometer (Digital & Machanical)
Bore Gauge
Vernier calliper (Digital & Machanical)
Height Gauge

MICROMETER
Micrometer also known as screw gauge is an instrument used to small distances. It is used
to measure diameter and thickness. It is available in different renges
0-25mm
25-50mm
50-75mm

Micrometer used in tool room are of two types :Digital Micrometer and Machinical
Micrometer

Machanical Micrometer Digital Micrometer

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Bore Gauge
A bore gauge is a convenient term for the measuring or transfer tools that are used in the
process of accurately measuring holes.

Vernier Caliper

The main use of the vernier caliper is to measure the internal and the external diameters of
an object. To measure using a vernier scale, the user first reads the finely marked "fixed"
scale (in the diagram). This measure is typically between two of the scale's smallest
graduations. The user then reads the finer vernier scale (see diagram), which measures
between the smallest graduations on the fixed scaleproviding much greater accuracy.

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Height Guage
A height gauge is a measuring device used either for determining the height of something,
or for repetitious marking of items to be worked on.
These measuring tools are used in metalworking or metrology to either set or measure
vertical distances; the pointer is sharpened to allow it to act as ascriber and assist
in marking out work pieces. Height gauges may also be used to measure the height of an
object by using the underside of the scriber as the datum. The datum may be permanently
fixed or the height gauge may have provision to adjust the scale, this is done by sliding the
scale vertically along the body of the height gauge by turning a fine feed screw at the top
of the gauge; then with the scriber set to the same level as the base, the scale can be
matched to it.

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PROJECT WORK

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I was assigned as a trainee in tool room with trainee id-114631. Various designed Jigs and
Fixtures, gauges, special tools, trolleys (material handling), shop equipment and dies etc.
are made here, according to the design from the tool cell.
We were lucky to get two project one on TPM and another on Jig fixtures.

Project on TPM
TPM(Total productive maintenance)
One of the main objectives of TPM is to increase the productivity of plant and equipment
with a modest investment in maintenance . Total Quality management (TQM) and Total
Productive Maintenance (TPM) are considered as the key operational activities of the
quality management system. In order for TPM to be effective, the full support of the total
workforce is required. This should result in accomplishing the goal of TPM: "Enhance the
volume of the production, employee morale and job satisfaction

Implementation of Total Productive Maintenance
Following are the steps involved by the implementation of TPM in an organization: Initial
evaluation of TPM level, Introductory Education and Propaganda (IEP) for TPM,
formation of TPM committee, development of master plan for TPM implementation, stage
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by stage training to the employees and stakeholders on all eight pillars of TPM,
implementation preparation process, establishing the TPM policies and goals and
development of a road map for TPM implementation .According to Nicholas, the steering
committee should consist of production managers, maintenance managers, and engineering
managers. The committee should formulate TPM policies and strategies and give advice.
This committee should be leaded by a top-level executive. Also a TPM program team must
rise, this program team has oversight and coordination of implementation activities. As
well, it's lacking some crucial activities, like starting with partial implementation. Choose
the first target area as a pilot area, this area will demonstrate the TPM concepts. Lessons
learned from early target areas can be applied further in the implementation process.

Objectives of Total productive maintenance
One of the main objectives of TPM is to increase the productivity of plant and equipment
with a modest investment in maintenance . By investing in -for example- equipment
maintenance, equipment losses can be prevented. Prabhuswamy et al., 2013 defines the
following six losses (similar to the "six big losses stated by Nicholas):
1. Breakdown losses caused by the equipment
2. Setup and adjustment losses
3. Minor stoppage losses.
4. Speed losses
5. Quality defect and rework losses.
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TPM report on Precision grinding ( machine no. 528.01 )

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CLITA sheet is used to check different machine parts

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Radar chart is used to show progress of employee skills.

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Know why sheets
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Project on Gear housing fixture (J54872
INTRODUCTION
Mass production aims at high productivity to reduce unit cost and intern ability to
facilitate easy assembly. This necessitates production dev vices to increase the rate of
manufacturing and inspection devices to speed up inspection procedure.
ELEMENTS OF JIGS AND FIXTURES
I. Locating Elements: These position the work piece accurately with respect to the tool
guiding or setting elements in the fixture.
2. Clamping Elements: These hold the work piece securely in the located position during
operation.
3. Tool Guiding and Setting Elements: These aid guiding or setting of the too ls in
correct position with respect to the work piece. Drill bushes guide the drills accurately to
the work piece. Milling fixtures use setting pieces for correct positioning of milling cutters
with respect to the work piece.

ADVANTAGES OF JIGS AND FIXTURES:
1. Productivity Jigs and fixtures eliminate individual marking, positioning and frequent
checking. This reduces operation time and increases productivity.
2. Interchangeability Jigs and fixtures facilitate uniform quality in manufacture.
There is no need for selective assembly. Any part of the machine would fit properly in
assembly, and all similar components are interchangeable.
3. Skill Reduction Jigs and fixtures simplify locating and clamping of the work pieces.
Tool guiding elements ensure correct positioning of the tools with respect to the work
piece. There is no need for skillful setting of the work piece or tool. Any average person
can be trained to use jigs and fixtures. The replacement of a skilled workman ith unskilled
labor can effect substantial saving in labor cost.

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STEPS INVOLVED IN MAKING JIG FIXTURES

Jig fixture of gear housing contained 11 drawings. Some of the drawings are

Drawing of bracket

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Drawing showing completed assembly of fixture

The drawings are sent to new tool area where the drawing are studied. Ater studying
drawing raw material requirement is send. The raw material is send to cutting where it is
cut as required.
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Then the parts are finished on milling machines and extra material is removed.

Parts are then marked , and after marking these parts are send to different machine such as
VMC , lathe & jig boring etc for different operation.
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Base plate being set on VMC for milling, drilling and other process

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Images below shows cutting of base plate on VMC

Base plate is filed to remove sharp edges. Base plate in the picture is up side down. The
base plate is send to standard room where dimension of the base are checked.

Image of part along with drawing Marking done different parts

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Images of two brackets, two supports, a holder and a pin

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The following picture shows different parts, some with there drawings

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Two brackets and an arm to hold gear housing are shown is the picture.

When the parts are partially made they are send to welding shop. Some parts require some
heat treatment and are therefore send to heat treatment shop. After all the parts are made
the Jig fixture is assembled. The main parts of the assembly are base plate, brackets ,
special screws, holding nuts and pin etc.

. Partially assembled fixture
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Completed assembled Jig Fixture
The Jig fixture is assembled and then gear housing is brought to see if it fits.

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Jig fixture J 54.807 with Gear housing in it

Fixture working on the machine in heavy machine section

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Conclusion

Sawraj tractor is a good tractor. It has all qualities that are necessary in a tractor. Sawraj has
good sale in developed areas. But low sale in underdeveloped areas. So the company should
take care of these things. Company must improve its quality. And the major problem of spare
parts will remove as soon as possible. Because of this problem the tractor often not ready for
sale. Sawraj tractor has more problems and less quality. The company must pay attentionon
the problems which are faces by agency holders indifferent areas. Sawraj export their tractors
so it gives all their attention on those tractors and then the quality of domestic tractors goes
down. Sawraj Tractor Company is in top five tractor manufacture companies. But if it will
solves the problems it will reaches at no 1 position.
My training was the most versatile experience. I had the pleasure to do the work with one of
the most reputed factory in their field-
Mahindra n Maindra Swaraj Division.
I received the blend of experience in Private as well as in Govt. sector. It was a good learning
time during my training as we were fortunate to be placed
in the department related to manufacturing. I feel training has give me exposure to undergo
projects in the Manufacturing field as well help me a lot to understand the company work
culture, working with teams and much more. In the end I will like to thank all persons who
helped me through out my training to enhance my experience. I also pay my regards to my
Lecturers for their guidance during my training and my Academics helped me to do a lot
during my training.
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Bibliography

1. http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm
2. http://www.mahindra.com/What-We-Do/farm-equipment/Products/Swaraj
3. http://en.wikipedia.org/wiki/Toolroom
4. http://en.wikipedia.org/wiki/Fixture_(tool)

Reference
B.B. Mynee (head of Tool Room)
S.K. Rana
Sukhwinder Room
Himanshu Jain

Jigs and Fixtures: Mahindra & Mahindra Swaraj

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SIX MONTH INDUSTRIAL TRAINING REPORT

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