Presentation on Internship at

Millat Tractors Limited (MTL)

Presented By:

1. Usman Hassan 2009-ag-3084

2. Nadeem Akram 2009-ag-3092
3. Tanzeel-ur-Rehman 2009-ag-3100
4. Azlan Zahid 2009-ag-3108
5. Muhammad Ali 2009-ag-3109
6. Haseeb Bilal 2009-ag-3150
7. Muhammad Aamir 2009-ag-3204

Submitted To:
Dr. Manzoor Ahmad
Objective of our Internship

1. Primary Objective:
To get training in a professional environment by engaging ourselves in one of
leading automotive company Millet Tractors Limited and to highlight the problems
and suggesting the suitable solutions.
 Objective of our Internship
2. Secondary Objective:
To know about the market structure.

To get training at Engine Assembly Plant.

To get training at Tractor Assembly Plant.

To get familiar with all machining processes.

To get familiar with the operations of Quality Assurance Department.

To analyze different problems in industry.

To give suitable suggestions regarding problems.

 Introduction of Millet Tractors Limited

•Millet Group is Pakistan’s leading engineering concern in automobile sector & has a
history that spans almost half a century, Millet Tractors Limited is market leading
industry of agricultural tractors & holds above 50% market share.
•Millet Tractors Limited (MTL) was established in 1964 to introduce and market
Massey Ferguson (MF) Tractors in Pakistan.
•An assembly plant was set up in 1967 to assemble tractors.
• Millet Group encompasses four major companies
MILLAT TRACTOR LIMITED
MILLAT EQUIPMENT LIMITED
MILLAT INDUSTRIAL PRODUCT LIMITED
BOLAN CASTINGS LIMITED
•Millet Tractors Limited manufactures MF-240, MF-350, MF-260, MF-375, MF-
385, MF-385 4WD, Implements, Prime movers, Forklift Truck & Power
Generation Sets.
 Features of MTL
1. Millet Tractors Limited turnover is Rs.2300 crore.
2. Export market comprises of countries like
Afghanistan, China, Namibia, Uganda, Somalia and other African
countries.
3. Highest market share in Pakistan of 64%.
4. Biggest assembly line in Pakistan.
5. Extensive dealership network and after sale services all over Pakistan.
Products of Millat Tractors Limited
• Tractors
 MF-240
 MF-260
 MF-350
 MF-350+
 MF-375
 MF-385
 MF-385 (4WD)
 MF-455
Multi Products

 Forklift Truck

 Generators

 Prime Mowers
 Marketing Division

Task 1:
Field Market Survey
Objective of Field Market Survey
Our objective was to conduct an analysis on

 Marketing Tactics
 Market share of MTL and its competitors
 Quality of the brand
 Dealership network and commissions
 Marketing regions
 Customer and dealer satisfaction level
 Current tractors demand
 Brand equity
 Future demand of tractors
Graphical Representation of Market Share across Pakistan

70

60

50

40
Millat tractors
Al-Ghazi Tractors
30
Others

20

10

0
2010 2011 2012
Internal Problems Analyzed At Marketing Division

1. Product development
2. Weak in aggressive marketing.
3. Unsatisfied delivery procedure.
4. Lack of proper survey (Market research).
5. Delay in tractor delivery.
6. No team work.
7. Totally centralized decision making.
8. Time consuming procedure.
9. No customer dealing department in real meaning.
 Problems Regarding The Quality

According to the dealers, the overall quality of the tractors was not found satisfactory
the reasons are summed up below.

1. The performance of Fuel Injection Pump is not good it consumes more fuel due to
the rotor clearance.
2. The major problem was of Differential System (Crown Pinion).
3. There is a problem of Rear Rim distortion in shape and early rusting of the rims.
4. Pressure is not maintained under loaded conditions in the Hydraulic System due to
the manufacturing fault.
5. Turbo charger oil kit leakage in MF-260.
6. The chassis is not properly painted due to which sometimes it rusts.
7. When the temperature reaches near 400C the seals of tractors standing in showroom
leaks.
 Reasons for Market Downfall

The downfall pattern shown graphically below in local market due to the
following reasons:

1. 10% Tax increase the prices.

2. Green Tractor Scheme and Sindh Government tractor scheme
45000
3. High price of tractors.
40000
4. High fuel price.
35000

30000

25000
Units Produced
20000
Units Sold
15000

10000

5000

0
2007 2008 2009 2010 2011 2012
 Suggestions and Recommendations

1. The delivery time period at MTL is 21-days, arrangement should be made

to decrease the delivery time so that service level can be improved.
2. There is some need to change the working environment of organization.
HR should be the most valuable person in the marketing department.
3. Do not just use newspaper or conferences for advertisement but there
should be proper publicity of the product so that people should be aware
of Millat.
4. There should be complete R & D development department in company.
This department should do market research and providing guideline for
developing new products and modifying existing ones.
 Machining Division

Task 2:
To Practically Experience The
Machining Operations
Lines in Machining Division

There are nine lines in the machining division listed below

1. Axel Housing Line (Right and Left)

2. Cylinder Block Line (old)
3. Cylinder Block Line (Ext)
4. Cylinder Head Line (old)
5. Cylinder Head Line (Ext)
6. Center Housing Line
7. Transmission Case Line
8. Lub Oil Sump Line (240)
9. Lub Oil Sump Line (385)
General Operations in Machining

1. Drilling
2. Rimming
3. Boring
4. Counter Boring(⌴)
5. Spot Facing
6. Counter Sinking(⌵)
7. Milling
8. Tapping
9. Facing
10. Turning
11. Honing
 Cylinder Block Line
It is foundation of the engine. All other engine parts are assembled
in or attached to cylinder block. There are two cylinder block
machining lines.

1. Old Manual Machining Line (48 Parts per shift )

2. New Automatic Machining Line (72 Parts Per Shift )

Cylinder Block line consist of 35 different machines performing

different machining operations.
Milling at Head Face
Honing Operation in Cylinder
Water Jackets and Oil Galleries Testing Operation
 Oil Sump

Sump is a part of a tractor engine in

which Lubrication oil is present. It is
filled with the bottom face of block where
the Crankshaft is present. It is also called
Lubrication Oil Pan.

Material for cutting tools

Carbide
 Production against Workers
100

90

80

70

60

50 Production/Shift
Workers

40

30

20

10

0
Transmission case Cylinder Head Axel housing Block(old) Block(Ext) Central Housing
 Suggestions and Recommendations
1. Different machines performing the same operation must be checked and
their number must be reduced.
2. The production efficiency could be increased by increasing worker’s
efficiency. This can be done by giving some kind of incentives to the
worker.
3. Old machines must be replaced by automatic plants. It will enhance the
rate of production, better finishing quality, reduce the labor cost, consume
less energy and would be space efficient as well.
4. CNC machine is required in OP‐53 on lube oil sump line because 0.064
tolerance cannot be controlled by manual Mill machine.
5. An alternate source is required for casting of lube oil sump due to casting
problems.
 Engine Assembly Plant (EAP)

Task 3:
To know about the operations
happening in Engine
Assembly Plant.
 Engine Assembly Plant
Engine Assembly line is a line in which all the parts of engine are fitted
with Engine block and this line starts with block and complete on full
engine.

 There are 10 operational sections for complete engine assembly and the
operations are given on engine build card.
 There are sub-assembly sections in which small parts like Engine
Head, Rocker Arm Assembly, Piston etc. are assembled.
 In 3 cylinder type there are engines MF-240, MF-260, MF-350, MF-
350+ which are used in tractors as well as fork lifters, generator sets and
prime movers.
 4 cylinder Engines of MF-375, MF-385, MF-385(4WD) are assembled
which are used in big tractors.
 Production Capacity of EAP plant is 95 per shift per day. Production can
be increased on demand.
Engine build card is followed in the engine assembly plant
Line Diagram of Engine Assembly Plant
 Sections of Engine Assembly Plant
Engine Assembly Plant (EAP) has been divided into 4 sections which are as
follow:

1. Segregation
2. Engine Assembly Line
3. Engine testing or Test shop
4. Rectification Section
Engine Test Section
 Engine Test Ranges
There is a complete testing setup for every engine that comes out of the main
assembly line. Here engine is thoroughly checked for its working and any
possible faults such as engine noise, rpm, loading, leakages, exhaust smoke etc.
Different ranges are given below:
Tester 1st Time 2ndTime Time R.P.M Brake Power
(minutes) (NM) (K.W)

Low Idling R.PM

750 750 5 1000 50-55 5.8

Low Idling Oil Pressure

5 1500 60-65 9.4

High Idling Oil Pressure

2470 2470 5 1500 90-95 14.9

Tappet setting
.010” .010” 20 2250 146-160 35-37
Engine Test Bed
 Weekly Production in Engine Assembly Plant
60
57

54
53
51
50
46

40

30

21
20
17

13
11 11
10 9 9 9

0
23-04-2013 24-04-2013 25-04-2013 26-04-2013 29-04-2013

MF 240 MF 375 Gen Set

Assignment Task

To suggest the possible problems of excessive engine noise

during testing which is the big problem and can cause engine
rejection.

We found following problems which are given below:

1. Excessive Back Lash between the gears
2. Excessive End Float in the idler gear
3. Improper fitting of timing case
 Suggestions and Recommendations
1. Gauges should be calibrated timely and properly and worn out gauges should be
replaced on time.
2. The company should put more effort in taking care of its workers especially daily
wages and contractual workers so that they are satisfied with their jobs and give
more quality output.
3. Another area which demand attention is that of job rotation. Employees are not so
much productive, motivated and efficient because of their routine job.
4. They are allowed the operational level employee in decision making process
especially when the decision are taken about the labor force because most of the
time they better know about what is beneficial and suits to them.
5. The Quality Circles should be introduced among workers so that their participation
in the improvement process increases.
6. Worker safety should be taken under consideration at the EAP (Engine Assembly
Plant).
 Tractor Assembly Plant (TAP)

Task 4:

• To conduct an analysis on Mishandling

• To analyze the problems in Material Flow
• To analyze Painting Section and Painting Quality
 Tractor Assembly Plant
This is the main plant of
Millat Tractors. All the
components of tractor
carried from different
locations are assembled
here. In this plant all the
parts of the tractor are
assembled on assembly
lines.
 Tractor Assembly Plant
Assembly Lines of TAP

There are three assembly lines in TAP:

 Initial Build Assembly Line
 Chassis Paint Assembly Line
 Final Build Assembly Line

Sections of TAP
These are as follows:
• Segregation and Degreasing
• Assembly line
• Sheet Metal Washing and Paint Shop
• Test shop/Rectification area
 Analysis on Mishandling

• Mishandling can be narrated as the miss use of the tool or the miss use of the
component to be assembled both are under the issue of mishandling.
• Mishandling is a very big issue in any industry and its cost is always beard by the
industry thus the profitability is decreased.
• Millat lost 2.5 million as mishandling expenses in Tractor Assembly Plant only
which is a big loss.

We the internees were asked to conduct the survey in Tractor Assembly

Plant on Mishandling. Our main concern was to know about three main
questions and to help understand the reasons and to give suggestions to limit
the mishandling losses.

Q.No.1. Do the worker know about what is mishandling?

Q.No.2. Why mishandling occurs?
Q.No.3. Suggestions by the workers i.e. how we can minimize this mishandling.
 Survey Questionnaire
Reasons why mishandling occurs
Lack of Expertise way of Rejection Inspector bias to Press machine Timely Rejection of the component Inspector Availability
Worker familiar with
of the laborers of the component vendor or sincere malfunctioning
the concept of
in rejection
Sr. #. mishandling Worker Inspector

01 Yes Yes Improper Sincere No Yes Yes Yes

02 Yes Yes Improper Sincere Yes Yes Yes Yes

03 Yes Yes Proper Sincere No No Yes Yes

04 No Yes Improper Sincere Yes Yes Yes Yes

05 Yes Yes Proper Sincere Yes No Yes Yes

06 Yes Yes Proper Sincere No Yes No No

07 Yes Yes Proper Sincere Yes Yes Yes Yes

08 Yes Yes Proper Sincere Yes Yes Yes Yes

09 No Yes Proper Sincere Yes Yes Yes Yes

10 No Yes Proper Sincere Yes Yes Yes Yes

11 No Yes Proper Sincere Yes Yes Yes Yes

12 No Yes Proper Sincere No Yes Yes Yes

13 No Yes Proper Sincere Yes No Yes No

14 Yes Yes Improper Sincere Yes Yes Yes Yes

15 Yes Yes Improper Sincere No Yes Yes Yes

 Reasons of Mishandling
The following are the main reasons of mishandling.

 Above all the reasons one thing in common was that newly appointed worker always do
losses as he is unfamiliar with the system, so less expertise of the laborer is the main reason
in mishandling. We also came to know that some appointments of workers on reference are
not right some of those workers are not fit for the job hence they greatly mishandle tools
and components as they are not eligible.
 QA should not allow the bad quality piece fed to assembly line, once it is assembled it
becomes mishandled willingly or unwillingly.
 Due to over burden of production mishandling occurs.
 Duties changing again and again cause mishandling as every worker best knows his work.
 Reasons of Mishandling

 While making fun at working time, sometime tools become the part of their fun.
 It occurs due to low quality of tools used.
 By the worker i.e. use of improper tool for specific function.
 By the negligence of the worker like sometimes the threads of the nut and bolt mismatch
and it is tightened so both the parts become waste.
 Millat Tractors Limited purchases low quality parts which breaks during working so it
also becomes the case of mishandling.
 Suggestions for Mishandling

1. It is the duty of the QA department that not to allow the bad quality part fed to the
assembly line.
2. The inspector should be on line for timely rejection of parts.
3. Supervisor should always focus on new workers and he should instruct them properly.
4. There should be optimum production load on the workers so the mishandling should be
limited.
5. Good quality tools should be used so components can be saved.
6. Proper tools should be used for proper jobs. Like to align the stud by hitting on the
threads should not be done this action was seen on line while visiting.
7. Training workshops should be conducted.
 To Analyze The Problems In Material Flow
The overall productivity of the plant depends on both input resources and
output of the plant. The productivity can be increased either by increasing
the output or decreasing the input resources.

Input resources includes:

• Man
• Material
• Machine
• Tools & Equipment
• Method
Material Flow Line Diagram
 Problems of Material Flow
Storage Bins
Storage Bins are not enough in every section. Some line facing severe shortage
of bins. Due to this, parts are placed on the floor that results in damaging of
parts.
Delivery of Parts
Due to the non-availability of the fork lifter or Stillage parts are not delivered at
station on time.
Handling of Components
Handling of components is done manually which require labor power and more
time.
Placement of the parts in bins and racks
The parts are not properly placed in the bins and racks by Segregation section
Colored bins for different model’s parts
There are no separate bins for different parts of different tractor models.
Rejection Bins
Rejection Bins are enough in number but placed far apart so time consuming and
tiresome job.
 Problems of Material Flow
• For higher productivity, the number of bins should be increased. This
will reduce Mishandling and time of production.
• Workers from Segregation section just throw the parts in the bins that
might results in damage of some parts. This results in poor production
cost.
• It would be great to add more bins but it could never be happened in
this scenario because presently the space available is not enough to
accumulate many bins at each station.
• Workers from segregation section don’t drop or deliver the parts to
each station. They just throw in into the Storage bins.
• Usually on time delivery doesn’t happen but sometimes it does happen.
The production rate is very fast, for this, material flow should also be
fast but the quantity of fork lifters and stillage doesn’t respond to the
number of work stations.
• Shortage of racks is also another factor for the delay of parts. Station
having only one rack of each part suffers the most.
 Suggestions and Recommendations
1. An electronic Fork lifter should be provided because it is compact in size and
produce no smoke.
2. Proper training should be given to workers to give them awareness to avoid the
piling of segregated material at work stations.
3. The number of bins should be increased. This will reduce Mishandling and time
of production.
4. Proper training should be given to worker to avoid mishandling
5. Material Management (MM) store should not be there within the plant area. It
should be in a separate building. This will release some space and it could be
utilized in a better way.
6. Fork lifters and stillage should be increased in number to make sure that each
part should reach its station on time.
7. Racks should increase in number in order to minimize the time lost in
movement.
8. Rejection Bins should be increased to avoid wastage of time. It should be
provided in easy reach of each worker or station.
 To analyze Painting Section and Painting Quality
• To know about the current painting quality, instruments used, processes
carried out, problems regarding the worker’s health and safety and to
find out the weaknesses and reasons behind poor worker health in that
section.
• Painting section is very critical section regarding the worker’s health.
Two of the workers are already suffering from Lungs infection.
• Our task was to find out the reasons behind that. We prepared a
questionnaire regarding the painting processes, equipment used and
prevailing health and safety conditions. The questionnaire is below
Q.1. What are the components painted in this section?

Red Gray Silver

Fender, Fender Plate, Fender Support Shroud
Dash board, Dash board path Tank clamp
Top hood, Side hood
Channel Strip Wrapper
Side panel
 Questionnaire
Q.2. Either spray paint guns are available or not in this section?
Yes, guns are available in this section. In fact are surplus in number.
Q.3. Either spray paint guns are of good quality or not in this section?
Yes, guns are of good quality made by Bashir Sons.
Q.4. Either safety nasal mask are available or not?
Yes, the masks are provided by MTL keeping in view the safety of the
workers.
Q.5. Either worker wears safety nasal mask or not?
No, Workers don’t wore. Masks in summer but in winter they often wore it.
Q.6. What is the effect of paint on the health of worker if the safety
measures are not taken into account?
Workers have no sound knowledge about their safety. Recently two cases are
reported in which the workers are suffering from lungs infection.
Q.7. Either quality of the paint is good or not?
MTL is using ICI Paints according to prescribed standards of Massey Ferguson
and it is of good quality
 Questionnaire
Q.8. Either work load for worker is manageable or not?
Yes, work load is very much manageable. After every 70 hangers the worker in the
paint booth is replaced.
Q.9. Either the worker are sufficient or not?
Yes, man power in this section is enough in number. Total 24 workers are
available in each shift including supervisor and housekeeping staff.
Q.10. Either paint is available on time or not?
Paint is available at paint booth and there is no delay
Q.11. what are the major problems faced by workers regarding the painting?
No problem at all. Workers consider themselves that they are highly skilled in
their respective job and can dealt with the problem
Q.12. Either proper temperature is there or not?
Stove oven temperature ranges from 140-150◦C. stove oven doesn’t start till the
temperature reaches to 140◦C. Dry oven temperature is 130◦C
 Suggestions and Recommendations
1. Training workshops should be carried out in TAP to give awareness to
the workers about their safety and health.
2. It should be made mandatory for the workers to wear safety nasal
masks during painting.
3. Training workshop should be carried out time to time in order to
improve the worker’s skills in order to enhance the painting quality.
4. Painting precision and accuracy should be improved in order to
minimize the paint losses.
5. The painting quality must be improved to avoid rusting.
 Quality Assurance Department

Task 5:

To Know The Working Of Quality

Assurance
 Quality Assurance

What is Quality?

Product or service that fulfills or completes its task or work effectively

for specified period of time is referred as quality.

QA has three sections

Bought Out Finished (BOF)
In House Quality Manufacturing
Production Lines Quality

To ensure the quality of the components to be assembled MTL have

different types of gauges, fixtures and jigs, micro gauges, dial gauges,
height gauges, depth gauges and many others.
• In every department of Millat Tractors Quality Assurance section is
present which assures the quality of all the processes happening there.
• At every step of manufacturing there are gauges present to check the
quality of the product at every step.
Different types of Gauges

Snap gauge: To determine the outer diameters

Plug gauge: To determine internal diameter or bore
Slip gauge: To determine the gaps between two components
Ring gauge: To determine the thread outer diameters
Dial gauge: To determine the multiple dimensions (ovality,
tapperness, bore, length, clearances) in microns.
 Coordinate Measuring Machine (CMM)
Quality of precision machined parts both in house manufactured and vendors
supplied is ensured by the use of CMM, CMM caters for precise
measurement of linear and geometrical size and assures the dimensional
integrity of complex parts with high speed. CMM can measure up to half
micron.

CMM can measure:

• Intricate sizes • Parallelism

• Positions • Concentricity
• Angles • Roundness
• Diameters • Straightness
• Squareness • Co-axial ties
• Flatness
Inspection and Testing Facilities in Labs

• Oil and Grease Testing

• Paint and Coating Testing Lab

• Rubber Testing

• Material Testing

• Mechanical Testing
 Quality Assurance

What is Quality?

Product or service that fulfills or completes its task or work effectively

for specified period of time is referred as quality.

What is Quality Assurance?

The Quality assurance department attempts to improve and stabilize the
production and associated processes to avoid or to at least minimize the
issues which leads to the defects.

To ensure the quality of the Tractors and other multiple products that are
assembled in MTL is the main task of the quality assurance department.
 Quality Assurance

Quality Assurance(QA) Department has 3-sections:

• Bought Out Finished (BOF)

• In House Quality Manufacturing
• Production Lines Quality
 Bought Out Finished

• This section is incoming inspection center that basically deals with the
inspection of incoming parts that were manufactured by different Vendors.
• It utilizes different types of instruments, gauges, micro gauges, fixtures and
jigs for measuring the different dimensions of different parts.
• Random sampling technique is adopted to collect the sample out of the total
lot and the dimensions are then measured and compared with the standard
one.
• Massey Ferguson(England) has predefined the acceptable quality level for
the different parts according to which lot is either rejected or accepted
depending upon the nature and sensitivity of the part, e.g. The acceptable
quality level is 2 for the lot of 100 pieces if a sample of 8 pieces is to be
taken.
 In-House Quality Manufacturing

• It basically deals with the quality of the components, parts or accessories that
are manufactured o machine d within the fences of MTL.
• There are the drawings for the different parts that allows only the specific
level of tolerance in the machining or finishing of these parts, this section has
basically the concern with that level of tolerance and has to maintain,
• This section utilizes very delicate and sensitive equipment's such as Co-
ordinate measuring machine(CMM) for the assurance of quality.
 Production Lines Quality

• This section has to dealt with the problems encountered on production or

assembling lines and is responsible for meting and maintaining the set
standards of the final products.
• There are pre-defined methods of assembling the different components and
sub components to get a final finished products.
• This section assures that these predefined methods of assembling should be
adopted by the different workers in order to met the standard
• Furthermore it resolves the problem encountered in following the specific
procedure of assembling.
 Gauges
• At every step of manufacturing there gauges are present to check the
quality of the product.
• These gauges are provided to help out the Engineers of Production
lines quality to check the various parameters during assembling.

Different types of Gauges:

Snap gauge: To determine the outer diameters

Plug gauge: To determine internal diameter or bore
Slip gauge: To determine the gaps between two components
Ring gauge: To determine the thread outer diameters
Dial gauge: To determine the multiple dimensions (ovality,
tapperness, bore, length, clearances) in microns.
 Coordinate Measuring Machine (CMM)
Quality of precision machined parts both in house manufactured and vendors
supplied is ensured by the use of CMM, CMM caters for precise
measurement of linear and geometrical size and assures the dimensional
integrity of complex parts with high speed. CMM can measure up to half
micron.

CMM can measure:

• Intricate sizes • Parallelism

• Positions • Concentricity
• Angles • Roundness
• Diameters • Straightness
• Squareness • Co-axialties
• Flatness
Coordinate Measuring Machine (CMM)
Detailed Report of CMM
Inspection and Testing Facilities in Labs

• Oil and Grease Testing

• Paint and Coating Testing Lab

• Rubber Testing

• Material Testing

• Mechanical Testing
 Inspection and Testing Facilities in Labs
Oil and Grease Testing:
• Flashing point apparatus
• Different viscometer and viscosity bath
Paint and Coating Testing:
• Salt spray testing machine
• Thickness meter
Rubber Testing:
• Durometer rubber hardness tester
• Ovens and weighing balance
Mechanical Testing
• Universal testing machine UTM (50 Tons)
• Rockwell hardness testing machine
• Brinell hardness testing machine
• Vicker hardness tester with micrometer
• Impact tester
 Suggestions and Recommendations

• MTL should be quality conscious rather than quantity conscious.

• It is the duty of the QA department that not to allow the poor quality part fed
to the assembly line.
• Good quality tools should be used so components can be saved.
• Bought out Finished(BOF) section should work more precisely and
accurately to ensure the best quality of the vendor’s product.
• CNC machine is required in OP‐53 on lube oil sump line because 0.064
tolerance cannot be controlled by manual Mill machine.
• To improve the quality, change the operating machines gradually.
• Vendors should be treated properly.
Thank You…