REPORT

on

DETAILED STUDY WORKING OF VARIOUS PRODUCTION

UNITS AT ESCORTS AGRI MACHINERY PLANT 2

at

ESCORTS AGRI MACHINERY

A Practice School 1 Station

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE PILANI

July, 2016

Submitted by-
Manav Jindal
(2017A4PS0765H)

Aman Lamba
(2017B5A40825P)
 REPORT

on

DETAILED STUDY WORKING OF VARIOUS PRODUCTION

UNITS AT ESCORTS AGRI MACHINERY PLANT 2

By-

Name of the student ID Number Branch

Manav Jindal 2017A4PS0765H

Mechanical Engg.

Aman Lamba 2017B5A40825P Mechanical Engg.

For
Practice School 1 course
Plant 3, At Escorts Agri Machinery, Faridabad

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI

July, 2019
 BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE
PILANI (RAJASTHAN)
Practice school Division

Station: Escorts Agri Machinery Center: Plant 3, Faridabad

Duration: 2 months Date of Start: May 23, 2016
Date of submission: July 10,2019

Title of the project: Improvement of standard operation sheet (SOS) through Non
Value Added activities (NVA) reduction

ID No.(s) and Names of the Students: Manav Jindal (2017A4PS0765H)

Name and Designation of the experts:

Mr. Ramnaresh Nirmal
Mr. Ravinder Singh
Mr. Shiv
Mr. Sandeep Singh
Mr. Vikas Kashyap
(Sr. Manager , Transmission PU.)
(Axle Line Manager, Transmission PU.)
(Gear Line Manager, Transmission PU.)
(Hydraulic Line Manager)
(Main Line Manager)

Name of the P.S. Faculty: Mr. R K Tiwary

Key Words:

Project Area: Improvement in SOS through NVA reduction

 ABSTRACT

Any industry has multiple dimensions functioning at the same time. A massive
machinery works at once to produce anything and it grows in size as the scale increases,
be it in terms of number, or the size of the product or its intricacies or multiple of these
together. We used the chance given to us in form of PS-1 to understand the functioning of
the one such industry, Escorts Agri machinery, Plant 3, Faridabad. Their final end product
is a tractor in the name Powertrac. We being from engineering background were more
inclined towards the technical aspect involved in making the tractor, and more
specifically in the making of transmission. Transmission is a part most of the automobile
industry outsources it and it is rare to get a chance to see this process so closely. We also
visited the remaining production units in the facility which include the engine
production unit and the rear axle production unit and the tractor assembly unit, which
also have been briefly described in this report. We realize that after graduating from BITS
we will be engineers and our scope of skill set though should be technically sound, we
should also need to be good at managing the work flow along with the work force and
being at this position we would be required to interact with people at both levels lower
than us and higher than us. It was an interesting journey to learn all that and we have
tried to encapsulate those lessons in this report to the best of our abilities.
 ACKNOWLEDGMENT

We would like to thank many people who supported and helped us though the project.
We would like to express our gratitude to Mr Ujjuawal Sharma for allowing us to
complete our training in such a big engineering firm.
We would also like to thank Mr. Ramnaresh Nirmal (Senior Manager , Transmission PU.)
to put us under guidance of highly able Mr. Ravider Singh (Axle Line Manager,
Transmission PU.) and Mr. Shiv(Gear Line Manager, Transmission PU.), and we would
like to thank both of them for guiding us through the assembly line and helping us
through the project so far.
We thank Mr. R K Tiwari (PS instructor) for helping us learn the values and the required
soft skills when one is a part of such a big company and his constant guidance towards
our practice school. We would also like to thank all the workers who helped us at the
assembly line, made us clear the basic doubts and last but not the least our other fellow
BITSian at escorts who were doing their projects in other production unit of same plant
3 at Escorts, who helped us understand the functioning of the P.U.s they were allotted at.
At the end, person we would like to thank is Mr. Shikhar Jamur, who was a fellow intern
with us. He was from SRM university, and was 3rd year automobile engineering student,
and had a good knowledge of the subjects he had studied, and observing the plant as a
team, he taught us quite a few basic mechanical engineering concepts in simple
language which was very enlightening.
 TABLE OF CONTENTS

I Overview of the P.S. and Project

II Abstract
III Scope of project to be used elsewhere
IV Acknowledgment

1. Introduction
2. About escorts Ltd. (Company profile)
3. Escorts’s Core values
4. Escorts agri machinery groups
5. Total productivity management: The management technique
5.1 Standard Operating Sheet (S.O.S)
6. Transmission production unit
6.1 Gear cutting area
6.1.1 Soft Metal Machining
6.1.2 Metal Hardening
6.1.2.1 Induction Heating Machine
6.1.2.2 Carubrizing furnace
6.1.2.3 Quenching
6.1.2.4 Steel ball blasting
6.1.3 Hard metal Machining
6.2 Case transmission
6.3 Assembly
6.4 Testing Labs
7. Rear Axle Production Unit
8. Tractor assembly Production Unit.
8.1 Engine Testing Unit
9. Engine Production Unit
10. Appendices
11. References
 INTRODUCTION

It was after becoming familiar with the work culture and people working there, and
getting in nice and friendly talking terms with them, that we started to find out about the
history and structure of the company. We understood the company profile properly and
the core values imbibed in the company as an inseparable part of it. Initial 3 sections of
this report talk about that.
In our study oriented towards understanding the manufacturing processes used at the
facility, we also found out that the entire plant 3, functions to produce a final tractor sold
under the name of Powertrac which is one of the types of tractors Escorts Agri machinery
produces. The process of making this tractor has been divided into various parts and this
plant 3 has several sub-plants which operates individually to perform these smaller
activity to make a final usable product. These sub plants (in the sequence they are located
in the facility from left to right when facing the buildings from front) are as follows:
 Engine Production Unit.
 Rear Axel Production Unit.
 Assembly Production Unit.
 Paint shop
 Transmission Production Unit.

In this report we shall start in the order given above and tell about our findings at the
facility about its functioning at a basic level and the process that is followed there in
order to complete the designated work. We shall tell about the same in a little more detail
about the Transmission PU.
Engine PU.
Plant with state of the art facility and the process flow and inventory management
systems beautifully designed, produces the engine of the Powertrac tractors.

Rear Axel PU.

Any one who has ever seen a tractor would not have helped noticing giant wheels on the
rear end of the tractor which seem to be more than half of the tractor. The mounting
and the system which gives drive to these big wheels, known as the rear axle assembly
is made in this part of the plant.

Assembly PU.
As the name suggests this is the place where all the parts come together to be assembles
to form what we know as a tractor. It at first might seem odd to have the assembly line in
the middle of the others, but we shall explain the strategic location of it in the subsequent
portions of the report.

Paint Shop
Though not very important in the functioning of machine, but pain plays a major role in
give the tractor the pleasant look it has and hence increasing its marketability
tremendously. And one might intuitively think of painting the components as an easy
task, but it was only after visiting this facility that we found out that it is not so and the
concerned section in the report shall talk about it in detail.

Transmission PU.
The central part in the tractor, both functionality wise and positioning wise, the
transmission is made here, understanding of which answers a lot of our curious
questions like how this power is transferred to the wheels from the engine? How the
speed of the vehicle varies? Does the engine supplies constant power and what happens
when you shift the gear stick of our vehicle?
And it was a brilliant opportunity to be in this section of escorts because we learnt that
escorts is one of very rare companies which makes their transmissions themselves, and
gear cutting is something one doesn’t get to see easily and we spent most of our time so
far here learning this only.

T.P.M.
T.P.M which stands for total productivity management, can said to be a technique to
improve the efficiency of whatever is being produced in the firm, through empowering
workers and autonomous maintenance. Be it a saleable product, or a deliverable service.
And there exist standardizations parameter and also certification agencies for these
standards. We got a chance to be a part of this process, while being under the guidance
of the TPM manager at this station. This chance proved helpful in understanding it to a
fair depth.
 ABOUT ESCORTS LTD. (COMPANY PROFILE)

Over six decades back two young men set out on a journey together armed with little
beyond intelligence, business acumen and determination and dreams aplenty. They
believed that India could only achieve total freedom with a breakthrough in the field of
agriculture and mechanization would have to rule the fields. Their youthful enthusiasm
had kindled the hope that one day they would make a mark of their own. They were in
fact writing the first chapter of what has come to be widely recognised as one of the
greatest success stories in Indian industry.

Escorts came into being with vision .a vision that eschewed easy paths to profitability,
and sought instead for ways to make a contribution. A vision that led two young brothers,
Yudi and Hari Nanda, to branch out of their family's prospering transport business and
institute ventures that were to become the foundations of escorts limited. On 17th
October 1944, escorts agents limited were born at Lahore (now in Pakistan) with Mr Yudi
Nanda as managing director and Mr Hari Nanda as chairman. It was a trendsetting
marketing house driven by the same business philosophy, which had given their family
enterprise an unrivalled reputation: customer concern. not long afterwards, this driving
ambition to go beyond the expected led Hari nana to the first of his many successful
business insights - the discovery of the great business potential that lay in India’s villages.
this led to the launch, in 1948, of escorts (agriculture and machines) ltd., with Yudi Nanda
as director .though separate business entities then, both companies had two great
strengths in common: the dynamic nana brothers and the unifying force of the name they
gave their companies; escorts, literally 'escorting' their products and services to the
customer while most other businessmen were just selling.

Tragically, Mr Yudi Nanda died in an accident in 1952 - but his spirit remained embedded
in the foundations of the company. Mr h p nana then took on the mantle to realize the
dreams which he had always seen with his brother.

escorts (agents) ltd. and escorts (agriculture and machines) ltd. merged in 1953 to create
a single entity -escorts agents p.v.t ltd. having initially started with a franchise for
Westinghouse domestic appliances, by this time the company had already expanded its
marketing and service operations, representing internationally known German and
American organisations such as man, age, Hanel & leg, knorr bremse, miag and bma for
sophisticated electrical and mechanical engineering equipment and Minneapolis Moline
and Wisconsin for agricultural tractors, implements and engines. Escorts made a major
thrust into the agricultural arena by taking on the marketing and service franchise for
Massey Ferguson tractors in northern India, which soon comprised 75% of mf's all- India
sales - a signal tribute to escorts' inherent strengths. Its first industrial venture came up
in 1954, in partnership with Goetzewerke of Germany for the manufacture of piston rings
and cylinder liners - followed by production of pistons in collaboration with male, also
of Germany, in 1960. The company's incorporation in its present name, escorts limited,
was effected on 18th January, 1960. Escorts' next major industrial activity was the
assembly of tractors in 1961 in technical cooperation with uses of Poland. Subsequently
this led to the manufacture of the country's first indigenous tractors under escorts' own
brand name, which were to play a pivotal role in the green revolution. this went on to lay
the foundations that even today are the company's core strengths -relevant, world-
standard technology through strategic international alliances; a broad-based marketing
and service network yet unrivalled; powerful symbiotic relationships with suppliers and
dealers; and above all, the crusade to make a difference.

Beyond the growth of the organisation, these principles have ensured that Mr H. p. nana’s
contribution to the cause of industry and the consumer will endure. He pioneered the
revolutionary concept of 'interdependence' between ancillary and large industries,
institutionalising vendor development and in the process building Faridabad and the
entire belt of townships in the region. He introduced the discipline of service going
before marketing, reassuring the customer that escorts would stay with them that they
were here for the long run. He built lasting alliances with an array of the world's most
respected names in tractors, industrial equipment, two-wheelers, construction
equipment and telecommunications. going further, he created institutions devoted to
value engineering and training, not only as investments in the company's future but also
as catalysts for the enhancement of Indian industry as a whole ¬knowledge management
centre and the unique escorts training and development centre (etc.). His concern
extended to the society in which he worked, and he manifested it by establishing the
escort’s medical centre at Faridabad, escorts heart institute and research centre at New
Delhi, as well as numerous village development programmes. And above all, he imbued
the corporation with his own pioneering, entrepreneurial spirit, instilling both a
conscience and a vision of leadership.

Escorts are testimony to the valour, vision and values of its founder Mr h p nana. He
remains the inspiration for our courage, spirit of adventure and ability to ‘think big’.
These qualities are his enduring legacy and have inspired and encouraged us down the
decades and will continue doing so in all our endeavours.
 ESCORTS’s CORE VALUES

We will demonstrate dignity and respect

Respect for for people in all our interactions. We will
not tolerate belittling of people,
People regardless of position, or circumstance.

People at all levels must be vested with

the power and confidence to take
Empowerment decisions concerning their area of work

People will understand the processes and

criteria used to arrive at decisions
Transparency concerning them.

We will work with our colleagues with

the spirit of collaboration and mutual
Collaboration: respect.
 ESCORTS GROUP OF COMPANIES

 escorts agri machinery:

o A pioneer of farm mechanisation in India, escorts agri machinery (EAM)
was launched in 1960. The company manufactures tractor under the brand
names of farmtrac and powertrac. EAM consists of four manufacturing
plants that cover an area of 134,000 sq. the company also has a plant in
Poland, which is a 100% subsidiary and functions in the name of farmtrac
Europe.

 escorts construction equipment:

o Escorts construction equipment (eke) manufacturers and markets
construction and material handling equipment like cranes, loaders,
vibratory rollers, backhoe loader and forklifts. The company introduced the
concept of pick 'n' carry hydraulic mobile cranes in the 1970s in India. The
eke manufacturing and assembly facility is located across 250,000 sq. of
space in Faridabad.

 escorts railway products:

o Escorts railway products (erg) is an 9001 certified company that
manufactures critical railway components. EAP supplies air brake system,
EP brake system, draft gears and couplers, composition brake blocks,
dampers and rubber components to Indian railways.

 escorts auto products:

o escorts auto products (EAP)[5] manufactures auto suspension products
such as shock absorbers, struts and telescopic front forks for the
automotive industry. the company pioneered automotive shock absorber
manufacturing in India in 1966 in technical collaboration with Fichte &
sacs, Germany. the EAP manufacturing unit is spread across an area of
12,500 sq. ft. in Faridabad.
 ESCORTS AGRI MACHINERY GROUP

Escorts - amg has tractor manufacturing capacity of 98,940 trs / annum which is the
highest in Asia at one location. Its manufacturing operations are divided in three plants
as

 component plant

 tractor assembly plant

 crankshaft & hydraulic plant

Component plant consists of machine shops in which all major castings such as engine
blocks, gear box housings, differential housings are being machined along with gears &
shafts. machine shop consists of state of the art machines such as conk horizontal
machining centres, conk turning centres and variety of other precision machines,
including gear hobbling and shaving machines, etc. it is important to note that all critical
components are machined in house.

tractor assembly plant is divided into two lines as farmtrac line and the powertrac line.
farmtrac line is a composite line that has machining as well as assembly activities of
engine, transmission & tractor whereas on powertrac line only assembly activities of
engine, transmission & tractor are being carried out. tractor assembly plant has state of
the art paint shop that has cede paint shop facilities. engine shop has state of the art
testing facilities that includes AVL make eddy current dynamometers in engine test
house.

crankshaft & hydraulic plant is divided into two parts as crankshaft line and hydraulics
line. crankshaft line consists of machine shop where crankshafts of all tractor models are
being machined. it has state of the art machines such as rotary miller, pin grinder, journal
grinder, etc. hydraulic line consists of machining as well as assembly activities where
critical parts of tractor hydraulics such as distributor, hydraulic cylinder, etc. are
being machined and assembled. it has state of the art honing and other precision
machines.

TOTAL PRODUCTIVITY MANAGEMENT

This portion of work falls more into the office and managerial work than the production
line work. We noticed its prominent presence throughout the plant 2 across all
production units. Owing to an audit that happened on the May 27th, 2016 for certification
of the efficiency of production and management in the company, we spent our very initial
days in the organization understanding this part of the work and learnt how crucial a
role management of the equipment and resources could play and how much more
intricate it might be than what it may appear on the surface.

Mr. Hemant Bharadwaj, who was earlier a central figure in TPM implementation at the
engine PU. since the beginning of this concept in the organization, now the TPM
supervisor in the Transmission PU. allotted us the work to write the complaint tags, from
the records from the past years. There are two types of complaint tags: white and red.
All tags are filled by the workers operating the machines and the line managers as and
when they find them. This empowers the workers to help improve the maintenance of
the machines, at faster pace, apart from as told to us by the workers themselves, a sense
of responsibility and belonging among them, comes along as a useful, and valuable by
product. The difference in the red and the white tags is in the demarcation of
responsibility (red tags are to be resolved by the people within the department while the
white tags are to be resolved by people of other departments like the maintenance
department), and they also specify the maximum permissible time for the complaint to
be resolved. The complaint could be of something as dangerous as short circuiting, of non
functional gauges to something as non significant seeming paint on the bolt of some
covering hood of the machine. The workers write a tag as and when required, hang one
copy on the part which the complaint is about and hand over another copy of the same
to the line manager for record keeping and tracking of the complaint. For the workers to
be able to spot the problem efficiently and quickly, they need to be familiar with the
machine properly and to be familiar that well with as many machines present
in the facility is very difficult. Hence to accomplish this, workers have been divided into
various circles, each circle being responsible for a limited number of machines. Every
circle is like a team, who have weekly meetings (of line manager and the worker), to
ensure that the spirit of the team remains high and the work is being done properly, all
the time lines and targets are being met and all other concerns are addressed as required.
To make sure that meeting goes on smoothly and no point is missed, even by mistake,
there is a proper meeting sheet designed, which is to be filled every meeting and a proper
record of that too is to be maintained and put up on public display inside the factory
itself, on a notice board of the circle which also contains information of all the machine
in the circle, tools used on them, their specifications, their assigned number, all the
operations performed on them, information of the raw and final product of the circle,
basic principles of TPM, and other information depending upon the Production unit, job
being done, circle etc.

After this we were taught personally by Mr. Kuldeep Singh Pawa, how to inspect/audit a
machine for any sort of shortcomings/ faults which are to be reported and subsequently
corrected. There was a sheet called the problem matrix, in which all the problems are
listen in the 1st column, and all the other columns are left blank, each for one machine,
and the line manager has to fill the matrix for all the machines he is responsible for,
periodically. Mr. Pawa told us that this is the work of the junior engineer, the level at which
we would enter the organization right after graduation if we in future plan to join this
company, or most of the other companies in similar industries. Spending a good amount
of time doing this activity, we learnt about the kind of care and attention this job requires
and the kind of stiff standards which should be ideally followed. Some things which drew
our special attention were how the electrical wiring inside of the machine should be, how
the piping for air, and hydraulics and lubricants should be colour coded, and should be
bent at 900 strictly and how pipes should run parallel to each other and the kind of
cleanliness standards are to be maintained, how a place is specified for not just gauges
and tools but also for something like cleaning cloth, and how proper paint on every single
part of the machine is mandatory.
Towards the end of this activity, marking the end of this phase of learning, Mr. Kuldeep
was clearing our doubts about the things we mentioned above. He told us that what to us
was seeming to be very stringent and strict rules, was just level 1 of regulations. There
are total 5 levels of TPM which as you move forward, regularize every single thing in the
facility. Things like place of pencil in the draws, proper rack for files, markings for chair
to be placed on the floor while working, name plates at each station, numbering of the
documents, and other things of such minute order are also regularized. He also made
asked us to learn these methods properly as they are universally applicable for all
organisations a would help us in future wherever we go. Taking his advise, we have to the
best of our capabilities tried to understand TPM and its intricacies and its general
application.

STANDARD OPERATING SHEET (S.O.S.)

SOS contains detailed listing of all components related to a particular process. Often
including elements like design, manufacturing and distribution, a standard operating
sheet will provide an estimate of the time required to complete each stage. It is also
frequently divided into two sections, manual and robot, to further define the time spent
between the two types of manufacturing labour. A standard operating sheet is a tool
used in lean manufacturing that aims to improve the process as a whole through
standardization. Standard operation sheets for two washing machines (WSM-05, WSM-
02) were made. Complete procedure of the machines used for washing CT and the
components was analyzed and entered in the sheets. Appendices 1and 2 contains the
SOS of the above machines.
 TRANSMISSION PRODUCTION UNIT

Transmission of the tractor, often referred to as the gear box, and almost all its
components including the gears like first, second, third, fourth, top, high/low gear, and
the shafts like main shaft and counter shaft and idle shaft are made in this section of the
plant. This plant is further divided into three major sections. First is the case
transmission where we the case or the housing of the transmission mechanism is made.
Second is the Gear lines which is where all the various gears and shafts already
mentioned above along with others are made. And the third section is the Assembly
where all these components are being given the final desired shape are put together to
make a finally usable product.

GEAR LINES
The raw material for gears, as it enters the factory goes directly to the gear lines in the
sequence mentioned below.
SOFT METAL MACHINING
Raw material is procured from the vendors is on purpose taken to be in soft metal
because it is easier to make the required cut, and cut the splines and gears, face and turn
the job, basically do all the necessary operations. This section is divided into 5 gear lines
each of which specializes in a different type of gear to be finally assembled in the
transmission. We to understand the working of these lines and also to understand the
machining work properly we noted the process flow of making of a counter shaft in our
diaries and followed it from starting end to the finish end as given below. Steps 1-15 are
related to the soft metal machining part of it. (The steps beyond the 15th are related to
the parts of the factory the work piece goes to after being done in the soft metal
machining section. These portions have been talked about after the complete process
flow)

COUNTER SHAFT
1. Inspection of component for parameters like internal/outer diameters,
threading, dimensions, depth, width, splines etc. as per outsource product
process sketch sheet for all possible products. This is done manually.
2. Finish turn outer diameter of 30T and face 30T and 55T and generate
chamfer on the outer and inner diameters with specified chuck clamping
pressure and cutting speed and feed using an NCL (numerically controlled
lathe)
3. Finish outer diameter and face 55T, hob face and generate chamfer using an
NCL
4. Finish broach 26T internal involute spline using VBR (vertical boring)
5. Re broach 26T internal involute splines using VBR
6. Shape 30T spur gear using NSP (numatic shaper)
7. Pre Shave hob 55T helical ear using GHB (Gear hobbing)
8. De burr the hobbing burrs on a bench manually
NOTE: Burrs are sharp rough pieces of metal at the edges and surfaces
after performing an operation of the job.
9. De burr the shaping burrs using CRL
10. Finish Shave 30T super gear using GSV (gear shaving)
11. Finish shaving 55T helical gear using GSV
12. De burr all over and wash and clean the component using the WSM
(washing steam machine)
13. Insect gear for 55T and 30T gear tooth characteristics using STG. INSPN
(standardizations teeth gear inspection)
14. Punch batch code on bench manually
15. Put the plugs in the component on bench manually
NOTE: plugs are inserted to prepare the component for heat treatment
16. Heat treat the gear as per process specifications in carbusizing furnace.
(G.C.F.)
17. Wash and clean the component in WSM
18. Temper the component using tempering furnace
NOTE: Tempering means heating the component and suddenly cooling it
down
19. Remove the plug from the component on bench manually
 20. Shot blast the component using the SBL (Shot blast)
21. Inspect the gear for metallurgical characteristics in MET Lab
22. Grind chamfer on front side of 30T spur gear and both sides of 55T helical
gear using GCG
23. Grind the counter bore dia 2.404/2.406” using IGR (internal gear rounder)
24. check composite error of 30T and 55T gear and remove high points if any
using GRT
25. Inspect finish gear using STG INSP
26. Apply rust preventive from oil tank

NOTE: The work piece is kept a little over the required dimension (about 1/1000 of an
inch) to leave scope for grinding after hardening.

METAL HARDENING
Once the job is given the desired shape in the 1st 15 steps mentioned above, it undergoes
hardening process so that it achieves the higher hardness (which is defined as resistance
against deformation) in order to improve the durability and resistance against wear and
tear of the component. The hardening process may vary depending upon the properties
desired for that particular component. Different types of hardening techniques
implanted in the transmission PU. are as mentioned below.

HARDENING USING INDUCTION HEATING MACHINE

Done in selective components, this type of hardening uses magnetic energy to heat
the job. The job is maintained at the negative pole of the magnet while another ring like
structure that comes down t surround it is maintained at the positive pole of the magnet.
The magnetic resistance between the two poles of the magnet developed here is what
produces heat in the component, making it red hot. Then a shower of coolant rapidly
cools the job down to handleable temperature. The benefit of using this type of heating
is that we can locally harden the job. We may choose the surfaces we wish to harden out
of the many it may have all of which without exception are hardened in the other
hardening techniques mentioned below.

HARDENING USING CABURIZING FURNACE

This is a heat treatment process in which iron or steel absorb carbon while the
metal is heated in present of a carbon bearing material, such as charcoal or carbon
monoxide. The intent is obviously to make the metal harder. Depending upon the time
for which and temperature at which the metal is heated, the carbon content can vary in
the affected area. Longer the exposure and higher the temperature, the depth of carbon
diffusion increases. In this technique all the exposed surfaces are hardened equally
without exception unlike in the induction heating method in which selective hardening
is possible as told before. After heating in this furnace, the metal is quenched in the
quenching tank, which is a critical process in hardening which is explained in the
following section.

QUENCHING
Quenching is the rapid cooling of a work piece to obtain certain material
properties. This in conjunction with carburizing heat treatment, hardens the high carbon
content on the outer surface hardening the surface itself via the transformation of
austenite to martensite, while the core remains soft and tough as a ferritic
microstructure.

STEEL BALL BLASTING

Metal upon hardening in the carburizing furnace becomes hard which was the
primary motive to heat treat it, but while doing this, the carbon in the furnace sticks to
the surface of the job. Hence to give it a shiny look it is put in a steel ball blasting machine
where the machine at higher that bullet speed showers extremely tiny steel balls which
get embedded on the work piece giving it a shiny look and increasing the size of the job
by 4/1000 to 5/1000th part of an inch. Now this might seem like a redundant reason to
perform an exclusive operation like this on the job. The alternate reason is that the
additional layer of steel on the job hardens it even more which improves the life span of
the component considerably and contributes in the main purpose of doing the whole
process of heat treatment.
The steps 16-21 in the processes flow for the counter shaft given above come under this
section of the factory.
After being done in this section of the factory, job proceeds to the hard metal machining
section.

HARD METAL MACHINING

After hardening the job return to the same gear line as it was in while the soft metal
machining phase, but in the hard metal machining part of it. The soft metal and hard
metal machining parts of a gear live though are next to each other, can be distinctly
noticed are separate.
As all shaping and cutting of the job is done already for the reason mentioned in the soft
metal machining section, the only operation that happened in this section of the factory
is grinding. On an average of 8 machine per gear line in this section, each machine
specializes in grinding different parts of the same gear in order to increase the
production and efficiency. This part brings down the job to the actual size to be used in
the final assembly not leaving any extra material like the soft metal machining section
did.
Once the job is ready, it is sent to the assembly section for assembly.

CASE TRANSMISSION
A casted gear case (without any operations done on it) is bought by the company from a
supplier and then a number of operations are performed on the gear case to make it
worthy of use in the assembly of the transmission (Gearbox) .The production is done in
three stages: rough operations, finishing operations and washing (in a large washing
machine). Since the case is already in a basic desired shape, very few processes are
repeated on it at multiple stations. Therefore instead of talking about each station
separately as we did for the gear line, we would rather describe all the operations
performed on it one time each. Major operations on gear case performed are as follows

Milling
Milling is the machining process of using rotary cutters to remove material from a
work piece advancing (or feeding) 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 can be done with a wide range of machine tools. The
original class of machine tools for milling was the milling machine (often called a mill).
After the advent of computer numerical control (CNC), milling machines evolved into
machining centres (milling machines with automatic tool changers, tool magazines or
carousels, CNC control, coolant systems, and enclosures), generally classified as vertical
machining centres (VMCs) and horizontal machining centres (HMCs). The integration of
milling into turning environments and of turning into milling environments, begun with
live tooling for lathes and the occasional use of mills for turning operations, led to a new
class of machine tools, multitasking machines (MTMs), which are purpose-built to
provide for a default machining strategy of using any combination of milling and turning
within the same work envelope.

Boring
 Boring is the process of enlarging a hole that has already been drilled (or cast), by
means of a single-point cutting tool (or of a boring head containing several such tools),
for example as in boring a gun barrel or an engine cylinder. Boring is used to achieve
greater accuracy of the diameter of a hole, and can be used to cut a tapered hole. Boring
can be viewed as the internal-diameter counterpart to turning, which cuts external
diameters. There are various types of boring. The boring bar may be supported on both
ends (which only works if the existing hole is a through hole), or it may be supported at
one end (which works for both through holes and blind holes). Line boring (line boring,
line-boring) implies the former. Back boring (back boring, back-boring) is the process of
reaching through an existing hole and then boring on the "back" side of the work piece
(relative to the machine headstock). Because of the limitations on tooling design imposed
by the fact that the work piece mostly surrounds the tool, boring is inherently somewhat
more challenging than turning, in terms of decreased tool holding rigidity, increased
clearance angle requirements (limiting the amount of support that can be given to the
cutting edge), and difficulty of inspection of the resulting surface (size, form, surface
roughness). These are the reasons why boring is viewed as an area of machining practice
in its own right, separate from turning, with its own tips, tricks, challenges, and body of
expertise, despite the fact that they are in some ways identical.

Reaming
A reamer is a type of rotary cutting tool used in metalworking. Precision reamers
are designed to enlarge the size of a previously formed hole by a small amount but with
a high degree of accuracy to leave smooth sides. There are also non-precision reamers
which are used for more basic enlargement of holes or for removing burrs. The process
of enlarging the hole is called reaming. There are many different types of reamer and
they may be designed for use as a hand tool or in a machine tool, such as a milling
machine or drill press

Grinding
The grinding of solid matters occurs under exposure of mechanical forces that
trench the structure by overcoming of the interior bonding forces. After the grinding the
state of the solid is changed: the grain size, the grain size disposition and the grain shape.

Tapping
The tapping of a hole or a bore means to cut threads of desired specification using
a tool called tap. Tap is mounted on a radial drilling machine and is inserted in the hole
as the tool rotates at high speeds. Interesting thing to notice in this process is that as the
tool goes inside the hole, it rotates in one sense, and the sense of rotation is
reversed when it is pulled out. It is analogous to tightening and loosening a screw. We
tighten it turning it in clockwise direction and loosed it turning it in counter clockwise
direction.

ASSEMBLY
All the parts produced in the other two production units are assembled in this unit. The
assembly is bone on a conveyor belt that runs on a minimal speed. .The gearbox (still
under assembly) is constantly inspected by the Quality Control Staff. The assembly of the
gearbox depends on the model of the tractor. Fully assembled gearbox is then
transferred to the main assembly line of tractors where all parts of a tractor are bought
together and assembled to make a tractor.

ASSEMBLY LINE AND STATIONS

Assembly line of transmission production unit of Farmtrac has several stations.
The station and their input details are as follows:

First station: Counter shaft after being mounted on a bearing is fitted in the
CT here along with a ring like structure called cone. After this they fit the double gear
and all other smaller components like the drain plugs and dol pins and window plates
with a gasket. The CT is passed on to the next station after checking the depth of the fitted
parts

Idler station: The sliding gear for top gear engagement and idler gear with
the shaft for reverse transmission are also put here and CT is further passed on to next
station.
Main shaft and rail station: The main shaft with first, second, third and
reverse gear with couplings are put in the CT. The rails and the connector that help in
shifting the gears by pulling levers are also put. Also, a safety switch is prepared in the
sub assembly and is put to ensure that the tractor does not start when it is in gear.

Input station: The input shaft is fitted here which deliver the power from the
engine to the transmission channel.

Rear plate and shimming station: Top gear and the high/low gear is attached
here and the rear plate is bolted. Also, shimming is done to reduce the gap between the
bearing and gear to prevent frictional heat.
Front plate: Front plate is bolted on this station covering the gear case and giving the
support to the input shaft. The clutch shaft is also fitted at this station with all the
peripheral components

Leak station: After fitting the over and levers of the CT, the pressure inside
the gear chamber is checked to prevent any leakage and CT is further moved on to the
testing bed.
 PAINT SHOP

It is very naive to think that the only thing that happens here is painting. If you look at
the bigger picture it can be take to be true, but a detailed study revealed to us that it is
not the case and application of paint on the component concerned is just one of the last
steps in a very long set of processes which are done on the work piece throughout the
paint shop facility. These processes have been divided in 3 major parts which further
have multiple phases each which are as given below

PRETREATMENT
The process of painting is done in many stages or steps.
The component to be painted enters the line is first have to be pretreated so it first enters
the pretreatment line. Pretreatment is done to make component suitable for further
stages and so that at the later stages chemical and paints would spread uniformly.
Another purpose of pretreatment is to remove the dust particles and grease oil present
on the surface of component which came while production of those components.
With these objective, component enters the Pre-Degrease stage which is spray system in
a 6000L tank. Here many chemicals like TPA-1 and TPB-1 are added, the temperature is
maintained at 50-60 degree celcius. And the mixture is titrated at 18-29 scale. By spray
system, we mean that the component is blasted with many nozzles shooting the solution
at the components from different sides.
After spray system pre-degrease stage, the component enters dip system Degrease stage.
Now in dip system, component is dipped in the chemical solution, here pre- degrease and
degrease are same chemical with same specifications but the kind of system is different.
Here the number of nozzles is less in case of degrease stage. The chemical solution is then
recovered from the chemical which after hitting the component and specific
concentration is maintained in the tank.
After degrease the component goes to Water Rinse stage consisting of two stages WR1
and WR2, where the former one being spray stem and the latter is a dip system. Here
caustic soda is added to remove access chemical. Here pH of solution comes from 14 to
7-8 hence caustic soda is added. Number of nozzles in WR1 is 1200 while in the latter it
is 100-150. Now the surface condition comes out to be from7.5 to 9.5 hence PROPYLENE
ZS IS added. The component is dipped because to have a uniform distribution of active
centers.
Next stage is ZINC PHOSPHATE STAGE which is carried in a 44KL tank. Chemical
present in the tank are 3004R, 3004M, A-4704,add-S at a concentration of N/10. Quality
checking of chemical is done on daily basis, here it is titrated with NaOH. Till earlier
stages the titrating agent used was sulfuric acid because of basic nature of solvent. But
from this stages caustic soda is used for the purpose. This is a dip system.
After this stage the component again goes to Water Rinse stage: WR3 and WR4
Same as earlier WR3 is spray system and WR4 is a dip system. The purpose of this
removal of excess chemical in this case the sludge.
After this it goes to DI dip which is distilled water dip to deionize the surface from
chemicals.
The line turns to next stage of Ultra Filtration UF1 and UF2 and as same as earlier former
one is a spray system while the latter one is dip system. Then it goes to the cathode
electrode deposition stage where paint is charged negatively and component is charged
positive. There is mixer downward is constantly rotating 24 hours a day and 7 days a
week because if it stops and the paint settles down I will dry and will cause loss of paint
as well as the machine. After this to dry off the CED paint the component is send to oven
after which it is sent to the main paint line and here the pretreatment is over.

MAIN TREATMENT PROCESS

There are five main stage in the main treatment process.
i. Loading stage
ii. Tag rag stage
iii. Primer stage
iv. Paint stage
v. Oven
The component is sent to loading stage where it is first cleaned with sand paper and
chemical to remove all the dust that come after CED and phosphate stage. Here quality
check also happen which includes checking dips and faulty part. After it is sent to line
it comes to the tag rag stage after approximately 1.5 hours later. Here air is blown over
the component to clean the dust and chemical and then is cleaned with a cloth to
remove the powdered chemical.
After this stage the component is sent to the painting chamber which itself consist of
four sub-stages itself
i) Primer stage
ii) Paint coat 1
iii) Paint coat 2
iv) Final coat stage
 After all these stages the comment is sent to the oven to dry off the paint. The
component comes out of the oven after 1.5 hours approximately which is the same
time taken by the component to comes to the tag rag stage from the loading stage of
the main line. After coming out of the oven it is unloaded where it again goes to quality
check. The defects in the component like dips and dust are marked and it is send to
the worker to remove those defect if it could be, and then it is again sent for the same
processes. Maximum number of times painted can be repeated is three after which
the component is regarded as failure as the thickness of paint would have larger than
standards with every repetition.
While painting is done a mixture of water and grease is simultaneous running on the
wall. This is so to prevent paint to stick on the stick on the wall and to prevent the
layering of the paint.
The way by which a component is determined faulty is by weighing the piece the
component would become heavy as the component passes through the paint stage.

PAINT MIXING
Paint mixing starts in a chamber containing all kind of paints and thinner. Paint is mixed
with thinner to lower its viscosity. There are 4 air valve that support pumping, mixing,
and carrying the mixed paint out. Air struck at the blades to rotate the mixer. Pump also
work on the power and the the air to pull the paint from feed vessel to mixing vessel.
Different type of paints and primers a]that are used are:
i) Blue colour
ii) Black colour
iii) Grey colour
iv) And primer
Main supplier for the paint in the plant is ‘kensai nerolac pvt. Ltd.’. the chemical that we
had discussed before like zinc phosphate is provided by ‘neon puckering pvt. Ltd.’
Different mixing vessel are allotted for different colour paint and one separate vessel is
allotted for primer. Both paint and primer are applied manually. The pump is responsible
for maintaining the flow of paint in the ‘paint shop’ plant. pump creates
vaccum pressure to push paint into the main line as a result of radial movement of piston.
This type of pump creates a lots of noise so all of these pump are put in a single place in
a glass chamber to prevent noise to come out. Escorts is not employing new types of
pumps because of cost issues. But the effectiveness can be increase many folds if the
pumps are replaced. The paint is sent to a main line from which it then transfer to a paint
gun sprayer.
A certain amount of TFT (thin film thickness) which in case of escorts in 60 microns is
required. To achieve this, a certain amount of pressure is required mainly (measured in
kg/cm^3). There are two type of controller one an overall controller and the other one
the in hand controller. Some of them work on mechanical control of pressure while some
are replaced by electronic controllers being more accurate one. Paint mixing is generally
a semi-continuous batch process. Every 4 hours feed is to be added to the feed vessel
which then moves to the co mixing vessel and the thoroughly mixed paint is supplied to
the line continuously from a bottom line in the mixing vessel itself.
At the gun the paint is mixed with the air to enhance the spread ability of the paint.

Types of component
Fender Top hood Rear hood
 REAR AXEL ASSEMBLY

The rear axle assembly comprises of mainly 2 parts, which are made in two different
sections of the plant and assembled in the third.
The two manufacturing/machining lines are the trumpet line and the central housing
line. The trumpet line again is divided into two, one for the left trumpet and one for the
right trumpet. Raw material for these is made of cast iron and is procured from outside
vendors, and in a manner very similar to the case transmission section, machining
processes are performed on the jobs moving on the conveyor belt to make finally
assemblable product. The left and right trumpet lines are separate because though at 1st
sight they both look similar, there are subtle differences in them, one of major one of
which being the curvature in the section which is attached to the central housing. The
Right trumpet have a concave structure while the left trumpet has slightly convex
curvature in the same place. This is because of the positioning of the differential system
being closer to the right trumpet in the final product demanding more space there.

The assembly section of the rear axle P.U too is very similar in many regards to that of
the transmission P.U. all 3 parts machined in the other two parts of the factory come here
along with other finished products procured from outside vendors and are put in order.
 TRACTOR ASSEMBLY PRODUCTION UNIT

This is the section where all parts from all section come together to be assembled into
what we call a tractor. It is located in the centre as it is so that all the components from
the different parts of the plant can come to a central location and no single part, each
being super heavy and difficult to transport until not mounted on wheels, has to travel a
very large distance to reach here.
Broadly speaking, there are three 1st steps in this P.U.
 One is where the rear axle and transmission are joined together. There is just one
component known as the cliff which is fits on the shafts of both the sides in order
to transmit the motion.
 Another beginning step is the engine testing. There are 18 engine testing beds
which confirm the proper functioning of the engines before being assembled in
the tractor. This facility is also used by the Research and Development
department of Escorts. After undergoing a very rigorous testing process (details
of which are given below under the heading Engine testing unit) , clutch, muffler
pipe for engine exhausts and breather pipe to exhaust the smoke of the engine oil
are attached. Turbo Charger may be attached depending upon the model of the
engine.
 Third initial step is the hydraulic sub-assembly which as the name suggests
makes the hydraulic systems of the tractor to lift or descend the attachment of the
tractor depending upon the need.
In the second step the engine and the hydraulic system is attached to the rear axle and
transmission’s combined unit. After addition of parts which need to be painted in the
body colour, like paddles, sprigs, rods, radiator stand, fuel tank, foot rests etc are
attached to this chassis of the tractor and sent to the paint shop for painting on a
conveyor on which all second step processes were being done. This area is called the
“Before paint” assembly.
The inter P.U. conveyor from before pain section goes to paint shop and comes back to
the assembly P.U. for other parts of the tractor to be assembled. (This is another reason
why the Assembly unit is made in the middle of the facility and next to the paint shop
and not at the corner as one might think naively). This section where the assembly from
the before paint assembly area comes after having been to the paintshop is called the
After paint assembly and components like fenders, head lights, battery, wheels,
electrical systems, filters,oil tank, seat, rear view mirrors, and other components like
these are attached and the tractor is ready for post production performance testing and
then delivery.

Upon detailed study of this section after our mid semester report submission, realised
that place which required a deeper study was the engine testing unit (talked about
below) and not the entire factor because all that happened in the rest of the factory is
fitments of various ready to use parts, hence we spent most of our time in the Engine
testing unit.

ENGINE TESTING UNIT

Escorts talks about quality in its core values. An integral part of the plant, located in the
building of the Assembly PU, the engine testing unit is not a separate production unit
but plays a very very crucial role. This is the place where the quality of the engine is
checked.
There are total 12 engine test beds. The testing time prescribed for an engine is 43
minutes and each shift being 410 working minuets long, each bed test tests 9-10
engines a shift where the dedicated and hard working workers even take time from
lunch and tea breaks to meet the targets. There are 3 new old test beds and rests were
recently reinstalled. the engine test machine used by escorts is produced a company
named “avl”. the procedure for engine testing is mentioned bellow.

 engine oil is poured into the engine

 engine is fixed in the mounting points
 the intake and exhaust are connected to the supply and draw line
 the hot water supply is connected
 the flywheel of the engine is connected to the rotor of the dynamo meter
 the engine is turned on using an electrical switch
 and is run on idle rpm for some time
 then after some time the engine is shifted to max throttle
 by Appling load using a dynamo meter the rpm is brought down to 2200
 and the further brought down to 1200rpm
  the engine speciation values are noted against these rpm and matched with
a specification sheet issued by the r&d department
 if the values are under the specified limits then is ok otherwise it is rejected
or kept on hold.

PARAMETERS OF ENGINE TESTING

 oil temperature
 water inlet temperature
 oil pressure
 fuel time ( mileage )
 water outlet temperature
 air temperature

ENGINE TESTING DEVICE

The device used for engine testing is called dynamo meter. the there are many
types of dynamo meter broadly.
 hydraulic dynamo meter
 eddy current dynamo meter
 switching field dc dynamo meter
 fan dynamo meter
 transmission dynamo meter
 chassis dynamo meter

what we use at escorts is an eddy current dynamo meter

WORKING OF AN EDDY CURRENT dynamo meter

 in this type load is applied to the engine by eddy current principle
 dynamo meter consist of stator and rotor
 rotor is connected with cardan shaft to engines flywheel
  stator is nothing but a coil winding which is connected with a constant
 440v supply with varying current (0-15amp)
 the current varies from 0-15 to control the engine load 0-250nm

ENGINE PU.

On one of the ends of the plant 2, is the Engine PU. where engines for all the models of
Powertrac are made. This PU. is basically divided in 3 major sections, the cylinder head,
the engine case, and the assembly.
We found many similarities in this PU. and the transmission PU. in terms of plant design,
and the operations being carried out on raw material and the conveyors, the assembly
processes, testing, etc.
In the cylinder head section, the top cover of the engine which as the name suggests
covers the cylinder heads. Raw material which is made of cast iron is procured from an
outside vendor which undergoes grinding, boring, drilling, chamfering, and tapping to
make necessary alterations in the already existing structure to be ready for final
assembly. For this a long conveyor belt has been set up on which the job moves, and
Operations are performed on it. For a better understanding of the structure of the
cylinder head and it’s components please refer to appendix E.
The section where the body of the engine (Also known as cylinder block) is prepared is
also similar with just raw material of different shape and different set of same
operations. These are the only two components which undergo machining in this factory.
Rest all other components are procured in a ready to use form from outside vendors.
All procured parts, the cylinder head and the body are then sent to the assembly section.
Here, again like the transmission PU. almost all components are washed before assembly.
The assembly section again has a conveyor belt with stands mounted on the belt itself.
And the stand was such that it could be rotated along an axis horizontal to the ground to
make the assembly easy.
The engine production unit is divided in six major sub areas as we understood it. These
sub areas are briefly explained bellow

WASHING
All the stored, outsourced or in-house parts are washed before assembly so
that the assembly areas is dust free and we can minimize the errors due the dust and
dirt particles .two types of washing machines namely ultrasonic washing machine and
hot water washing machine .

ENGINE BLOCK SUB ASSEMBLY

 disassemble and place the main bearing caps on the station
 assemble crank shaft on block
 assemble main bearing shell on block
 selection and assembly of main bearing shell on mbc’s
 assemble mbc 1, 2, 3 and mbc 4
 assemble rear oil gallery plug to block
 assemble rear seal carrier and rear seal
 cam shaft assemble
 cam shaft to block
 assemble gear crank shaft to crank shaft
 assemble adaptor oil pressure drain cock oil galleries plug
 loading
 rotate block-lift block from conveyor
 load cylinder block –crank shaft to assembly fixture

PISTON SUB ASSEMBLY

 select piston, piston pin, connecting rod
 punch cylinder bore number on the on connecting cod assembly
 assemble piston pin on connecting rod
 assemble 1,2,3
 disassemble con rod cap
 and assemble bearing liners
 remove cap con rod no 1
 bearing shell fitments on con rod
 assemble thread protection cap to bolts on con rod
 cap con rod shell fitments 1
 install piston and con rod assembly to cylinder block

FIP SUB ASSEMBLY

 assemble fipsub assembly
 assemble the cam gear, idler gear, fir gear
 assemble oil pump drive gear
 rotate assembly fixture
 assemble timing plate and wire timing plate
 assemble 0 ring to crank shaft
  assemble spacer
 assemble front cover to block front seal fitments

OIL PUMP SUB ASSEMBLY

 assemble to oil pump to block
 assemble dip stick tube, alternator mounting and bracket, bracket guard
mounting
 assemble timing cover plate
 oil pan –rotate assembly fixture 90degree
 apply sealer on sump face
 assemble oil pan gasket
 assemble oil pan to block

HEAD SUB ASSEMBLY

 push rod fitments and rocker shaft assembly fitments
 assemble injector assembly to cylinder head
 assemble fuel leak off tube

The engine is tested for leakages at the last station and after approval is sent for further
testing in the engine testing section in the assembly production unit which has been has
been talked about earlier in this report. Further on, after getting approval from there the
engine is taken to be fit for use and then assembled in the tractor.
 APPENDIX A

GEAR ENGAGEMENT IN GEAR BOX

A Gearbox is a mechanism that changes the input drive speed to a lower or higher
output speed or reverses the direction of rotation. Gears with different ratios are
mounted on the shafts inside the gear case and the arrangements are established in
order to deliver different torque and speed to the wheels. Tractor here has 4 gears and a
reverse gear and every gear has a low and high speed. The arrangement of the gears can
be understood with the help of the below diagram. The power from the engine comes
through the input shaft, it then passes to the double gear and further rotates the
counter shaft, all the gears rotating. When the driver shifts the gear, the coupling on the
above main shaft shift towards the corresponding gear thus rotating the main shaft
with the speed depending on the gear ratio of the gear in contact. Further, if the driver
wants that particular gear in high then the power transmits straight to the output shaft
and further to wheels and if he shifts the H-L lever to L then the power comes down to
top gear and the coupling shift towards the low gear and the power transmits through it
to the output shaft and further to wheels. The order in which the power is transmitted
in different gears can be seen in appendices 3-7. The arrows shows the transmission of
power through gears from input to output shaft in both low and high gear.
 APPENDIX B

1ST GEAR ENGAGEMENT

APPENDIX C
TPM AUDIT SHEET
 APPENDIX D
LAYOUT OF PLANT 2, ESCORTS AGRI MACHINERY, FARIDABAD

ENGINE REAR AXEL ASSEMBLY PAINT TRANSMISSION

PU PU SHOP PU
PU

FRONT OFFICE

OTHER OFFFICES (ERD, EHS, CANTEENS etc)

 APPENDIX E
STRUCTURE OF CYLINDER HEAD
In an internal combustion engine, the cylinder head (often informally
abbreviated to just head) sits above the cylinders on top of the cylinder
block. it closes in the top of the cylinder, forming the combustion chamber.
this joint is sealed by a head gasket. in most engines, the head also provides
space for the passages that feed air and fuel to the cylinder, and that allow
the exhaust gas to escape. internally, the cylinder head has passages called
ports or tracts for the fuel/air mixture to travel to the inlet valves from the
intake manifold, and for exhaust gases to travel from the exhaust valves to
the exhaust manifold. in a water-cooled engine, the cylinder head also
contains integral ducts and passages for the engines' coolant - usually a
mixture of water and antifreeze – to facilitate the transfer of excess heat
away from the head, and therefore the engine in general. in the overhead
valve (ohv) design, the cylinder head contains the poppet valves and the
spark plugs, along with tracts or 'ports' for the inlet and exhaust gases. the
operation of the valves is initiated by the engine's camshaft, which is sited
within the cylinder block, and its moment of operation is transmitted to the
valves pushrods, and then rocker arms mounted on a rocker shaft – the
rocker arms and shaft also being located within the cylinder head.

COMPONENTS OF CYLINDER HEAD

 ENGINE VALVES:
four-stroke engines of spark ignition or compression ignition varieties, use
engine valves to allow air (or an air/fuel mixture) into the cylinder and
exhaust gases out. the valve which allows mixture into the cylinder is the
inlet valve; the one through which the spent gases escape is the exhaust
valve. they are designed to open and close at precise moments, to allow the
engine to run efficiently at all rpm. the shape and position of the cam
determines the valve lift and when and how quickly (or slowly) the valve is
opened. the cams are normally placed on a fixed camshaft which is then
 geared to the crankshaft, running at half crankshaft speed in a four-stroke
engine.

 VALVE SEAT:
the valve seat in an internal combustion gasoline or diesel engine is the
surface against which an intake or an exhaust valve rests during the portion
of the engine operating cycle when that valve is closed. the valve seat is a
critical component of an engine in that if it is improperly positioned,
oriented, or formed during manufacture, valve leakage will occur which will
adversely affect the engine compression ratio and therefore the engine
efficiency, performance (horsepower), exhaust emissions, and engine life.

 VALVE GUIDES:
in IC engines, a valve guide is provided for each engine valve in the cylinder
head. along with the valve spring, it serves to positively locate the valve so
that it may make proper contact with the valve seat. a valve guide is a
cylindrical piece of metal, pressed or integrally cast into the cylinder head,
with the valve reciprocating inside it. guides also serve to conduct heat
from the combustion process out from the exhaust valve and into the
cylinder head where it may be taken up by the cooling system. bronze is
commonly used, as is steel; a balance between stiffness and wear on the
valve is essential to achieve a useful service life.

 ROCKER ARM

In IC engines, a rocker arm is an oscillating leveller that conveys radial

movement from the cam lobe into linear moment at the poppet valve to
open it. one end is raised and lowered by a rotating lobe of the cam shaft( at
places it is done directly but in escorts ft-35db it is done using tappet and a
pushrod)while the other end acts on the valve stem. when the camshaft
lobe raises outside of the arm the inside presses down the valve stem,
opening the valve .when the outside of the arm is permitted to return due to
camshaft rotation , the inside rises allowing the valve spring to close the
valve.
 REFRENCES
 http://www.wikipedia.com
 S.O.P. at company
 Guidance form
 Mr. Ramnaresh Nirmal (Sr. Manager , Transmission PU.)
 Mr. Ravinder Singh (Axle Line Manager, Transmission PU.)

 Mr. Shiv (Gear Line Manager, Transmission PU.)

 Mr. Sandeep Singh (Hydraulic Line Manager)

 Mr. Vikas Kashyap (Main Line Manager)