project end semester report- 6 months industrial training - mahindra and mahindra- swaraj tractor...

Mahindra and Mahindra Limited | Swaraj Division

Industrial Training Report End Semester Industrial Training Report - May 2009

Submitted by: Harpreet Singh

Roll number: -11235 Registration number: - UCE (P)-05-194

B.Tech. (Mechanical Engineering) – 4th Year University College of Engineering

Punjabi University

Information

Report submitted by: Harpreet Singh B.Tech. (Mechanical Engineering) 8th Semester Roll Number :11235 Registration Number : UCE (P)-05-194 Batch: 2005-2009 University College of Engineering Punjabi University Patiala India

Company Address where Industrial training was undertaken

Acknowledgement |

Sometimes words fall short to show gratitude, the same happened with me during this project. The immense help and support received from Reliance Money Limited overwhelmed me during the project. It was a great opportunity for me to work with Swaraj Tractor division, pioneers in the field of farm equipment manufacture, a part of Mahindra and Mahindra Ltd. I am extremely grateful to the entire team of Swaraj Tractors, SAS Nagar (Mohali) who has shared their expertise and knowledge with me and without whom the completion of this project and my industrial training would have been virtually impossible.

My sincere gratitude to Mr. Rajendra Singh (Senior Manager and my mentor, Swaraj division, Mahindra and Mahindra Ltd. , SAS Nagar(Mohali)) for providing me with an opportunity to work with them as a trainee who has provided me with the necessary information and his valuable suggestion and comments on bringing out this report in the best possible way. I feel great pleasure to thank Mr.Avtar Singh (In charge-PDI) and all other team members. I am also very thankful to my friends, partners during the training period and all the workmen at the Swaraj Division, Plant -1 and who helped me in the completion of my projects. I am thankful to that power that always inspires me to take right step in the journey of success my life. Harpreet Singh

Contents

1. The Indian Tractor Industry Page 1 2 Introduction and Business Description

Swaraj Tractor Division - Mahindra and Mahindra Limited

Page 2

3 Background of the company Page 2 4 Timeline of the company Page 3 5 Company Organization chart 6 Manufacturing facilities at plant -1

1. Light machine shop 2. Heavy machine shop 3. Paint shop 4. Assembly shop 5. Heat treatment shop 6. Quality Engineering

Page 7 -14

7 Products and specifications Page 15 - 23 8 Project Reports

1. Project – 1 (Elimination / reduction of water-mixing in the engine oil )

Page 24 - 49

2. Project – 2 (Elimination / reduction of diesel leakage from fuel cock)

Page 49 - 65

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The Indian Tractor Industry |

India is mainly an agricultural country. Agriculture accounts for approximately 25 percent of India’s

GDP. Agriculture in India is the means of livelihood of almost two thirds of the workforce in the

country and employs nearly 62 percent of the population. It accounts for 13 percent of India’s

exports. About 42 percent of India’s geographical area is used for agricultural activities. It is therefore

considered a vital sector of the Indian economy.

The Indian tractor industry is the largest in the world, accounting for one third of global production.

The other major tractor markets in the world are China and the USA. The global spotlight on tractor

manufacture in terms of unit volume seems to be swinging away from the USA, UK and Western and

Eastern Europe towards India and China, where growth in the number of producers and the total

volume of production in recent years has been impressive.

Until 1960, the demand for tractors was met entirely through imports. Indigenous manufacture of

tractors began in 1961, but India continued to import tractors to bridge the total volume needs up to

the late 1970s. The Indian Tractor Industry has come a long way since then. Volume growth in the

past four decades show a compound annual growth rate of 10 percent, despite seasonal variations

that cause natural fluctuations in the demand for tractors, subsequently impacting the industry

volumes.

The Indian tractor market is traditionally a medium-horsepower market consisting of mostly 31-40

hp, which constitutes almost 51 percent to growth in this category. Growth of the Industry is closely

related to growth in this category. In other-size categories, 41-50 hp category achieved the second

highest growth of 34 percent and constitutes 24 percent of the total market share. The rest of the

market share is largely with the 21-30 hp category followed by the category of tractors having more

than 50 hp.

The Indian Tractor Industry has numerous challenges, some of them being:-

1. Reducing the average age of tractor buyers from the age group of above 40 to younger people

2. Development of new products using latest technology and advancements in the field of

electronics and mechatronics and making the tractors more comfortable, stylish and yet

keeping them in range of a farmer.

3. Reduction of emissions in accordance with the new international emission standards

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Introduction and Business Description |

Swaraj Tractor Division, Mahindra and Mahindra Limited, is the farm equipment manufacturer

division and the flagship company of the erstwhile Punjab Tractors Limited of which a major share

was acquired by Mahindra and Mahindra Limited in the year 2007. The Company's principal activity

is to manufacture, market and servicing of tractors ranging from 25-100 HP. Other products include

self propelled harvester combines, forklifts, tractor drawn agricultural implements, gears, spare

parts, casting and accessories. The Company has manufactured and sold more than 600,000 tractors

over the past 30 years (with 36000 tractors being manufactured and sold in the fiscal year 2008-

2009 alone).The basic credibility of the company is the manufacture of reliable tractors requiring

least maintenance and low cost of ownership. The Company is one of the major share-holder in the

Indian Tractor Industry in a market with rivals like John Deere, Case New Holland, TAFE, etc. The

company has in-house competence in producing engines and transmission systems and has been the

best financially managed company in the Indian Tractor Industry. The reputed Swaraj brand of the

company is sold through 475 exclusive dealers stocking only Swaraj products The manufacturing

plants and the Research and Development centre of the company are located in Mohali, Punjab. The

company exports auto components to the markets of African/SAARC countries.

The company has 3 farm equipment manufacturing facilities:-

1. Swaraj Tractor Division (STD) Phase –IV, Industrial Area, SAS Nagar(Mohali)

2. Swaraj Foundry Division (SFD) Mazri, SAS Nagar(Mohali)

3. Swaraj Combine Division (SCD) chapparcheri, SAS Nagar(Mohali)

Background of the company |

Keeping in mind Punjab’s agrarian economy, it was decided by the Punjab government to encourage the growth of the industries, which complement Punjab’s agriculture growth. This task was entrusted to P.S.I.D.C. (Punjab State Industrial Development Corporation), which has played a major role in bringing Punjab to the threshold of the industrial revolution. With the dual objective of industrial & agriculture growth, Punjab Tractors Limited was established on 27th June 1970 as a project of Central Mechanical Engineering Research Institute (CMERI), Durgapur, West Bengal.

Punjab Tractors Limited (PTL) was promoted by Punjab State Industrial Development Corporation (PSIDC) to commercialize the indigenous tractor developed by the Central Mechanical Engineering Research Institute (CMERI). The Swaraj brand of tractors were India's first indigenously made tractor suitable for medium land holdings. A number of plants of the company are situated in the S.A.S. Nagar (Mohali) District, Punjab, India. The construction of the first plant of the company located at phase-IV, Industrial Area, S.A.S. Nagar (Mohali) started in March 1972 and the first batch of tractors rolled out on 14th November 1973. The commercial production commenced in the year 1974. Initially, PSIDC contributed 42% equity capital against the total paid up capital of Rs.140.00 lakhs. The facility was initially created to manufacture 5000 tractors and the capital cost at that time was Rs.321 lakhs

The company's product line also includes Combine Harvestors and Forklifts. The production capacity of tractors has increased to 60000 tractors per year from the level of 5000. The company, over the

Page | 3

years, has also promoted two companies, namely, Swaraj Mazda Limited (manufacture of Light Commercial Vehicles) & Swaraj Engines Ltd. (manufacture of Diesel Engines in collaboration with Kirloskar limited). Both Kirloskar Oil Engines limited and Swaraj Engines Limited manufacture tractor engines for the Swaraj Brand of tractors.

Timeline ||

Year Event

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

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

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

1974 Swaraj 724 (26.5 HP) tractor commercially introduced.

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

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

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

1981 Issue of maiden Bonus Shares (2:5), paid-up equity moves to Rs 15.4 million.

1983 4th Tractor Model - SWARAJ 855 (55 HP) developed by own R&D, commercially introduced.

Expansion of annual capacity to 12,000 tractors per annum at Plant 1.

1984 SWARAJ MAZDA Ltd. promoted in technical and financial collaboration with Mazda Motor Corporation. & Sumitomo Corporation. Japan for manufacture of Light Commercial Vehicles. PTL's equity participation is Rs. 30.4 million (29%) and that of Mazda and Sumitomo's Rs. 27.0 million (26%).

1985 Industrial Forklift Trucks developed by own R&D, commercially

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introduced.

1986 SWARAJ ENGINES Ltd. promoted in technical and financial collaboration with Kirloskar Oil Engines Ltd.(KOEL) for manufacture of diesel engines. PTL's equity participation is Rs. 6.9 million (33%) and that of KOEL's Rs 3.6 million (17%).

1989 1st Right Issue (1:1) at a premium of Rs 50/- per share (plus reservation of 200 Shares per employee) paid up equity moves to Rs 31.6 million.

1990 2nd Right Issues (1:2) at a premium of Rs 60/- per share (plus reservation of 200 Shares per employee) paid-up equity moves to Rs 50.6 million.

1992 1st right issue of Bonus Shares (1:1), paid up capital moves to Rs. 101.2 million.

1993 Annual tractor capacity expanded to 24,000 per annum at Plant 1.

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

1996 3rd issue of Bonus Shares (1:1), paid up equity moves to Rs. 202.5 million.

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

1999 5th and 6th tractor models - SWARAJ 733 (34 HP) & SWARAJ 744 (48 HP) developed by own R&D, commercially introduced. FY 1999's divided @ 250% was corporate India's highest.

2000 Expansion of annual tractor capacity to 60,000 completed. 4th issue of Bonus Shares (2:1), paid up equity moves to Rs 607.6

million.

2001 PTL won National Championship trophy in competition organized by All India Management Association (AIMA) for young managers.

Economic times and Boston Consulting Group selects PTL as one of the India's finest 10 companies out of Economic times top 500 Companies.

2002 Cumulative tractor sales crosses 500,000.

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

2004 7th & 8th tractor models - Swaraj 939 (41 HP) & Swaraj 834 (34 HP) developed by own R&D, commercially introduced

2005 PTL disinvested 15,73,000 equity shares of Rs. 10/- each of Swaraj Mazda Ltd. (constituting approx. 15% of SML's paid up capital) in favour of Sumitomo Corporation, Japan, a joint venture partner in Swaraj Mazda Ltd. at a total consideration of Rs. 629.2 million

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

M&M made open offer to shareholders for another 20% equity of the Company.

Mahindra Group's equity holding in the Company stands at 64.6%

Page | 5

Cumulative Tractor Sales cross 600,000. Swaraj Track Type Combine designed and developed by in-house

R&D, commercially launched

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

Company organization chart |

Board of Directors

Working Directors

Vice Chairman Managing Director

4) Executive Directors:

Finance

Human Resource and Development

Manufacturing International Business Division,

Material Services

Swaraj Automotive Limited

Swaraj Motors Limited

Senior Vice-President (Marketing)

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5) Vice Presidents:

each under Executive Director (in previous level)

6) Assistant Vice President

7) General Manager

8) Deputy General Manager

9) Senior Manager

10) Manager

11) Assistant Manager

12) Senior Engineer

13) Engineer

14) Assistant Engineer

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15) Junior Engineer

Operating Class

The level 5-15 is under each vice president of level 4

Manufacturing Facilities at Plant-1 |

A number of manufacturing facilities are available at the Mahindra and Mahindra, Swaraj Division, Plant -1

The whole manufacturing system is divided into a number of departments

1. Light machine shop

2. Heavy machine shop

3. Paint shop

4. Assembly shop

5. Heat treatment shop

6. Quality Engineering

Light Machine shop ||

LMS is the largest section in the factory. All transmission components including shafts and

gears used in tractors are manufactured here. It has 117 machines. Facilities of this shop

include equipment for blank operation, boring, drilling etc. Except the bevel gear

generator & gear shaver, which have been imported from WMW & Churchill of West

Germany respectively, all other machines are from HMT Ltd. The Rs. 31 million plant and

machinery of this shop are installed in an area of 33,000 sq. ft. and casting/forging and bar

worth Rs. 24 million are machined annually. In view of complexity of operation and high

standard of quality this shop is manned by 160 highly experienced operators and

inspectors.

Heavy Machine shop ||

All heavy casting of tractors are machined in this shop with the help of variety of special machine

(SPM). These machines are tailors made by IIMT to suit component requirements. In addition,

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facilities of this shop include general-purpose turning, drilling and milling machines. About 20 SPM

and 30 GPM are installed in a covered area of 47,000 sq. Ft. At a cost of 20 million, 2600 tones of

castings are machined every year on a two-shift basis. In addition to the machining of casting for

the tractor, some jobs are also performed for Swaraj Mazda Limited.

Paint shop ||

Paint Shop is the place where the different sheet metal components are painted. They are

made to pass through various chemicals before they are actually painted. The painting

method opted is that of Spray Painting. The paint shop at the plant is equipped with the

washing and drying facility for the engine and transmission section of the plant as well as

the sheet metal components of the tractor.

Heat Treatment shop ||

Heat treatment shop plays a very important role in every industry. In automobile industry all the

gear and shafts need to be heat treated to impart desired strength and increase life of the

component. The Heat Treatment shop at plant is equipped with several gas carbonizing furnaces,

quenching tanks, induction hardening machines and shot blasting furnaces. All the gears and

shafts that have been manufactured in the plant are heat treated before they are ready to be

installed in the tractor.

Assembly shop ||

The Assembly line at Swaraj Tractor division deals with the assembly of tractor models 722, 724, 733, 735 FE, 735 XM, 744, 834. Assembly is the joining of various constituents to form a final product. The assembly process is carried out on the main line, which has various sub assemblies along its length. Assembly shop can be divided in two main areas: -

1. Before paint area

2. After paint area.

Before paint area The area before painting can further be divided into sub assemblies/ loops namely

a) Differential loop.

b) Gearbox loop.

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c) Rear cover loop.

d) Engine assembly loop.

Differential Assembly loop

In the differential loop, the differential casting is mounted on trolley after washing and left and right Bull pinion Shaft is fitted. Then the Cage assembly consisting of Crown Wheel is fitted. Tall pinion assembly, Roller bearing, PTO shaft, Rear axle/trumpet, PTO shifter assembly ,Gearbox assembly, Rear cover assembly , Brakes , Parking brake, Suction pipe, PTO cover,Trailer hook, Angle bracket, Rocket link ,Footboard and Clutch pedal is fitted.

Gearbox loop In the gear box loop, the Gearbox housing mounted on trolley, Drive shaft, input shaft ,output

shaft , Lay shaft, connecting shaft assembly, Shifter rod assembly, Steering assembly are

assembled.

Rear cover loop

In the rear cover loop Rear cover mounted on trolley. Control valve and response valve assembly,

Ram assembly are fitted.

Engine Assembly loop

In the engine loop the Engine mounted on trolley, Dynamo, Self-motor, Oil pump, Front axle beam

and bracket and Clutch plate is fitted.

After that the chassis is carried to the next level by the lift where the engine & the 3-point

assembly of the tractor along with the other components are fixed. The parts fitted here are:

3-point linkage which contains the following parts:

Bracket.

Lower link fitted at the left side.

Leveling rod fitted at the right side.

Stabilizer stainer.

Draw bar.

Top link.

Battery frame.

Front frame.

Tie rod attached with the drop arm of the steering system.

Accelerator link.

Delievery pipe.

Engine attachement.

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The engine is attached with the chassis system in this level of assembly. The engine is also carried

to this level with the help of the lift crane, which lifts the engine assembly & delievers it to this

level. Shlug is applied at the corneror we can say at rhe circumference of the gearbox where

engine is attached with studs & bolts. Shlugs works as gaskets or seals & avoid the oil leakage and

water mixing in the engine. Then the engine and chassis system, mounted on the coveyor system

enter the paint shop area, where it is washed, dried and painted.

The engine and chassis assmbely after the paint shop reach here, and gets fitted with

following parts:

Front axle.

Extension in the front axle used for the setting of the wheels.

K.P.S.A. (King Pin Shaft Axle) with the wheel disc & nuts fitted in there for the fitting of the wheels.

Drop arms.

Tie rods.

Bucket.

Clutch plates

Alternator.

Self starter.

Fuel pump.

Then the whole assembly is mounted over the conveyor, which takes that piece to different chambers

of washing, drying, primering, baking, painting & again baking.

The chassis and the engine going for washing and drying and then it goes to the paint shop

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After paint area After painting the conveyor takes the assembled piece to the Dismounting stage where

different parts & components like tyres, radiator, dashboard, sheet metal parts, seating,

steering wheel ,etc are fitted on the tractor & the tractor was completed. After that the

testing of the tractor is done. A tractor has to pass through different tests to claim itself to be

worthy to be sold and if there is some problem coming out in this stage, the tractor is send to

the recovery shop, where the problem of the tractor is recovered. After the recovery the

tractor is again tested & after passing the test the tractor finally send to the yard from where

it is dispatched after Pre – dispatch inspection (PDI).

The assembly line

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Quality Engineering ||

Quality engineering is that department of the plant that deals with the analysis of a manufacturing system at all stages, to improve the quality of the production process and of its output. It is divided into two parts: -

1. Suppliers quality

Suppliers section consists of maintaining the quality of products that are being supplied by

suppliers. It contains inspection of the raw materials being supplied by suppliers. It also

includes discussion regarding delay of raw material and defective parts supplied.

Subsequent actions are taken if the supplied products being supplied are found defective

and inspectors from the industry are sent regularly to avoid such defects. This inspection

is regularly done by the industry so maintain good quality supply and sound relationship

with suppliers.

2. In-House Quality

It is said the prevention is better than cure. To eliminate any problem in the further stages, In house quality is embedded into every department of the industry. As such there are six in-house quality check posts:-

– Q.E.L.M.S (Light Machine Shop) – Q.E.H.M.S (Heavy Machine Shop) – Q.E.H.T (Heat Treatment) – Q.E.P.M (Plant maintenance) – Q.E.A (Assembly) – IQS – Pre-Dispatch inspection (Final check post)

Pre-Dispatch Inspection P.D.I (Pre Dispatch Inspection) is the final quality post which carries a major responsibility of

dispatching the tractors as manufactured by the assembly line of plant-1. This is similar to giving

final touches to the jewellery being sold. This department carries rigorous checks as per the pre-

designed checklist prior to dispatch of machinery.

P.D.I acts as one of the major diagnosing center for every daily to daily outgoing failure and

scrutinizing them and hopefully trying to remove these failures. This way forthcoming problems

reported by dealers are reduced. This helps to maintain a healthy relationship with dealers and

customers.

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Measures under PDI

1. TRANSMISSION FLUID LEVEL 2. ENGINE OIL LEVEL 3. FUEL INJECTION PUMP OIL LEVEL 4. WATER LEVEL IN RADIATOR 5. ELECTRICAL FUCTIONING 6. COMPONENT STORAGE 7. CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER

Transmission oil dipstick

Fuel Injection Pump

Page | 14

Page | 15

Products and Specifications |

Mahindra and Mahindra limited, manufactures a number of farm equipments under the Swaraj Brand.

Given below is the list of the farm equipment manufactured along with some of its specifications being

manufactured at Plant-1, phase IV, SAS Nagar (Mohali): -

Specifications:

Engine :

HP : 39 S.A.E Type : 4 Stroke, direct injection, diesel engine. No. of Cylinders : 3 Bore and Stroke : 100 X 110 mm Displacement : 2592 cc

Page | 16

Rated Engine Speed : 2000 rev/min. Air Cleaner : 3 stage Air cleaning system comprising of Cyclonic pre-cleaner, Oil bowl &

Paper element to enhance engine life. Cooling System : Water cooled with No Loss tank. TRANSMISSION Clutch : Heavy duty single dry plate type, 280 mm diameter No. of Gears : 8 forward, 2 reverse speeds with high and low selector lever. Speed Chart

Gear 1st 2nd 3rd 4th Rev.R Low 2.3 3.1 4.6 7 2.84.7 High 8.9 12.1 18 27.4 11.2

P.T.O. 21 splines for 1000 rpm 6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)

BRAKES Heavy Duty self energizing, water sealed disc brakes Parking brake for additional safety, Oil immersed disc brakes (Optional)

STEERING Heavy Duty single drop arm steering for high efficiency and comfortable drive.

HYDRAULICS 2 lever live hydraulic system having automatic position & draft with mix control

a) Position control To hold lower links at any desired height. b) Automatic Draft Control To maintains uniform draft. c) Mix Control For optimum field output Hydraulic lift pump Gear type hydraulic pump delivers 17 l/min at rated engine speed.

LIFTING CAPACITY 1000 kgf at lower link ends.

ELECTRICALS 12 volt, 88 Ah. Battery Starter motor & alternator Head light with parking lamps INSTRUMENTS Engine rpm cum hour meter, Fuel gauge, Water Temp. Gauge, Oil pressure

gauge, Ammeter, High beam indicator, Trailer light indicator. TYRES Front 6.00 x 16 Rear 12.4 x 28 WHEEL TRACK Front 1200 - 1750 mm Rear 1350 - 1900 mm

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Specifications:

Engine :

HP : 34 S.A.E. Type : 4 Stroke, direct injection, diesel engine. No. of Cylinders : 3 Bore and Stroke : 100 X 105 mm Displacement : 2474 cc Rated Engine Speed : 2000 rev/min. Air Cleaner : 3 Stage Air cleaning system compromising of cycolonic pre-cleaner,

Oil Bowl and Paper element to enhance Engine Life Cooling System : Water cooled TRANSMISSION Clutch : Heavy duty single dry plate type, 280 mm diameter No. of Gears : 8 forward, 2 reverse speeds with high and low selector lever. Speed Chart

Gear 1st 2nd 3rd 4th Rev.R Low 2.1 2,9 4.4 7 2.6 High 8.3 11.3 17.4 27.4 10.4

P.T.O. 21 splines for 1000 rpm 6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)

BRAKES Heavy Duty self energizing, water sealed disc brakes Parking brake for additional safety, Oil immersed disc brakes

STEERING Heavy Duty single drop arm steering for high efficiency and comfortable drive.

HYDRAULICS 2 lever live hydraulic system having automatic position & draft with mix control

a) Position control To hold lower links at any desired height. b) Automatic Draft Control To maintains uniform draft. c) Mix Control For simultaneous use of position and draft controls for optimum field

output. Hydraulic lift pump Gear type hydraulic pump delivers 17 l/min at rated engine speed.

LIFTING CAPACITY 1000 kgf at lower link ends.

ELECTRICALS 12 Volt, 75 Ah. Battery, starter motor & alternator.

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Starter motor & alternator Head light with parking lamps INSTRUMENTS Tractor meter with direction indicators, Fuel Gauge, Ammeter, Water

Temp. Gauge & Oil Pressure Gauge TYRES Front 6.00 x 16 Rear 12.4 x 28 WHEEL TRACK Front 1200 - 1750 mm Rear 1350 - 1900 mm

Specifications:

Engine Specifications:

HP : 48 S.A.E. Type : 4 - Stroke, Direct Injection, Diesel Engine No. of Cylinders : 3 Bore and Stroke : 110 X 110 mm Displacement : 3136 cc Rated Engine Speed : 2000 rev/min Air Cleaner : 3 Stage Air cleaning system compromising of cycolonic pre-cleaner, Oil Bowl

and Paper element to enhance Engine Life Cooling System : Water Cooled with Oil Cooler for engine oil. Transmission:

Clutch : Heavy Duty single dry plate type, 305 mm dia, Dual Clutch, 280 mm dia. (optional)

No. of Gears : 8 forward, 2 reverse speeds with high and low selector levels. Gear Speeds (Km/hr)

1 2 3 4 R Low 3.1 4.2 6.5 8.9 4.3 High 10.2 13.8 21.4 29.2 14.3

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P.T.O.

21 Splines for 1000 rpm at rated engine 6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)

Brakes

Heavy Duty Self energizing, water sealed disc brakes with parking brake for additional safety. Oil immersed disc brakes (optional)

Steering

Heavy Duty single drop arm steering for high efficiency and comfortable drive. Hydraulic and Implement Linkage 2 Lever live hydraulic system having automatic position and draft with mix control.

Position Control: To hold lower links at any desired height Automatic Draft

Control: Maintains uniform draft.

Mix Control: For simultaneous use of position and draft controls for optimum field output.

Hydraulic Lift Pump: Gear type hydraulic pump delivers 17 l/min at rated engine speed. 24 l/min for 1500 kg capacity hydraulics.

Linkage

3 point category-I suitable for category-II type implement pins Lifting Capacity

1000 kgf at Lower Link Ends 1500 kgf at Lower Link ends (Optional)

Electricals

12 Volt, 88 Ah. Battery, starter motor & alternator. Instruments

Tractor meter with direction indicators, Fuel Gauge, Ammeter, Water Temp. Gauge & Oil Pressure Gauge.

Tyres:

Front : 6.00 X 16 Rear : 13.6 X 28 Wheel Track:

Front : 1200-1750 mm Rear : 1350-1900 mm Deluxe Features

Higher capacity hydraulic (1500 kg.) with improved sensitivity. * Concealed lockable battery near starter. Aesthetically designed heavy duty telescopic front axle beam. Telescopic stabilizers bars for easy adjustment and better implement stability. Adjustable sliding P.U. seat for operator's comfort. Centrally located horn switch on steering wheel (like cars) - for operational convenience. Oil immersed (multi disc) wet brakes. *

(*optional) Features

Horse Power - 48 SAE Improved fuel combustion system - lesser diesel consumption. Most modern oil Cooler - for longer life of engine. 8+2 speed gear box (combination of CM & SM Gears) with suitable speeds for haulage,

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field, straw making machine PTO available in 540/1000 rpm Dual Clutch for PO driven implements (Optional)

Specifications:


HP : 34 S.A.E. Type : 4 - Stroke, Direct Injection, Diesel Engine No. of Cylinders : 2 Bore and Stroke : 100 X 116 mm Displacement : 2204 cc Rated Engine Speed : 2000 rev/min Air Cleaner : 3 Stage Air cleaning system compromising of cycolonic pre-cleaner, Oil Bowl

and Paper element to enhance Engine Life Cooling System : Water Cooled with Oil Cooler for engine oil Transmission:

Clutch : Heavy Duty single dry plate type, 280 mm dia No. of Gears : 8 forward, 2 reverse speeds with high and low selector levels. Gear Speeds (Km/hr)

1 2 3 4 R Low 2.1 2.9 4.4 7.0 2.6 High 8.3 11.3 17.4 27.4 10.4

P.T.O.

21 Splines for 1000 rpm at rated engine speed. 6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional)

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Brakes

Heavy Duty Self energizing, water sealed disc brakes with parking brake for additional safety.

Steering

Heavy Duty single drop arm steering for high efficiency and comfortable drive. Hydraulic and Implement Linkage 2 Lever live hydraulic system having automatic position and draft with mix control.




Hydraulic Lift Pump: Gear type hydraulic pump delivers 17 l/min at rated engine speed. Linkage

3 point category-I suitable for category-II type implement pins Lifting Capacity

1000 kgf at Lower Link Ends Electricals

12 Volt, 75 Ah. Battery, starter motor & alternator. Instruments


Tyres:


Front : 1200 - 1750 mm Rear : 1350-1900 mm Deluxe Features

Concealed lockable battery near starter. Aesthetically designed heavy duty telescopic front axle beam. Telescopic stabilizers bars for easy adjustment and better implement stability. Adjustable sliding P.U. seat for operator's comfort. Centrally located horn switch on steering wheel (like cars) - for operational convenience. Features

Horse Power - 34 SAE Most modern air Cooler - for longer life of engine. 8+2 speed gear box (combination of CM & SM Gears) with suitable speeds for all farm

operations. Live hydraulics. Alternator - for powerful headlights and longer battery life. Water separator in fuel line for extra protection of fuel injection pump. PTO available in 540/1000 rpm. Low Diesel Consumption Ideal for all field and haulage operations. Ideal for paddy cultivation Shorter turning radius

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Specifications:


HP : 26.5 S.A.E. Type : 4 - Stroke, Direct Injection, Diesel Engine No. of Cylinders : 2 Bore and Stroke : 100 X 110 mm Displacement : 1728 cc Rated Engine Speed : 2000 rev/min Air Cleaner : 3 Stage Air cleaning system compromising of cycolonic

pre-cleaner, Oil Bowl and Paper element to enhance Engine Life

Cooling System : Water Cooled Transmission: Clutch : Heavy Duty single dry plate type, 254 mm dia No. of Gears : 8 forward, 2 reverse speeds with high and low

selector levels. Gear Speeds (Km/hr)

1 2 3 4 R Low 2.3 4.2 6.3 7.2 3.2 High 8.9 16.4 24.9 28.4 12.5 P.T.O. 21 Splines for 1000 rpm at rated engine speed. 6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional) Brakes Heavy Duty Self energizing, water sealed disc brakes with parking brake for

additional safety. Steering Heavy Duty single drop arm steering for high efficiency and comfortable drive. Hydraulic and Implement Linkage 2 Lever live hydraulic system having automatic position and draft with mix control.

Page | 23




Hydraulic Lift Pump: Gear type hydraulic pump delivers 17 l/min at rated engine speed.

Linkage 3 point category-I suitable for category-II type implement pins Lifting Capacity 1000 kgf at Lower Link Ends Electricals 12 Volt, 75 Ah. Battery, starter motor & alternator. Instruments


Tyres:


Front : 1200 - 1750 mm Rear : 1350-1900 mm Deluxe Features

Concealed lockable battery near starter. Aesthetically designed heavy duty telescopic front axle beam. Telescopic stabilizers bars for easy adjustment and better implement stability. Adjustable sliding P.U. seat for operator's comfort. Centrally located horn switch on steering wheel (like cars) - for operational

convenience. Features 8+2 speed gear box (combination of CM & SM Gears) with suitable speeds for all farm

operations. Live hydraulics. Alternator - for powerful headlights and longer battery life. Water separator in fuel line for extra protection of fuel injection pump. PTO available in 540/1000 rpm. Economical in haulage, ploughing, threshing and pump-set operations Shorter turning radius Ideal for paddy cultivation

Project 1

Elimination of water mixing in the engine oil

Project Leader : Mr. Rajendra Singh ( In House Quality )

Team Member : Mr. Satpal Parmer ( In house quality –Assembly )

Mr. Ashwani Kumar (Supplier quality – SEL)

Mr. R.k jain (Research and development)

Mr. Avatar Singh (SCPC)

Mr. Brij Lal (Quality)

Department of Quality Engineering | Swaraj Division | Mahindra & Mahindra Ltd.

Project 1: Eliminating / Reducing Water Mix in Engine Oil

Page | 24

Problem Identification and Definition |

Eliminate the rejection/wastage of the engine oil in engine assembly due to mixing of water in all

models of tractor which is observed in Re-work and Pre-delivery Inspection Stage in the plant

before dispatch. Its average in the last 5 months has been 4475 PPM at present while the target

is to achieve is 1000 PPM.

Component(s) under focus: Complete engine assembly.

Brief description of the problem |

Engine “M” oil is used in the engine for lubricating moving parts to reduce friction between them.

While checking the correct level of oil in the sump with the help of dipstick during pre-dispatch

inspection of the tractors, colour of the engine oil was found changed due to water mixing.

||Water mixing in engine oil leads to

1. Rejection of oil is a monetary loss to the company

2. Wastage of man hours in replacing defective oil

3. Wastage of oil leads to national loss and environment pollution

4. Engine paper oil filter swells and has to be replaced

5. Engine moving parts get rusted

6. Loss of lubricating properties of oil which may result even in engine

seizure


Page | 25

History of problem|

Dealer PDI (Pre-dispatch inspection) report and MQN (market quality news) had

given feedback for the water mix in the engine oil of the tractors of all models. This

water mixing leads to the loss of value of oil and also affects the life of the engine

components working inside the engine assembly. Based on the feedback from the

PDI area of the plant, same problems were also being faced in the plant also.

Tractors having such problem were taken for investigation and analysis for the

problem identification.

Supplier/ month

Aug’08 Sept’08 Oct‘08 Nov’08 Dec’08 Jan’09 Feb’09 Mar’09

Swaraj Engines Limited

1 3 1 1 10 6 7 6

Kirloskar Oil Engines Limited

8 4 4 3 9 2 1 1

Numbers of engines found to be defective from both the manufactures



Page | 26

Total number of cases observed from August ’08 to March ‘09


Page | 27

Observation| Recognition of the features of the problem

||Observation of the process

SEL Engine

with oil filled

KOEL Engine

empty

Engine

storage on

conveyor

SEL Engine

KOEL engine filled

with Oil filled by

Assembly

department

Engine

coupled

with

chassis

Tractor

washed and

cleaned with

high pressure

Problematic

zone

Tractor

dismounted

PDI

Tractor R/W.

Oil changed

NO

Dispatched If water

mix observed

YES

Tractor roller

tested

If water mix

observed

Tractor

R/W Oil

changed

YES

No



Page | 28

The problematic area – Tractors being washed and washed with high pressure

This washing of the tractors with high pressure takes place on the assembly line before the paint shop, where the engine assembly is washed, dried and then painted.


Page | 29

||Observation of symptoms

In certain cases oil level in oil sump is found high and water level in radiator low.

In other cases there is no rise in oil level.

In all the cases engine oil red colour turns whitish ( milky ) as shown in the photograph

The water-mix paste turns to a milky colour when it comes in contact with water in the oil



Page | 30

Air leakage test conducted on 5 engines reveals as under –

a. Air leakage observed from breather pipe joint in three cases –KOEl-2 & SEL-1

b. Air leakage observed oil filler cape in one case- SEL

c. Air leakage observed from dipstick one case – ASSEMBLY

A

B


Page | 31

||Observation of variation

52%48%

Supplier wise contribution in problem

KOEL SEL



Page | 32

Analysis| discovery of main root causes

The analysis of the problem lead to the formulation of theories and sub-theories in their logical

inter relationship. These came forward after experiments were conducted and brainstorming was

done with team members, line supervisor and work force.

|| Possible causes

The analysis of the problem led to following possible causes

1. Water may be entering through

a. Masking cap for Hour meter cable mounting if Masking cap–

i. fitment not as per SOP ( standard operating procedure)

ii. Loose fitted due to outer diameter under size

iii. (cap) is missing

b. Breather pipe inserting hole in Oil Filler Body if –

i. Excessive clearance between pipe outer diameter and hole in Oil filler body

ii. Breather pipe is not fully inserted

iii. Sealing material not applied as per the SOP

iv. Design is poor

c. Oil filler cap assembly due to

i. Non conformance of SOP

ii. Rubber plug ( bellow ) outer diameter undersize


Page | 33

iii. Bellow material not ok

iv. Bellow eccentric and not perpendicular with respect to cap

v. Plain washer corner sharp

vi. Inadequate design

d. Dipstick assembly if

i. Dip stick not seated fully

ii. Sealing ring damaged

iii. Sealing ring loose in groove

iv. Guide inner diameter over sized

v. Design not adequate

vi. Diameter over outer ring undersized

vii. Flash over plastic molding not dressed

e. Oil filler body

i. Blow hole in casting.

ii. Variation in diameter 60 mm.

iii. Variation in bore diameter 50mm.

f. MISC

i. Gap between Rubber Bush and Push Rod

ii. Leakage in joint between Fuel Injection Pump and Gear Casing

iii. Leakage in joint between Oil Filler Body and Gear Casing

iv. Excessive clearance between pipe outer diameter and hole in Oil Filler Body

v. perpendicularity of face with respect to bore



Page | 34

|| Cause and effect diagram| the cause and effect diagram gives a systematic overview of the problem


Page | 35

|| Probable causes selected for testing |establishing root causes

1) Breather pipe not inserted fully in hole.

2) Breather pipe not seated or eccentric.

3) Excessive clearance between pipe O/D and hole in Oil Filler Body

4) Breather Pipe fitment design inadequate.

5) Oil filler cap assembly not fully tightened as per SOP.

6) Bellow eccentric and not perpendicular w.r.t. cap.

7) Bellow material not as per requirements

8) Bellow O/D u/s after expansion i.e. tightening

9) Filler Body bore o/s

10) Dipstick not fully seated

11) Sealing ring loose on plastic body.

12) Dip Stick design not adequate.

13) Flash over plastic molding not dressed

14) Water accumulates inside oil filler cap.

15) Gap between Rubber Bush and Push Rod

16) Leakage in joint between Fuel Injection Pump and Gear Casing

17) Leakage in joint between Oil Filler Body and Gear Casing

O/D- Outer diameter u/s – under sized o/s - over sized SOP –standard operating procedure



Page | 36

||Testing of hypothesis

All the possible causes were tested after discussion with the team members and marked as a

valid reason or invalid reason accordingly.

Sr. no.

Probable causes

Testing and observations Conclusion

1 Breather Pipe

not fully inserted

in hole

Besides observation on defective tractors, for this

defect ,100 engine assemblies were visually

inspected in plant and were found OK

Hypothesis

invalid.

2 Breather pipe not seated or eccentric.

Visually inspected. No case found.

Hypothesis invalid.

3 Excessive clearance between hole in Filler Body & pipe Outer Diameter.

Failed in Air & Water leakage test

Hypothesis Valid.

4 Gap between

bush Outer

Diameter and

hole in Oil Filler

Body

Observation on 5 defective engines 26.945, 26.952, 26.958, 26.948 & 26.937mm. In addition to above Bush Outer Diameter checked with micrometer at SEL for 25 pieces. All pieces in between 26.93/26.958mm. Hence found OK.

Hypothesis

invalid.

I) Bush Outer

Diameter Under

Sized

ii) Oil Filler Body hole U/S

Specification: Hole size 27+.033/+0 Bore Inner

Diameter checked with plug gauge for 5 Defective

engines and 25 engines from the latest supply of

engines. All were found OK with plug gauge.

Hypothesis invalid.

5 Sealant

application not

OK

Failed in air & water leakage test. Air leakage test

was conducted at 2kg/ cm2 pressure on five

defective engines. Air leakage was observed in 3

engines at this point. Then possibility of water

leakage was checked by pouring water as shown in

Hypothesis

valid.


Page | 37

photograph. Leaking water can be seen inside.

In one such opened up case sealant application was

there but seemed to be inadequate.

Proper sealant was applied in this case and test was



Page | 38

re-conducted. In this case no air or water leakage

was found. Hence the reason is established.

When checked at SEL, application method was not

mentioned in SOP.

6 Sealant not

applied

While analyzing defective tractors & 50 other cases at SEL, it was found that although the sealant application was done, but sealant was not applied appropriately & the phenomenon was listed in point no. 5.

Hypothesis invalid.

7 Oil filler cap

assembly not

tightened

Observation on defective cases & randomly audited

50 cases in two shifts in plant no case was found

where the cap was not fully tightened.

Hypothesis

invalid.

8 Rubber plug

sealing not

effective

Out of 5 engines, water leakage was observed in one

engine because of this fault.

i ) Rubber Plug

eccentric and

not

perpendicular

w.r.t cap

100 pieces were checked with gauge at the supplier

end and 10 pieces were found defective as nut

welding fixture was not there.

Hypothesis

valid

ii) Rubber Plug

material not as

per requirement

Required material : Nit rile rubber

Rubber material of failed parts were checked and

found as per specifications.

Hypothesis

invalid

iii) Rubber Plug

head Outer

Diameter less by

design

50 Cases were checked for leakage. Seepage was

observed in 2 cases.

Hypothesis

valid

9 Oil filler cap

assembly Design

inadequate.

I)Steel washer

Leakage observed in1 out of 5 cases when water was

poured at this point.

There was metal to metal contact due to steel

Hypothesis

valid.


Page | 39

ineffective washer, As the hand tightening could not compress

the steel washer required enough to provide

effective sealing. When steel washer was replaced

with “O” ring , no leakage was observed.

10 Filler body Gap

between bush

Outer Diameter

& hole

i )Bore Over

Sized

Specified bore size: 50.8+0.25/*0.00 mm

Checked with Vernier for failed cases & 25 new

cases. It varied from 50.81 to 51.02 mm which was

within limits.

Hypothesis

invalid.

11 Dipstick not fully

seated.

Checked visually. No case was found among

defective and 100 other cases observed.

Hypothesis

invalid.

12 Dipstick “O” ring

sealing not

effective.

I)“O” Ring size & thickness not OK

Specification: Diameter 5.0 mm, Thickness 2.0 +/- .08

Observation on failed engine.

Hypothesis invalid.

ii) Groove

diameter under

sized

Specification Dia. - 4.99 /5.1 mm, Thickness- 1.98/ 2.04 mm

Found OK.

Actual : OK with Plug gauge

No case was found in 100 cases Checked.

Hypothesis invalid.

iii) Hole diameter over sized in Crank Case

Specification : 5.3mm + 0.1 with plug gauge

Actual : OK with Plug gauge

No case found in 100 cases checked

Specification: Dia. 9.0±0.03

Hypothesis invalid.

13 Dipstick design

not adequate.

Dipstick looses in 10 out of 100 Cases. Water

seepage was also observed .Thus Design needs

Hypothesis

valid.



Page | 40

improvement. As per given tolerances on hole size,

Maximum hole diameter. = 9.03mm

Min. diameter over “O” ring after fitment in groove =9.04mm

So sealing compression on "O" ring is 10 micron only.

Minor flash / oval-ness or eccentricity of “O” ring groove

diameter in plastic mold made the ring free (without

compression) on one side. Thus making way for water.

Besides Dipstick Head design being flat is not helpful in

preventing the water reach “O” ring.

14 Flash over plastic

molding not

dressed.

I)Die not

reworked

Water seepage was observed due to flash over plastic

Mold. It causes the dipstick tilt to one side thus creating

gap on one side of the “O” ring

In one case of engine oil contamination by water,

Dipstick had conspicuous flash on parting line. This

dipstick was tried on loose Crank Case (as shown in

photograph) by pouring water.

Water seen dripping across “O” ring

Supplier has no Die rework schedule.

Again all these defective dipsticks were refitted after

proper dressing and no leakage were observed. Hence the

problem is established.

Hypothesis

valid


Page | 41

Air leakage test|||

Air leakage test is done to find out any points of leakage in the equipment. In the present

situation the air leakage test was performed on the engine assembly to find out and

leakage point from where water was supposedly getting mixed with the engine oil in the

sump.

After the test was performed, following results were observed

Air leakage observed from breather pipe joint in three cases –2 KOEL engines & 1 SEL

engines.

Air leakage observed oil filler cape in one case - SEL

Air leakage observed from dipstick one case – ASSEMBLY

|| Root causes identified

1. Sealant not applied properly between Breather Pipe bush Outer Diameter and Oil Filler

body Inner Diameter

2. Rubber Plug (Bellow) eccentric and not perpendicular w.r.t. cap. (Oil filler cap).

3. Rubber Plug head Diameter less as per Design.



Page | 42

4. Steel Washer ineffective in Oil Filler Cap Assy.

5. Dipstick design not adequate.

6. Flash over Plastic Outer Diameter due to plastic molding (Dipstick).

Actions| Actions Taken To Eliminate Root Causes

Sr.No. Root Cause Remedial Action

1 Sealant not applied properly (breather pipe bush ) SOP provided and operators were educated as per SOP at the suppliers end

2 Rubber plug eccentric and not perpendicular w.r.t. cap (oil filler cap)

New welding fixture designed ( J68080 ). Alternate design for nut welding provided (vides drawing no. V085633/1)

3 Rubber plug head diameter less Diameter changed from 61mm to 63.5 mm

4 Steel washer ineffective in oil filter cap assembly Design changed 1 ) Steel washer replaced with “O” ring

5 Dipstick design inadequate Dipstick head made cup shaped “O” ring thickness increased from 2mm to 2.15 mm

6 Flash over plastic molding (dipstick) Dye re-work schedule made (50,000 cycles )


Page | 43

Check| Confirmation of effectiveness of actions

Source of data : testing and PDI

1700

1800

1900

2000

2100

2200

2300

March WK1 March WK2 March WK3 March Wk4

Week Wise Rejection for the defect - Water mix in Engine oil ( in PPM)

Month Wise Rejection for the defect - Water mix in Engine oil ( in PPM)

Target: 1000

PPM PPM



Page | 44

|| Tangible & Intangible Benefits

5.2 Return on investment

Following are the areas from where Impact of cost due to failure was reduced

@Return on investment (expected)

Investment- Nil

Cost of mobile Oil (Multi grade) = Rs. 463

Cost of Paper element (P719101) = Rs. 27

Cost of Diesel (3.5 Lts) = Rs. 100

Cost of Labour (Rework) = Rs. 100

5.3 Intangible benefits ----- 1) Engine life improved.

2) Waste oil disposal problem solved.

3) Timely dispatch of tractors.

5.4 Adverse effects (If any) -------- Nil -----


Page | 45

Standardization| Permanent Elimination of Problem

List of documents changed ||

SOP for sealant application at Engine suppliers end

Permanent welding fixture (J68080) designed and provided at supplier end. Alternate design for nut welding provided vides Drawing no.V085633/1. Resistance welding (weld nut) option in place of tack welding was given

Drawing released Rubber Plug head diameter changed from Ǿ61mm to Ǿ63.5mm (vides drawing no. V085633/2)

Oil Filler Cap Assembly o ring introduced instead of plain steel washer (For better sealing) vides drawing

no.V085633. o Concentricity of Ǿ 10±0.2 hole w.r.t. Ǿ65.5 of Cap mentioned vides Drawing

no.V085633/3

Dipstick modified o Head made Cup type (Drawing no. V085632 o b) “O” Ring thickness increased from 2mm t0 2.15mm Clearance of altered parts obtained

thru΄ P PAP. 6.2 Die rework schedule provided to suppliers.



Page | 46

Conclusion|

|| Lessons Learnt

1. Where ever possible , fool proofing should be done

2. Adequate design considerations before implementation

3. CFTs are very important for fast project results

4. Process adherence is must for good results

5. SOPs should be displayed at all the work stations

|| Horizontal developments

The gain of all the achievements will be automatically achieved in Plant -2

|| Critiquing

The selection of team members was very judicious. It went right up to the completion of the project. In the beginning, the magnitude of the work involved in the project was not realized. The pace of the project was rather slow so all members had to over exert in the lateral part of the project. The work should have been started at war footing from the very outset.


Page | 47

Final report | Submitted to the plant management on the requested pattern

Project Resolution Format – Early Hour Failures

M & M Swaraj tractors division.

Title of Project: Reducing problem of water mix in engine oil. Date of

Implementation:

OBJECTIVE

TO resolve PDI and early hour failure (R/1000) in the tractor before and after

dispatch.

COMPONENT(S)

UNDER FOCUS Complete engine assembly

BACKGROUND /

OBSERVATION OF

FIELD DATA

Dealer PDI report and market quality news feed back for the water mix in the

engine oil of tractor. Which leads to loss of value of oil and also effect the life of

engine components working inside the engine assembly.Based on the feed

back, same problem were being faced in the plant also. Tractors having such

problem were taken for the investigation and analysis for the problem

identification.

Water mixed in engine oil on tractor in the plant and MQN as given below

Supplier/

Month

Jan-09 Feb-09 March Total

SEL 6 7 6 19

KOEL 2 1 1 4

DESIGN

SPECIFICATIONS

No water ingress into the engine oil being used for lubricating the running

various engine parts and components.



Page | 48

ROOT CAUSE

ANALYSIS

For finding the root cause of the problem. A reverse Engineering method were

developed and implemented to find the real cause. A dry air test method

design and developed as shown in the fig. test was conducted on the

problematic engine. Air leakage observed through the following points like:

Air Leakage Test


Page | 49

Sr. No. Defect Frequency

1.

2.

3.

4.

5.

6.

Oil filler cap not fully tightened.

Breather pipe not inserted in the oil teller

body; gaps remain left between the bush

Outer dia. and Inner Dia. of the housing.

Oil teller body not seated with gear casing.

F. I. P assembly not fully seated with gear

casing housing due to loose of

manufacturing nut. Tappet cover

manufacturing nut loose; gasket not seated

(torn or not match with casting profile).

Push rod bottom rubber plug damaged

during assembly.

Dip stick not fully pressed.

1

3

2

2

3

1

SOLUTION

IDENTIFICATION

Dry air test recommended to both engines supplied and introduced RTU rubber

solution application, tightening of fasteners; care to be taken in push rod

assembly, etc.

SOLUTION

VALIDATION SOP made and implemented for the above said solutions.

SOLUTION

IMPLEMENTATION All the recommended solutions has been implemented.

CONCLUSION Problem has drastically reduced

FURTHER ACTION

PLAN - TRACKING

/ HORIZONTAL

DEPLOYMENT

Will be monitoring for further, for some time being till the fool proofing not

done at the supplier end.

Audits and checks are being carried out for the holding gains.

Project 2

Elimination / Reduction of diesel leakage from fuel cock assembly

Project Leader : Mr. Rajendra Singh ( In House Quality )

Project under completion – In final stage

Project 2: Eliminating / Reducing Diesel Leakage from fuel cock assembly

Page | 51

Problem Identification and Definition |

Eliminate Rejection / Wastage of Diesel due to leakage from fuel cock Assembly – High Diesel

leakage from fuel cock assembly. Its average in the last 4 months has been 7408 PPM at present

while the target is to achieve is 500 PPM.

Brief description of the problem |

Fuel Cock Assembly is connected between the Fuel Tank Assembly and to the Water Separator

through Fuel Pipe, Fuel Cock Assembly is used in the diesel circuit to stop and open the Diesel

flow to the feed pump by gravity. Fuel cock Assembly is connected to the Fuel Tank with a sealing

Rubber ring between Fuel Cock and Fuel Tank. A Fuel Pipe is used to carry the Diesel to Water

Separator with a banjo bolt and two metallic sealing washers (Aluminum)

|| The Diesel Leakage through Fuel Cock Assembly leads to

1. Loss of Diesel, which is monitory loss to the customer and to company also 2. Entire area below the Fuel tank Assembly becomes oily which is major irritation 3. Leakage accumulate on the parts showy shabby looks and eye sore to the customer 4. If the complaint is not attended immediately, this may lead to engine stop 5. It also leads to delay of the finish goods dispatch. 6. Environment of safety



History of problem|

Based on the gate audit of the quality engineering. Reference 10% Audit report.

Based on the gate audit of the quality engineering. Reference 10% Audit report

0

2000

4000

6000

8000

10000

12000

PP

M


Page | 53

Observation| Recognition of the features of the problem

||Observation of the process

Correction

stage

Fuel tank assembly fit on

the tractor along with fuel

cock Assembly

Fuel cock Assembly fitment

to the fuel Tank Assembly

Rework

OK Tractor advised to

store

Yes No

Rework and

Correct PDI at STD before

Dispatch

Roller

Testing

Sent to

QP6

stage

Road

Testing

No

Yes

OK

Leakage

Dispatch



||Observation of symptoms

Heavy leakage of diesel on tractors in rework.

P.D.I audit (leakage)

IQS score

1. I5 cases of Diesel leaksge from PDI area & 5 cases from tractor re-work area were studied.

In 15 Cases leakage was observed from bottom face of banjo bolt ,in 4 case mountings

with tank & 1 case from Fuel cock knob.

2. Leakage from the bottom face of the banjo bolts

3. This defect observed in all models of tractors.

4. Torque value of 18 lbsft for banjo bolt tightening was observed under torque with dial

type torque wrench. In other 4 cases leakage found from interface of Fuel cock Assembly

& Fuel Tank Assembly. In one case leakage was observed from Fuel Cock knob.


Page | 55

||Brief Description

Fuel cock assembly is used in fuel line of the tractor assembly. Its main function is to cut-

off or release the fuel to the fuel line. Fuel cock assembly is consists of main parts like

body, knob, and rubber sealing ring. Fuel cock is fitted to the main tank with rubber

ring.Fuel pipe is fitted with fuel cock with banzo and aluminium washer.

Interface of Fuel Cock

& Fuel Tank Assembly

Upper leakage

point AL washer

Bottom leakage

point AL washer Diesel Off / On

Knob leakage

point

Fuel Cock

Assy

Banjo bolt



Fixed Torque wrench

||Observation of variation

Observation of leakage from fuel cock Assy and joints on 20 defective tractors. The Following

observations were made:-

Tractors belong to both the shifts. Assembly was done by different persons and at

different times. So there is no variation from

Shift to Shift

Person to Person

Time to time


Page | 57

Analysis| discovery of main root causes

The analysis of the problem lead to the formulation of theories and sub-theories in their logical

inter relationship. These came forward after experiments were conducted and brainstorming was

done with team members, line supervisor and work force.

|| Possible causes

The analysis of the problem led to the following possible causes Diesel leakage may have occurred due to

1. Carelessness of the workmen

a. Torque wrench not used b. Assembly not as per Standard Operating Procedure (SOP) c. SOP not adequate d. Wrong torque wrench used e. Person not skilled

2. Machine

a. Wrong impact no torque b. Torque Ranch Setting

i. Setting over ii. Setting under

3. Material

a. Fuel pipe rejected i. Face dent or damage

ii. Crimping not ok iii. Butting face not ||to each other

b. Al. washer i. High hardness

ii. Face dented



c. Fuel Tank ‘O’ Ring Seat depth access d. Banjo bolt defective

i. Circular finish NOT OK ii. Concentricity of Ø14 and M14x1.5 thread portion not ok

iii. Thread portion length less or more iv. Thread inclined w.r.t face

e. Fuel cock assembly i. M5 hole through

ii. M14x1.5 mot ┴ w.r.t to face iii. Knob ‘O’ ring damaged iv. Material porosity

f. Sealing mtg. ‘O’ Ring i. Damage/cut

ii. Outer diameter undersized 4. Method

a. Grease not applied b. Sop not displayed c. SOP not made d. No holding device used e. ‘o’ ring setting Not OK


Page | 59

|| Cause and effect diagram| the cause and effect diagram gives a systematic overview of the problem

MATERIAL

Setting

under

SOP not made

Grease not

applied

Torque wrench

setting

Setting

over

No holding

device used

SOP not display

‘O’ Ring

setting not

ok

FUEL COCK

LEAKAGE

Al. washer

Fuel pipe

rejected

Face dented

Fuel Cock Assy

M14x1.5 mot ┴

w.r.t to face

Banjo bolt

defective

Circular finish

not ok

Sealing mtg.

‘O’ Ring

Wrong torque

wrench used

SOP not adequate

Torque wrench

not used

Assy not as

per SOP

Concentricity of Ø14& M14x1.5

thread portion not ok

Thread

inclined

w.r.t face

Thread portion length less or more

M5 hole

through

Material porosity

Knob ‘O’ ring

damage

Crimping

not ok

Face dent

or

damage

Butting face not

// to each other

High

hardness

Fuel Tank

‘O’ Ring

seat

depth

excess

Damage/cut

O/D U/S

Person not

skilled

Wrong

impact no

torque

MAN METHOD

MACHINE



|| Probable causes selected for testing |establishing root causes

1. Banjo bolt under torque. Banjo bolt (M14x1.5 threading) 2. Washers face damage. 3. Washer hardness high. 4. Fuel cock M14 face (where banjo has to sit) not flat 5. Banjo bolt butting face not ┴ or to M14x1.5 thread axis. 6. Banjo bolt Ø 14 not concentric with m14x1.5 thread portion. 7. ‘O’ Ring diameter under size 8. ‘O’ Ring hardness excess. 9. ‘O’ Ring not seated in groove 10. Fuel Tank groove depth excess 11. M16x2 thread not ┴ or to groove. 12. Fuel Pipe faces not parallelism to each other. 13. Fuel cock assembly knob sealing rubber defective.

||Testing of hypothesis

All the possible causes were tested after discussion with the team members and marked as a valid reason or invalid reason accordingly.

Sr. No.

Probable Causes

Testing of hypothesis Conclusions

1 Banjo bolt under torque

On 15 defective tractors we have checked the leakage tractor testing of banjo bolt found under torque on 15 tractors. Specified = 18 lbsft Observed =12 -14 lbsft

Hypothesis valid.

2 Aluminum washer face

In all 15 defective tractor AL washer face checked all were ok

Hypothesis Invalid.


Page | 61

dented

3 Al washer High hardness

At random 10 Pc of Al washers checked for hardness. Given hardness = 40-42HB Observed = 40-41HB

Hypothesis Invalid

4 Fuel cock M16x2 face not flat

All fuel cock was checked for flatness with the help of calibrated square gauge. All pieces, were qualified the gauge.

Hypothesis Invalid

5 Banjo bolt Ø 14 not concentric with M14x1.5

Five banjo bolts removed from the defective tractor and checked with concentric gauge (J61405A). All were qualified the gauge. ┴ =.05 max.

Hypothesis invalid.

6

Rubber sealing ring not seated in fuel tank groove

In four out of 20 defective tractors when dismantled rubber ring found damage all sealing ring replaced with new ring fitted with tractor not leakage found.

Hypothesis valid



7 Sealing ring (P395208) diameter undersize & hardness variation

15 Sealing ring were checked for diameter & shore hardness. Diameter-ØO/D Specified = 16.5±.10 Ø O/D Observed = 16.5±.10

Thickness = 1.78±..076 Shore hardness - Specified = 65±5 Observed= 63-66

Hypothesis invalid.

8 Fuel Tank groove depth excess & M14x1.5 thread not ┴ or to the groove.

Five defective fuel tank were checked for depth & ┴ 0.1 or all were qualified in the gauge No. J61408. Squareness checking gauge number Also 100 pieces at random were also checked on line with gauge all were qualified.

Hypothesis invalid.

9 Fuel pipe butting not parallel to each

All defective pipes checked for parallelism with micro meter. All reading Specified = 0.1mm Observed = 0.09mm

Hypothesis invalid.


Page | 63

other

10 Fuel pipe butting not parallel to each other

In one case out of 20 , leakage observed from Fuel Cock knob when tested with air pressure at 1.5 kg /cm2

Hypothesis Valid

|| Root causes identified

1. Banjo bolt found under torque. 2. Rubber sealing not seated in groove 3. Fuel leakage from fuel cock knob



|| Results of good product tests

10 tractors with no diesel leakage through fuel cock Assy and their joints were checked. For verifying the observed possible root cause the following observations were made:-

All the banjo bolts were fully tighten at 18 lbsft torque.

Sealing rings were perfectly ok.

No Fuel leakage from fuel cock knob

Actions| Actions Taken To Eliminate Root Causes

|| Development of remedies

|| Final remedies

Sr. no.

1.

Root Cause Banjo bolt under torque

Remedial Action Standard operation process (SOP) made and worker educated for adhering to this.

S.NO Root cause Why Why Why

1.

2.

3.

Banjo bolt under torque Rubber sealing ring not seated in fuel tank groove. Diesel leakage from fuel cock knob

Torque wrench not used Assembly not done properly Air leakage performed

workmen not aware about SOP SOP not followed To find out leakage point

SOP not prepare SOP not made


Page | 65

2.

3

Rubber sealing ring not seated in fuel tank groove. Fuel leakage from fuel cock knob

Standard operation process (SOP) made and worker educated for adhering to this. System designed

Final report |

The final report, testing and checking of this project is still underway. The project is still under

process

project end semester report- 6 months industrial training - mahindra and mahindra- swaraj tractor...

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