EVALUATION OF BERAING LOSSESA CASE STUDY

AT

SIX MONTHS TRAINING REPORT

 SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE

AWARD OF THE DEGREE OF  

BACHELOR OF TECHNOLOGY(MECHANICAL ENGINEERING)   

SUBMITTED BY

PARMOD KUMAR (ROLL NO.81202114069)

DECEMBER 2011

PUNJAB COLLEGE OF ENGINEERING & TECHNOLOGY, LALRU MANDI (MOHALI)

PUNJAB TECHNICAL UNIVERSITY, JALANDHARPUNJAB, INDIA

PUNJAB COLLEGE OF ENGG. & TECH., LALRU MANDI

CANDIDATE'S DECLARATION  I hereby certify that the work which is being presented entitled “ANALYSIS & EVALUATION AT ESCORT LTD.(HARYANA)”in partial fulfillment of requirements for the award of degree of B.Tech. (Mechnaical engg,.) submitted in the Department of Mechanical Engg. At Punjab College, lalru under …Punjab Techanical univ name….. is an authentic record of my own work carried out during a period from Jan, 2010 to Dec, 2011 under the supervision of Mr Deepak khanna.The matter presented in this training has not been submitted by me in any other University / Institute for the award of b.techDegree.

 Parmodkumar This is to certify that the above statement made by the candidate is correct to the best of my/our knowledgeEr. ……………. Dr…………….. Associate Professor Former Director Deptt of Mechanical Engg. P.C.E.T .institute Technology ...Engineering College,LALRU

The B.TECH Viva-Voce Examination of …….... NAME.................. has been held on ____________ and accepted

Signature of supervisor(s) Signature of Examiner

Er. BEANT SINGH Assistant Professor & Head, Deptt. of Mechanical Engg. Pcet,lalru (LALRU)

CERTIFICATE

This is to certify that training entitled “ANALYSIS & Upgradtion in Escort Ltd.

(Haryana)” submitted by Mr.Parmod kumar in partial fulfilment of the requirement for

the award of the degree of Bachelor of Technology in Mechanical Branch. Of Punjab

Techanical University, Jalandhar is a record of student’s own work carried out under

our supervision and guidance.

To the best of our knowledge, this training has not been submitted in part or full

elsewhere in any other University or Institution for the award of any degree or diploma.

SUPERVISORS

(Er. ) (Dr. )

COUNTERSIGNED

Er........................ Assistant Professor & Head, Deptt. of Mechanical Engg. Pcet,lalru

ACKNOWLEDGEMENT I am highly thankful to the Director,…….……..Engineering College, lalru, for his

patronage and rendering great help to me for completing the present training.

I am also thankful to Er. ………………… Asstt Prof. and Head, Department of

Mechanical Engineering ,pcet, for rendering constant guidance and encouragement in the

matter of completion of training

Besides I pay my thanks from the core of my heart to my guides Er.R, Associate Prof.,

Department of Mechanical Engineering, pcet, and Dr. …., ……..institute of

Technology ;pcet for their valuable guidance from time to time which help me to carry

out this uphill task. In absence of their guidance perhaps it might have rendered helpless.

I will remain obliged to them for whole of my life.

The help in completion the present training is also attributable to Er.Beant singh,

Astt.Prof, PCET, Lalru for their guidance and Mr. RAVISH RATHOR (HR), Escort Co.

Ltd......which goes a long way to complete the work. I thankfully acknowledge their help.

 I express my deep sense of gratitude to Mr.DEEPAK KHANNA, Warranty Manager,

and my friends Mr.UMED SINGH ,MAHINDER SINGH from Escort Co. Ltd, Faridabad

who have not only permitted me to carry out this work in their company but have also

provided all facilities for successful completion of my training

I am also thankful to other faculty members of Mechanical Engineering Department of

pcet for their intellectual support throughout the course of this work.

Finally indebted to all whosoever have contributed in this training work.

 

 Parmod kumar

PREFACE

WITH IMMENSE SINCERITY AND PLEASURE I HAVE COMPLETED

MY TRAINING AT WELL-DEVELOPED PLANT WITH LATEST

TECHNOLOGY OF ESCORTS LIMITED. THE PURPOSE OF

TRAINING IS TO TAKE ONE TECHNICALLY SOUND AND WORK

EFFICIENTLY AND EFFECTIVELY. IT HELPS ONE TO GET THE

REQUIRED KNOWLEDGE OF MANPOWER, ACTUAL WORK

REQUIREMENT, INDUSTRIAL AND HUMAN RELATIONSHIPS. THE

EXPERIENCE AT THE INDUSTRY DEALING WITH SUPERVISORS

AND ACTUAL WORK ENVIRONMENT GAVE ME SOME

PRACTICAL KNOWLEDGE WITH RESPECT TO WHAT WE HAVE

STUDIED THEORETICALLY FROM THE CURRICULUM BOOKS.

THIS SIX WEEKS TRAINING GAVE ME SOME KNOWLEDGE OF

THE THINGS STATED ABOVE OF THE INDUSTRIAL TRAINING

AND WE HAVE UTILIZED THE SAME TO THE BEST OF MY

EFFORTS.

O B J E C T I V E S O F I N D U S T R I A L T R A I N I N G

The main objective of semester project is to enable the students to:

Expose them to the industrial environment which cannot be simulated in the classrooms.

Apply theoretical knowledge to practical situations and to appreciate the limitations and knowledge gained in the classrooms.

Appreciate the importance of discipline, punctuality, team work, sense of responsibility, value of time & money and dignity of labor.

Formalise with various materials, process products and their applications along with relevant aspects of quality control and shop floor management.

Learn the operation of special plant and machinery.

Appreciate the need for co-ordination efforts of various persons at different levels in achieving set goals and targets.

Understand the scope, functions and job responsibility in industry.

Appreciate the need for scientific and practical approach to problem solving.

Get exposed to current technological developments relevant to subject area to which training pertains.

Understand the social, economic and administrative considerations that influence the working of industrial organization.

Appreciate research and development, improvements and innovations, expansion and diversification and modernization being planned and carried out in an industry.

PROCEDURE OF WARRANTY

When we can sale the tractors to the dealers then the TSM can be handled it each one.

TSM have 2 to 10 dealers if dealers have any problem in the tractors if there are some

small problems like horn not working the problem can be solved by TSM( territory saler

manager) at dealers place and if such big problem then company sent the claim from to

the dealer then he can fill the form and the original copy can be sent to warranty

department with the duplicate copy of claim form and he can also send letters .in this

letter he can define the problem and the parts can come to warranty department then at a

gate pall the warranty number can be denoted and the security can sent the parts in and

the assistance mangers can check the engine. They can check such like engine in wty.

And not an old engine ant then the engine to the engine workshop and the engine can be

properly checked or part can be replace and short out the problem then the problem of

engine can be tested and then send it to the dealer and this process is called RTV( return

to vendor) and also the cost of packing and transport can be mentioned and taken from

the vendor. Then the report can be sent by finance and the waste material or waste parts

can be counted and that can be collected by scrap dealers.

WARRANTY CLAIM FORM AND REPORTPRODUCT : In this column the things which have warranty like tractors etc

MODEL: In this column the name of the tractor is put like F1-60, FT-45,FT-35.

HOURS: In hours we can put the hours that is in the tractors can run how many hours

like the tractors can run only 345 hours then put this value ti the hours column.

DLR CODE: The dealer code is given by the company to the dealer. When dealer is

filled the dea;er code. And dealer code is different for different dealer.

TR SL NO. This is denoted for tractor serial no. and the tractor have different serial

no. and put on the tractor.

APPLICATION NO: If we can joint any thing in the application we can use this

application code.

IMPLIMET CODE: We can have any work in the place so we have code, that

code is known as implement no.

JOB CARD NO When dealer can saw the problem and customer is put on a sheet ,

this sheet is job card sheet and sheet number can be put, then we call that sheet as job

card no.

ENGINE NO. Number on the can be put and every engine have a separate number.

DATE OF PDI. Pre delivery inspection before sale called date of PDI

JOB DATE: When the dealer can be prefer the problem , then job card can done

after claim.

AGG..NO. Aggregate number can be number. In this column , number is put on the

damange parts.

DATE OF INSTALLATION: Dealer ship can sale the tractor in which date

called as date of instalaation.

FIRST INTIMATION DATE: The first intimation date is defined as the date

the in which the tractor is drawn . the customer can’t go to the company for that day he

can inform that date.

DEALER’S NAME AND ADDRESS: The name of the dealer and address

is mentioned

CUSTOMER’S NAME AND ADDRESS: The name of the customer and

the address is mentioned.

CAUSAL FAILED PARTS DETAILED: Causal have like a fist problem,

nut problem, can be lose and the other problem.

CONSEQUENTIAL : Then after causal the main problem is come out i.e.

consequential.

FINISH CODE: The code of parts which have failed called finished code.

DEFECT CODE: Company can make a different code for different product and

defect. These code is known as defect code.

SERVICE RECORD

TRANSIT: During transport any part is broken or filled , the transport form is filled.

FAILED PARTS DISPATCHED DETAILS VIA.: Dealership can send

the failed parts in detailed to the company.

RP NO./G.R.NO./POST PARCEL: In this part can send by which type.

TSM: It can make the SCR( service concerned repart).

CLAIM DISPOSAL: Dealer can send the claim desposal can done by company.

GR.NO : Godown Receipt no.

DINIEND: Process in which time.

COMPANY PROFILE

INTRODUCTION

Escorts ltd. is one of the pioneer manufacturer and exporter of Agri Machineries. The

company manufactures and exports Tractors and Tractor Parts, Diesel Engines, Gears,

Shafts, Gear boxes, Engine blocks, Crankshafts, Cylinder Heads, Connecting rods and

Spindles. They also offer brakes, couplers, shock absorbers, rail fastening systems,

composite brake blocks and vulcanized rubber parts. The company through their

subsidiaries operates in the ITES and financial services sectors.

HISTORY

Escorts ltd. was incorporated in the year 1944 as Escorts Agents ltd. in Lahore. In

the year 1951 Escorts established India‟s first private institute of Farm

Mechanization at Delhi and in year 1953 Escorts (Agents ltd.) and Escorts

( Agriculture and Machines) ltd. merged to form Escorts Agents Pvt. Ltd. the

company was converted into a public limited company in December 1959 and

subsequently the name was changed to Escorts Ltd. in January 1960.

In year 1961, Escorts Tractors ltd. made a technical and financial joint venture

with the global giant Ford Motor Company, USA for manufacturing Ford Tractors

in India. And in February 1, 1971, the first tractor FORD 3000 rolled out of the

factory.

1n 1977, the company set up their first independent R&D center namely Escorts

Scientific Research Center at Faridabad. Also, they set up their second plant at

Bangalore for manufacturing piston assemblies. In 1979, they made collaboration

with JCB Excavators Ltd., UK for manufacturing of Excavators.

In 1980, the company forayed into healthcare and set up Escorts Hospital and

Research Center in Faridabad. In 1984, company signed an agreement with the

Japanese bike giant Yamaha to manufacture motorcycles with Yamaha technology.

Also, they made collaboration with Jeumont Schneider of France and Dynapac of

Sweden to manufacture EPABX systems and vibratory road compactors

respectively.

In 1997, the company made a joint venture agreement with New Holland and

launched Farmtrac Tractor. Also, they made a joint venture with First Pacific

Company of Hong Kong and formed Escotel Mobile Communications. In 1998, the

company launched Powertrac tractors. They signed a MoU with Long

Manufacturing Company of USA for setting up a joint venture in USA.

1n 1999, the company signed a MoU with a Polish Company POL-MOT for

assembling, manufacturing and marketing of Farm Machinery. In September

1999, they set up a subsidiary namely, Escosoft Technologies Ltd. in the

Information Technology Sector.

During the year 2001-02, the company sold their 26% shareholdings in Yamaha

Motors Escorts Ltd. they entered into an agreement with Claas KgaA, Germany,

their joint venture partner in Escorts Claas Ltd. for sale of their 60% equity in the

joint venture for a consideration of Euro 13.2 million. During the year, Escorts

Heart and Super Speciality Institute Ltd., Escorts Heart Centre Ltd., Automatrix

India Pvt Ltd and Escorts Research and Development Ltd. became the subsidiary

companies.

In January 2004, the company entered into an agreement with Idea Cellular Ltd.

to divest their share in Escorts Telecommunication Ltd.

In September 2005, the company entered into an agreement with Fortis

Healthcare Ltd to divest their shares in Escort Heart Institute and Research Centre

Ltd for a consideration of Rs 520 crore.

During the year 2005-06, tha company set up a new manufacturing facility in

Rudrapur, Uttrakhand for manufacturing of new range of railway equipment. The

company sold their stake in in the software companies and all divested 49% stake

in joint venture, Carraro India Ltd. in which the company is getting out of all the

unrelated business and to remain focused on the three core businesses.

During the year 2006-07, the company embarked on entering into the

manufacturing of shock absorbers for commercial vehicles.

Throughout the evolution of Escorts, technology has always been its greatest ally for

growth. In the over six decades of their inception, Escorts has been much more than just

being one of the India‟s largest engineering companies. It has been a harbinger of new

technologies, a prime mover on the industrial front, at every stage introducing products and

technologies that help take the country forward in key growth areas. Over a million tractors

and over 16,000 construction and material handling equipments that have rolled out from

the facilities of Escorts, complemented by a highly satisfied customer base, are testimony

to the manufacturing excellence of Escorts. Following the globally accepted best

manufacturing practices with relentless focus on research and development, Escorts is

today in the league of premier corporate entities in India.

Technological and business collaboration with world leaders all over the years, globally

competitive indigenous engineering capabilities, over 1600 sales and service outlets and

footprints in over 40 countries have been instrumental in making Escorts the Indian

multinational. Today, when the world is looking at India as an outsourcing destination,

Escorts is rightly placed to be the dependable outsourcing partner of world‟s leading

engineering corporations looking at outsourcing manufacture of engines, transmissions,

gears, hydraulics, implements and attachments to tractors and shock absorbers for heavy

trailers and armoured tanks.

In today‟s Global Market Place, Escort is fast on the path of an internal transformation,

which will help it to be a key driver of manufacturing excellence in the global arena.

ESCORTS (AGRI MACHINERY GROUP)

Background

In 1960, Escorts set up the strategic Agri Machinery Group (AMG) to venture into

tractors.

In 1965, the company rolled out its first batch of tractors under the brand name of Escort.

In 1969, a separate company Escorts Tractors Ltd., was established with equity

participation of Ford Motor Co., Basildon, UK for the manufacturing of Ford agricultural

tractors in India.

In 1996, Escorts Tractors Ltd. formally merged with the parent company Escorts Ltd.

Technologies

Escorts AMG has three recognized and well accepted tractor brands, which are on distinct

and separate technology platforms.

Farmtrac: World class premium tractors, with single reduction and epicyclic reduction

transmissions from 34 to 75 hp.

Powertrac: Utility and Value-for-money tractors, offering straight axle and hub-

reduction tractors from 34 to 55 hp. India‟s No. 1 economy range-engineered to give

spectacular diesel economy.

Escort: Economy tractors having hub-reduction transmission and twin cylinder engines

from 27 to 35 hp. Pioneering brand of tractors introduced by Escorts with unbeatable

advantages.

INTERNATIONAL SUBSIDIARIES

Escorts AMG has two international subsidiaries.

Farmtrac North America LLC in USA

Farmtrac Tractors Europe Sp.z.o.o. in Poland.

SWOT ANALYSIS

STRENGTHS

Company is having good image in the market.

Always able to deliver the product in time.

Excellent distributorship network across India.

The use of latest technology.

Good quality standards of production.

Provide better services all the time.

WEAKNESSES

High prices as compared to the market

OPPORTUNITIES

The growing domestic demand for food grains and agri products promises a very

good future for company‟s core business.

India being a major exporter of grains and other Agri products can increase

demand both for domestic and international market resulting more sale in this sector

especially TRACTORS.

Government upliftment towards the loan waiver scheme can also help the farmers

to attract towards the tractors.

New technologies are invented for the production of the tractors which can help the

company to produce tractors at a much cheaper rate and in less time.

Government launching new schemes for the farmers to buy latest technologies for

their farming techniques. So this sector is having wide scope to enhance its sales

which results in an increase in its market share.

THREATS

The sales of tractors are seasonal according to the requirement of the farmers.

Even now, the farmers are unaware about the schemes and the upliftment made by

the government.

Many of the farmers are illiterates and does not know the various uses of tractors.

LITERATURE REVIEW

India is mainly an agricultural country. Agriculture in India is unique in its characteristics,

where over 250 crops are cultivated in its varied agro-climatic regions, unlike 25-30 crops

grown in many of the developed nations of the world. Agriculture is one of the most

important sectors of the Indian economy contributing 18.5 percent of national income,

approximately 25 percent of India‟s GDP, about 18 percent of total exports, supporting

two-thirds of the work force and employ about 62 percent of the population.

Tractors are part of agricultural machinery industry and forms an integral part of farm

mechanization and plays a very crucial role in increasing productivity. Tractor is used for

multitude of uses, it is used in agriculture for both land reclamation and for carrying out

cultivation of various crops. It is also employed for carrying out various operations related

to raising of crops by attaching suitable implements and to provide the necessary energy for

performing various crop production operation involved in the production of agricultural

crops. Tractors are capital intensive, labour displaying used as a mode of transport, in

electricity generation, in construction industry and for haulage operation.

As a Green Revolution in the sixties, the total food grain production increased from a mere

50.8 million tonnes during 1950-51 to 217 million tonnes in 2009-10 and productivity

increased from 522 kg/ha to more than 1,500 kg/ha. The increase in production of food

grains was possible as a result of adoption of quality seeds, higher dose of fertilizer and

plant protection chemicals. Irrigation played a major role in increasing the productivity.

Increased cropping intensity and higher quantity of inputs can no longer be effectively

managed by animal power alone and, therefore, farmers adopted tractors, irrigation pumps,

harvesters and power threshers extensively.

HISTORY

At the time of independence the level of mechanization was low so the government started

investing in establishing agricultural research farms and colleges and large scale

irrigational schemes to improve the situation. The five year plans during the 1950‟s and

1960‟s aggressively promoted rural mechanization through joint ventures and tie-ups

between industrialists and international tractor manufacturers. Tractor came to India

through imports and later on the manufacturing started with the help of foreign

collaborators the manufacturing process started in the year 1961-62. Despite the

aggressiveness the production of tractors grew slowly in the first three decades.

The history of tractors in India can be described in following phases:-

1945 to 1960

War surplus tractors and bulldozers were imported for land reclamation and cultivation in

mid 1940‟s. In1947 Central and State Tractor Organizations were set up to develop and

promote the supply and use of tractors in agriculture and till 1960, the demand was met

entirely through imports. There were 8,500 tractors in use in 1951, 20,000 in 1955 and

37,000 by 1960.

1961 to 1970

Home production began in 1961 with five manufacturers producing a total of 880 units per

year. By 1965 this had increased to over 5,000 units per year and the tractors in use had

risen to over 52,000. By 1970 annual production had exceeded 20,000 with over 1,46,000

units working in the country.

1971 to 1980

Six new manufacturers were established during this period although three

companies (Kirloskar Tractors, Harsha Tractors and Pittie Tractors) did not survive.

Escorts Ltd. began local manufacturing of Ford tractors in 1971 in joint

collaboration with Ford, UK and total production climbed steadily to 33,000 in

1975 reaching 71,000 by 1980.

1981 to 1990

Five new manufacturers began production during this period but only one among

them survived due to increased competition in the market place. By 1985 annual

production exceeded 75,000 units per year and by 1990 it crossed the mark of

1,40,000 units when the total in use was about 1.2 million. Then India-which was a

net importer till seventies became the exporter in the 1980s mainly to the African

countries.

1991 to 1997

Since 1992, obtaining of the license was not necessary for the tractor manufacturing

in India. Annual production exceeded 255,000 units and the national tractor

population had passed the two million mark. India now emerged a one of the world

leaders in the tractor production.

1997 to 1999

Five new manufacturers have started production since 1997. In 1998 Bajaj Tempo,

already well established in the motor industry, began tractor production in Pune. In

April of the same year New Holland Tractor (India) Ltd launched production of

70 hp tractors with matching equipment. The company made a $US 75 million

initial investment in a state of the art plant at Greater Noida in Uttar Pradesh state

with an initial capacity of 35000 units per year. Larsen and Toubro have

established a joint venture with John Deere, USA for the manufacture of 35-65 hp

tractors at a plant in Pune, Maharashtra and Greeves Ltd will produce Same tractors

under similar arrangements with Same Deutz Fahr of Italy. Looking to South

American export markets Mahindra and Mahindra are also developing a joint

venture with Case for tractors in the 60-200 hp range.

1999 to present

Facing market saturation in the traditional markets of the North West (Punjab,

Haryana and eastern Uttar Pradesh) tractors sales began a slow and slight decline.

By 2002 sales went below 200,000. Manufacturers headed towards the eastern and

southern India markets in an attempt to reverse the decline, and began exploring the

potential for overseas markets. But sales remained in a slump. By 2004, once again

there was a slight increase in sales due to stronger and national and to some extent

international markets. But by 2006 sales once again were down to 216,000 and now

in 2007-08 have slid further to just over 200,000. 1

Present Scenario

India‟s gross cropped area which is 42 percent of the total geographical area is next only to

Unites States of America and Russia along with fragmented land holdings has helped India

to become the largest tractor market in the world. But because of its very low penetration

level in India as compared to the world standards it drops to the eighth position in terms of

total tractor in use. Also the penetration levels are not uniform throughout the country.

While the northern region is now almost saturated in terms of new tractor sales, the

southern region is still under penetrated. The medium horse power category tractors, 31-40

HP, are the most popular in the country and fastest growing segment.

Indian tractor industry is comparatively young as compared to the world standards and has

expanded at a spectacular pace during last four decades. Consequently, it now occupies a

place of pride in India‟s automobile industry. U.S.A., U.S.S.R. and only a few Western

European countries exceed the current production of tractors in India but in terms of

growth, India‟s growth are unmatched even with countries of long history of tractor

manufacturing. About 20 percent of world‟s tractor production occurs in India only. The

spectacular achievement reflects the maturity and dynamism of tractor manufacturers and

also the policies adopted by the government to enable it to effectively meet the demand.

The tractor industry in India has made a significant progress in terms of production and

capacity as well as indigenization of technology. It is a typical sector where both imported

technology and indigenous developed technology have developed towards meeting the

overall national requirements. In India tractor industry has played a vital role in the

development.

SOME RECENT ACHIEVEMENTS

• Won a major export order from the Government of Ghana worth $8.5 million. This order is for the supply Escort's Farmtrac range of tractors and other farm mechanisation implements Currently, Escorts commands 80 percent market share in Ghana.

• Its wholly owned subsidiary, Escorts Agri Machinery Inc., USA, has acquired 100% equity in the Polish company, Farmtrac Tractors Europe.

N E W K N O W L E D G E A N D E X P E R I E N C E G A I N E D S O F A R

N E W K N O W L E D G E

Machining of resting pads on the cylinder block. These are made so that the job can be placed horizontally on the machine and thus prevent taper.

The concept of manufacturing holes. These are two holes drilled, hole milled and then reamed to very high tolerances. These play a very important role in the location and alignment of the other operations that are performed on the casting. All the fixtures of the subsequent operations have two locator pins one diamond and the other round which go into these manufacturing holes and after this the job is other clamped hydraulically or mechanically. Hence if the orientation of these holes is slightly deviated, the locations of the subsequent operations will also he deviated and the casting becomes scrap.

Engines without cylinder liners. Most of the engine designs are such that they have cast cylinder bores which are machined to very fine tolerances and they do not make use of cylinder lining. In due course if the bore wears off the bore is machined (boring is done) and then a liner is fitted.

GPM (general purpose machines) and SPM (special purpose machines).

Machining centers; they do high speed wet machining. They make use of carbide tip tools. Palletization is also done here, in this while one job is being machined the other is fixed to the pallet, this saves setup time and increases productivity

Honing: this process creates diamond shaped pattern on the cylinder bore and gives very fine tolerances. These patterns retain the oil thus reducing the friction between the piston and cylinder.

Broaching: had a look at horizontal surface broach.

Different special purpose gauges. Some of them are: -

1. air gauge {to check the dia)

2. plug gauge (to check the dia)

3. brush pin type gauge (to check the depth)

4. qualifying gauge {to check the distance between the manufacturing holes)

5. balance testing (for connecting rods)

6. centre distance (con rod)

7. bend (con rod)

8. twist (con rod)

The different steps in the assembly of engine.

Timing of injectors during assembly.

Study of injector and its testing against choking, desired pressure and dripping.

Fuel pumps study (in line pump), the function of governor, plunger and cam in the fuel injector pump.

Professional Practices

Attendance is compulsory.

One has to be on time and cannot leave the compound before 4:30 pm

Cannot leave the company once in without a gate pass

Trainees have to follow a dress code. Shoes are a must.

Material procurement is done through the material gate with proper receipt and

checking is done of person leaving after work.

Time for lunch and tea is fixed in between nothing is served

All the electrical appliances like fans and desert coolers are not

left running without purpose.

The different jobs are tested at regular intervals during machining

to get a quality product

Anything that goes on the line is reported by the worker to the floor Manager

Various safety norms are followed to prevent any accidents

S O M E C O L L A B O R A T I O N

Carraro India Limited (CIL) is a join- venture between Escorts

Limited and Carraro SpA of Italy.

Long Agribusiness LLC in the USA is a joint venture between Escorts Limited

through its subsidiary Escorts Agri Machinery Incorporation. Escorts Limited has

now acquired a majority equity holding in the company and it is now in the process of

being renamed Farmtrac North America Incorporation.

Polmot Escorts Spoolka Z.o.o, which is a joint venture between Escorts and Polmot

Holding SA, a Polish company for the assembly and marketing, tractors in Central

and Eastern Europe has already sold around 1000 tractors in Poland and other

countries. Polmot Escorts Spolka Z.O.O, which is currently in the process of

changing its name to Farmtrac Europe, will hence lead to increased exports, by

becoming a supply base for whole of the European Union in order to achieve a

significant growth in exports to new countries in the current year.

E S C O R T S P R O D U C T P R O F I L E

Escorts came into being with a vision that was natured by Mr. Hari Nanda and Late Mr. Yudi Nanda.

The foundation of Escorts Limited was laid in the formation of Escorts (agents) Ltd on 17th October, 1944 and of Escorts (Agriculture and machines) Ltd. in 1948. These two were later merged in 1953 to form Escorts agents Pvt. Ltd. The company’s incorporation in its present name, Escorts Ltd. was affected on 19th January, 1960

Having initially started with a franchise with Westing House Domestic Appliances, it has come a long way in manufacturing and marketing a range of products. It has pioneered farm mechanization in India through import and distribution of agriculture tractors.

The manufacturing operation commenced in 1954 since then the following range of new products been produced in the country.

A G R I M A C H I N E R Y G R O U P R & D

Modern Research and Development Centre of Agri Machinery Group Escorts Agri

Machinery Group (AMG) has invested over US$ 7.5 million in a state-of the-art

Research and Development Centre. Virtual prototypes of components and aggregate

assemblies are made and assembled on computer workstations using 3D technology. The

performance is checked on computers using simulation techniques thus saving a lot of

time for the end-user as welt as low-development costs The R&D Centre uses advanced

3D modeling, analysis and simulation software for engines, transmissions and vehicles

Physical prototypes are then extensively tested for performance, durability and

reliability. Facilities include a high-technology engine laboratory featuring fully

computerised beds with online control, data acquisition and analysis. Engine emissions

tested for meeting the Bharat TREM norms, US Environmental Protection Agency

(EPA) norms and European (Euro) norms. Additional capabilities of the engine lab are

engine performance, durability, reliability, tribology and fluid dynamics studies an

advanced vehicle-testing laboratory includes fatigue-testing dynamometer testing for

chassis and power-take-off and smooth as well as torture test tracks. Other facilities

include Noise Vibration and Harshness (NVH) Lab. Metrology Lab., and Materials

Engineering Lab. Product styling is earned out in a computerized virtual environment,

which is supported by a model-making shop for physical prototypes.

Product Range

The products are manufactured in a world class manufacturing plants, under the supervision of skilled professionals. Care is taken to use the latest technology available and is subjected to stringent quality tests in order to produce flawless products comparable to international standards. Our Quality Control Department always tests the incoming raw materials and outgoing finished products for their quality, and only after they meet the required criterion are they sent to the next process. We are the manufacturer and exporter of the following product range:

ESCORT range of Agricultural Tractors

MPT Jawan - 25 HP: 2 Cylinder 2wd Multi Purpose Tractor

Escort 335 Josh - 35 HP: 2 Cylinder 2wd tractor

POWERTRAC range of Agricultural Tractors

Powertrac 434 - 34 HP:

3 Cylinder 2wd tractor

Powertrac 439 - 39 HP:

3 Cylinder 2wd tractor

Powertrac 445 - 43 HP: 3 Cylinder 2wd tractor (Power Steering optional)

Powertrac 455 - 53 HP:

3 Cylinder 2wd tractor (Power Steering optional)

T R A I N I N G P R O G R A M M E

The training programme included the observation of

following:-

Cylinder Block machining

Cylinder head machining

Connecting rod machining

Engine assembly

Engine testing

This is followed by a project on which we are working

at present.

on

E n g i n e P r o d u c t i o n U n i t ( E P U )

Dpartment in Engine Production Unit:-

1. Head cell

2. Connecting rod cell

3. Engine Block Cell

4. Engine Assembly Cell

C O N N E C T I N G R O D

It is engine part. It is made by casting material. It is connected to the piston and

crank shaft and transfer motion, reciprocating motion in to rotary motion. In

tractor engine there are three pistons used and three connecting rods connect to

piston.

Weight : 2180 gm

Small Head Side : 800 gm

Cranking Side : 1380 gm

Length : 25 inches

H e a d C e l l

It is the cover of engine made by casting. It is attached to the

cylinder block of the Tractor Engine.

There are many works on head casting as given below:

1. Upper facing work (on vertical milling machine)

2. Drilling – on Radial Drilling M/c

3. Rear Face – Milling

4. Front Face – Milling

5. Intex Face – Triple Milling Machine

6. Exort Fact - Triple milling machine

7. Drilling

8. Exort Face Drilling – Horizontal Drilling Mounting Hole.

I n s p e c t i o n a n d C a l i b r a t i o n L a b

There are many measuring instrument to measure and calibration by the standard size weight, angles, length material approved by the R & D Section.

In lab the instruments which also check time to time by the Indian government lab and other authorized labs. There are many measuring and calibrating instrument as given below:-

1. Profile Projector

It is instrument to check the angles in degree or minutes. It is manufactured by MITUTOYO, Japan.

2. Floating Carriage Dia Measuring Machine

It is used to measure the length in mm.

Its range is : 0 – 100 mm

3. Center Bench

It is also measuring instrument to check the run out of the shaft in micro-meter.

4. Manual Comparator

To check accuracy 0.00005”

(All dimensions for Ford Tractors in inches)

5. Pluck Gauge

To check the accuracy of Dia.

6. Flush Pin Gauge

7. Air Pluck Gauge

A s s e m b l y B l o c k C e l l

There are many stages for completing the Engine Assembly. These stages are:

Stage I (Interim cylinder head assembly)

In the first stage the cylinder block which is cleaned and washed and in which the washers and dowel are fitted using loctite is taken. In this cylinder block, installation of main bearing cap is there in which mount bearing cap assembly and tighter the main bearing cap bolt to specified torque. Upper and lower half bearings must be from the same supplier. Then there is

Stage II (Cam shaft assembly)

In the second stage the crankshaft gear installation in which the properly cleaned crankshaft gear assembles with key. After that the camshaft gear tappet and push rod installation is there in which by keeping the cylinder block in upside down assemble he tappets, ensure that tappet bore and tappet are pre lubricated with engine oil and check in cam bore keeping the block in upside down position, do not hammer the camshaft while assembly. Ensure free rotation of cam shaft. Assemble camshaft thrust plate and ring. Pushrod will assembled after fitment of cylinder head.

Stage III (FI pump assembly)

Fuel Injection Pump is assembled on cylinder block. Fuel injection pump is mounted on timing and gear housing with given hardware which is attached to cylinder block with tightening torque 25 N-m. The function of fuel injection pump is to inject the fuel to the engine.

In the third stage also the installation of gear fitment.

Four gears are used:

1. Camshaft Gear2. Ideal Gear3. Timing Gear4. Crank Gear(All gears are helical)

Stage IV (Piston Con rod assembly)

In the fourth stage the installation of piston which lubricates the liner with engine oil. Insert piston-connecting rod assembly into the cylinder liner using proper ring compression tool such that the arrow marked on piston top is pointed towards timing gear end of the engine. Ensure proper fitment of big bearing shells. Connecting rods and bolts threads must be cleaned and oiled. After lacing the connecting rod bearing cap in right orientation ensure uniform tightening of connecting rod bolts to a torque of 6.5 – 7.5 kgm. Ensure the free rotation of engine after assembly of pistons. Check projection of piston top writ cylinder block face.

Stage V (TG cover assembly)

In the fifth stage the turning gear cover is mounted on the timing gear housing to provide a sealed type cover. There is an inspection plate on turning gear cover for adjusting the turning of pump. Turning gear cover is mounted to protect the gear from dirt and dust.

Stage VI (cylinder Head Assembly)

In the sixth stage the cylinder head assembly is there in which ensure the proper cleaning of cylinder head make sure that there are no dirt, dust, abrasive particles. Ensure the proper fitments of valve stem seal on valve guide using special tool. Ensure proper fitment of valves in the valve guide utmost valve guide to avoid damage of the seal tip by cotter groove of the valve. There are pairs of inlet and outlet valves attached on the cylinder head in which the inlet valve is of larger diameter and outlet valve is of smaller diameter. Then ensure the proper fitment of valve spring, disc and pressed with the help of rocker arm. Then the intake and exhaust is mounted on the two ends of cylinder head. Intake is made up of aluminum. Intake s through which the air enters into the engine and through exhaust hot air comes out of the engine. Cylinder head is tight on the cylinder block.

Stage VII (Rocker arm assembly)

In the seventh stage the rocker arm assembly is performed in this while preparing rocker shaft assembly ensure that the front mark on rocker shaft is towards timing gear end of engine. Ensure the fitment washer on either side of each rocker arm.

Ensure tappet clearance in cold condition as follows:

Inlet valve – 0.3 mm

Exhaust Valve – 0.4 mm

Stage VIII (cylinder head cover assembly)

In the eighth stage the cylinder head cover is mounted on the cylinder head. Ensure the proper cleaning of cylinder head make sure that there are no dust. Ensure the cylinder head gasket of specified thickness for identification on part.

Stage IX (bell housing assembly)

In the ninth stage the bell housing is mount on he engine in which the fly wheel is mounted which helps in the working of engine.

Stage X (Lubricating oil pump assembly)

In the tenth stage the lubrication oil pump is mounted on the engine through which oil get filtered before entering the cylinder. Then the alternator is mounted on engine which helps in charging the battery and then stator is mounted on the engine which helps in starting the engine.

Stage XI

In the eleventh and last stage the transmission is attached to the engine. Now the tractor engine is completed.

E n g i n e T e s t i n g

Fill the lubricating oil of 13 liters to 17 liters

Drive the final assembly with electric motor connecting the input shaft which

it.

Hot test to be performed in accordance with the engine hot test specifications

release separately.

Performance and oil economy test to be performed in accordance with

appropriate specifications.

Injection timings are mentioned in respective hot test specification.

Test Specification:-

RPM Temperature Specified Torque Time

2100 16°C - 30°C

31°C - 45°C

91.5 – 98.5

89.5 – 96.0107 – 111 seconds

1200 16°C - 30°C

31°C - 45°C

104.0 – 116.0

102.0 – 112.5166 – 174 seconds

TYPE OF ENGINE TESTS

4.1) FULL THROTTLE PERFORMANCE TEST

This test is performed to find out the performance of the engine when the throttle is at its

maximum position. First the engine is warmed up till the temperature of the lubricating

oil reaches 80 °C. The throttle is set at the maximum position and rpm of the engine is

decreased by applying load on the engine through dynamometer. Parameters recorded

are torque, speed, power, fuel consumption, BSFC (brake specific fuel consumption),

Smoke level, Temperature of oil and Temperature of test cell (ambient temperature).

4.2) PART THROTTLE PERFORMANCE TEST

This test is performed to find out the performance of the engine when the throttle is at

various intermediate positions. During this test, engine speed (RPM) is kept fixed and

load on the engine is decreased. But the speed increases with decrease in load. In order

to keep the speed constant the throttle was decreased. The test is performed at rated

speed, Intermediate speed & peak torque speed. Parameters recorded are the same as

above.

4.3) GOVERNING TEST

This test is performed at high idle speed, rated speed and an intermediate speed.RPM is

decreased in steps of 20 and it is observed at what RPM maximum power is obtained.

For a good RPM engine, the difference between maximum power and the RPM at which

the test is being performed should not be more than 100-120 RPM.

4.4) FRICTIONAL HORSE POWER TEST

This test is performed to find out the power lost in the engine due to friction. In this test

the fuel supply to the engine is cutoff and the engine is rotated in the opposite direction

with the help of a special dynamometer known as motoring dynamometer. The power

required to do so is known as frictional horse power.

4.5) ENDURANCE TEST

This test is done to estimate the life of the engine. This test is generally performed on a

new engine or an engine with some part modified. The test procedure depends on type of

modification done. A new engine is run continuously for 3000 hours. After every 40 hours

engine oil is checked, every 100 hours FTP test is done and in every 500 hours engine oil

is checked.

4.6) EMISSION TEST

This test is performed to analyze the exhaust gases given out by the engine under various conditions. The amounts of carbon monoxide, hydrocarbons, oxides of nitrogen (NOx) and particulate matter are measured in ppm. The software converts these values to g/KWh. These values are compared with emission norms set by the government. For tractors parameters are measured at 8 points-at rated RPM 4 points are taken(full load,75% of full load,50% of full load,10% of full load),at peak torque RPM 3 points are taken(full load,75% of full load,50% of full load),at low idle speed 1 point is taken at no load. For car engines 13 points are taken whereas for genset engines 5 points are taken.

100% MODE : 5 MODE : 1

75% MODE : 6 MODE : 2

50% MODE : 7 MODE : 3

10% MODE : 4

No Load MODE : 8

Low Idiling speed

Peak Torque speed

Rated speed

Load

Weighatage Factor - 15%

Weighatage Factor - 10%

Speed

Figure 4.1 8 Mode Emission cycle

4.7) INDISET TEST

The setup for this test consists of four units crank detection module(CDM) that

measures the crank angle, pickup that measures the pressure at pump end or cylinder as

required, transducer that measures cylinder pressure and a special injector nozzle that

has sensors to measure the needle lift. These units send signals to the indimeter that is

connected to a computer which records and displays the reading.

It is mainly conducted to know

Duration of injection.

Dynamic start of injection.

Peak combustion pressure.

Gas entry inside the nozzle.

Secondary injection.

Injector needle lift w.r.t crank angle.

Rate of pressure rise.

The result comes in the form of diagram as shown in figure3.2

1) Combustion pressure as a function of deg crank angle.

2) Needle lift as a function of deg crank angle.

3) Line pressure as a function of deg crank angle.

5.1) ENGINE TEST CELL LAYOUT

Figure 5.1 Engine Test Cell Layout

No. EQUIPMENT DESCRIPTION1 Dynamometer Device used to put variable external load

on the engine2 Test Engine The engine to be tested3 Smoke Meter Measures the amount of smoke in exhaust4 Fuel meter Measures the amount of fuel input to the

engine5 Air mass flow meter Measures the mass of air taken in by the

engine6 Blow by Meter Vapors of engine oil constitute the blow by

gasses. Blow by meter measures these gasses.

7 Throttle Actuator Varies the throttle from low idle position to high position speed

8 Particulate Meter Measures the particulate matter in the exhaust

9 Cable Boom10 Water Conditioner Maintains the temperature and pressure of

water input to engine for cooling11 Lube oil Conditioner Maintains the temperature and pressure of

engine oil input to engine for lubrication12 Exhaust back pressure

controllerControls the exhaust back pressure

(pressure exerted on the valves by the

exhaust when it faces restrictions in the

silencer). If the back pressure is more

smoke will be more.

13 Intake air conditioner Maintains the temperature and pressure of air input to engine for combustion

14 PUMA 5 Controller Electronic device which controls all units

15 Control room computer Displays various parameters about the

engine in real time during the test as

recorded by the instruments

16 Indiset Measures and displays Cylinder pressure injector pin lift duration and injection pressure during indiset test

17 Smart Sample Controller18 Exhaust Gas Analyzer Analyzes exhaust gas for levels of gasses

like NOX, CO etc19 Host computer20 Printer Prints out the result

DEFAULTS IN ENGINE

1. The main default is come from lubricant.

2 Piston seej

3. Crank joint/ Seej

4. Oil gallery seej

5. Water gallery seej

6. Over heating.

7. Break and damage is also the fault in engine.

PARTS IN CYLINDER HEAD

1. Valve

2. Rocker arm

3. Cam lift

4. Tappet.

5. Cam shaft

6. Push rode, etc.

PARTS IN CYLINDER BLOCK

1. Piston.

2. Piston rings.

3. Cylinders

4. Connecting rod

5. Combustion chamber between cylinder head and cylinder block

6. Oil gallery

7. Water gallery

8. Cam shaft

9. Crank shaft.

ABREVIATIONS

1) NOx - Oxides of Nitrogen

2) HC - Hydrocarbons

3) CO - Carbon monoxide

4) PM - Particulate matter

5) ID - Ignition delay

6) SOI - Start of Injection

7) SOC - Start of combustion

8) EGR - Exhaust gas recirculation

9) BSFC - Brake specific fuel consumption

10) SOF - Soluble Organic Fraction

11) CRT -Continuous Regenerative Trap

12) BT 3A -Bharat Trem 3A

13) IVC -Inlet Valve Closure

14) LLR -Light Load Retard

15) DV -Delivery Valve

16) FIP - Fuel Injection Pump

17) ACS -Air Conditioning System

C o n c l u s i o n

As my training comes to end here in Escorts Tractor, I would like to share my experience with you. Now I realize the importance of training & practical applications. During my Engineering Course, I always wonder about theoretical knowledge, which are seeking, would ever be implemented practically. But after my industrial training at Escorts Tractor, I can say that have been put to good to use. It was the result of the training only that I got to see the object in real, practical use, which I had only read about & seen as 2-D objects in the books.

These 6 weeks of training gave me a chance to get exposed to the industry culture & work environment these 6 weeks at escorts tractor were learning experience all the way. Here I must mention that learning experience all the way here was due to the full co-operation of the management, staff which helped me in gaining whatever knowledge I gained today about the production improvement & the assembly of tractors. According to me industrial training helped me in the following ways:-

It gives us a chance to come across the industrial culture.

It tunes and modifies the attitude and always keeps you in learning and inspiring mood.

It helps in developing skills for a particular field.

In the end, I would like to conclude that the training is an essential part of the education program. We are pursuing theoretical knowledge which is indeed and a must to have a foundation.