Project End Semester Report- 6 Months Industrial Training - Mahindra And Mahindra- Swaraj Tractor Division

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. 2

3 4 5 6

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The Indian Tractor Industry Introduction and Business Description Swaraj Tractor Division - Mahindra and Mahindra Limited Background of the company Timeline of the company Company Organization chart 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 Products and specifications Project Reports

Page 1 Page 2

Page 2 Page 3 Page 5 Page 7 -14

Page 15 - 23

1. Project – 1 (Elimination / reduction of watermixing in the engine oil )

Page 24 - 49

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

Page 49 - 65

The Indian Tractor Industry | Page | 1 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

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 Page | 2 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 20082009 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

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. Page | 3

Timeline ||

Year 1965 1970 1971-73 1974 1975 1978 1980

1981 1983

1984

1985

Event Govt. of India's research institute (CMERI) at Durgapur initiates design and development of SWARAJ tractor based on indigenous know-how. Punjab Govt. through PSIDC acquires SWARAJ tractor's design from CMERI and establishes Punjab Tractors Ltd. (PTL) for its commercialization. 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. Swaraj 724 (26.5 HP) tractor commercially introduced. 2nd tractor model SWARAJ 735(39 HP) developed by own R&D, commercially introduced. 3rd Tractor model SWARAJ 720 (19.5 HP) developed by own R&D, commercially introduced. Maiden equity divided declared. 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. Issue of maiden Bonus Shares (2:5), paid-up equity moves to Rs 15.4 million. 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. 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%). Industrial Forklift Trucks developed by own R&D, commercially

1986

1989 1990 1992 1993 1995 1996 1998 1999

2000

2001

2002 2003

2004 2005

2007

introduced. 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%). 1st Right Issue (1:1) at a premium of Rs 50/- per share (plus reservation of Page | 4 200 Shares per employee) paid up equity moves to Rs 31.6 million. 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. 1st right issue of Bonus Shares (1:1), paid up capital moves to Rs. 101.2 million. Annual tractor capacity expanded to 24,000 per annum at Plant 1. Setup of tractor Plant II at Village Chappercheri, SAS Nagar with annual capacity of 12,000 per annum. 3rd issue of Bonus Shares (1:1), paid up equity moves to Rs. 202.5 million. Commencement of expansion to 60,000 tractors (30,000 at each plant). Capital outlay of Rs 1000 million, funded mainly through internal accruals. 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.  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.  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. Cumulative tractor sales crosses 500,000. 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%. 7th & 8th tractor models - Swaraj 939 (41 HP) & Swaraj 834 (34 HP) developed by own R&D, commercially introduced 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  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%

 

2008

Cumulative Tractor Sales cross 600,000. Swaraj Track Type Combine designed and developed by in-house R&D, commercially launched

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) Page | 6

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

15) Junior Engineer Page | 7

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. 2. 3. 4. 5. 6.

Light machine shop Heavy machine shop Paint shop Assembly shop Heat treatment shop 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,

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 Page | 10 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

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 Page | 11 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

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: Page | 12

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 predesigned 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.

Measures under PDI 1. 2. 3. 4. 5. 6. 7.

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TRANSMISSION FLUID LEVEL ENGINE OIL LEVEL FUEL INJECTION PUMP OIL LEVEL WATER LEVEL IN RADIATOR ELECTRICAL FUCTIONING COMPONENT STORAGE CHECKING OF AIR LEAKAGE FROM THE AIR INTAKE FILTER

Transmission oil dipstick

Fuel Injection Pump

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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 : Type : No. of Cylinders : Bore and Stroke : Displacement :

39 S.A.E 4 Stroke, direct injection, diesel engine. 3 100 X 110 mm 2592 cc

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Rated Engine Speed : Air Cleaner : Cooling System : TRANSMISSION Clutch : No. of Gears : Speed Chart Gear Low High P.T.O.

2000 rev/min. 3 stage Air cleaning system comprising of Cyclonic pre-cleaner, Oil bowl & Paper element to enhance engine life. Water cooled with No Loss tank. Heavy duty single dry plate type, 280 mm diameter 8 forward, 2 reverse speeds with high and low selector lever. 1st 2.3 8.9

a) Position control b) Automatic Draft Control c) Mix Control Hydraulic lift pump

2nd 3rd 4th Rev.R 3.1 4.6 7 2.84.7 12.1 18 27.4 11.2 21 splines for 1000 rpm 6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional) Heavy Duty self energizing, water sealed disc brakes Parking brake for additional safety, Oil immersed disc brakes (Optional) Heavy Duty single drop arm steering for high efficiency and comfortable drive. 2 lever live hydraulic system having automatic position & draft with mix control To hold lower links at any desired height. To maintains uniform draft. For optimum field output 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

BRAKES STEERING HYDRAULICS

INSTRUMENTS

TYRES WHEEL TRACK

Engine rpm cum hour meter, Fuel gauge, Water Temp. Gauge, Oil pressure gauge, Ammeter, High beam indicator, Trailer light indicator. Front 6.00 x 16 Rear 12.4 x 28 Front 1200 - 1750 mm Rear 1350 - 1900 mm

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Specifications: Engine : HP : Type : No. of Cylinders : Bore and Stroke : Displacement : Rated Engine Speed : Air Cleaner : Cooling System : TRANSMISSION Clutch : No. of Gears : Speed Chart Gear Low High P.T.O.

34 S.A.E. 4 Stroke, direct injection, diesel engine. 3 100 X 105 mm 2474 cc 2000 rev/min.

3 Stage Air cleaning system compromising of cycolonic pre-cleaner, Oil Bowl and Paper element to enhance Engine Life Water cooled Heavy duty single dry plate type, 280 mm diameter 8 forward, 2 reverse speeds with high and low selector lever. 1st 2.1 8.3

BRAKES STEERING HYDRAULICS a) Position control b) Automatic Draft Control c) Mix Control Hydraulic lift pump

2nd 3rd 4th Rev.R 2,9 4.4 7 2.6 11.3 17.4 27.4 10.4 21 splines for 1000 rpm 6 Splines for 540 rpm corresponding to 1650 engine rpm (Optional) Heavy Duty self energizing, water sealed disc brakes Parking brake for additional safety, Oil immersed disc brakes Heavy Duty single drop arm steering for high efficiency and comfortable drive. 2 lever live hydraulic system having automatic position & draft with mix control To hold lower links at any desired height. To maintains uniform draft. For simultaneous use of position and draft controls for optimum field output. 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.

Starter motor & alternator Head light with parking lamps INSTRUMENTS

TYRES WHEEL TRACK

Tractor meter with direction indicators, Fuel Gauge, Ammeter, Water Temp. Gauge & Oil Pressure Gauge Front 6.00 x 16 Rear 12.4 x 28 Front 1200 - 1750 mm Rear 1350 - 1900 mm

Specifications: Engine Specifications: HP : Type : No. of Cylinders : Bore and Stroke : Displacement : Rated Engine Speed : Air Cleaner : Cooling System : Transmission: Clutch : No. of Gears : Gear Speeds (Km/hr) 1 Low 3.1 High 10.2

48 S.A.E. 4 - Stroke, Direct Injection, Diesel Engine 3 110 X 110 mm 3136 cc 2000 rev/min 3 Stage Air cleaning system compromising of cycolonic pre-cleaner, Oil Bowl and Paper element to enhance Engine Life Water Cooled with Oil Cooler for engine oil. Heavy Duty single dry plate type, 305 mm dia, Dual Clutch, 280 mm dia. (optional) 8 forward, 2 reverse speeds with high and low selector levels. 2 4.2 13.8

3 6.5 21.4

4 8.9 29.2

R 4.3 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 Maintains uniform draft. Control: 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)

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Specifications: Engine Specifications: HP : Type : No. of Cylinders : Bore and Stroke : Displacement : Rated Engine Speed : Air Cleaner :

34 S.A.E. 4 - Stroke, Direct Injection, Diesel Engine 2 100 X 116 mm 2204 cc 2000 rev/min 3 Stage Air cleaning system compromising of cycolonic pre-cleaner, Oil Bowl and Paper element to enhance Engine Life Water Cooled with Oil Cooler for engine oil

Cooling System : 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)

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. Position Control: To hold lower links at any desired height Automatic Draft Maintains uniform draft. Control: 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. 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 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 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: Engine Specifications: HP : Type : No. of Cylinders : Bore and Stroke : Displacement : Rated Engine Speed : Air Cleaner :

26.5 S.A.E. 4 - Stroke, Direct Injection, Diesel Engine 2 100 X 110 mm 1728 cc 2000 rev/min 3 Stage Air cleaning system compromising of cycolonic pre-cleaner, Oil Bowl and Paper element to enhance Engine Life Water Cooled

Cooling System : Transmission: Clutch : No. of Gears : Gear Speeds (Km/hr) 1 Low 2.3 High 8.9 P.T.O.

2 4.2 16.4

Heavy Duty single dry plate type, 254 mm dia 8 forward, 2 reverse speeds with high and low selector levels. 3 6.3 24.9

4 7.2 28.4

R 3.2 12.5

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.

Position Control: Automatic Draft Control: Mix Control: Hydraulic Lift Pump:

To hold lower links at any desired height Maintains uniform draft. For simultaneous use of position and draft controls for optimum field output. 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 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 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

Page | 23

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)

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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 Page | 24 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

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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 Swaraj Engines Limited Kirloskar Oil Engines Limited

Aug’08

Sept’08

Oct‘08

Nov’08

Dec’08

Jan’09

Feb’09

Mar’09

1

3

1

1

10

6

7

6

8

4

4

3

9

2

1

1

Numbers of engines found to be defective from both the manufactures

Page | 25

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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

Page | 26

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

Observation| Recognition of the features of the problem Page | 27

||Observation of the process SEL Engine with oil filled KOEL Engine empty

Engine storage on conveyor

Problematic zone SEL Engine KOEL engine filled with Oil filled by Assembly department

Engine coupled with chassis

Tractor washed and cleaned with high pressure

Tractor dismounted

Tractor roller tested

YES If water mix observed

Tractor R/W. Oil changed

YES No Dispatched NO

If water mix observed

PDI

Tractor R/W Oil changed

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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.

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

||Observation of symptoms Page | 29



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

Project 1: Eliminating / Reducing Water Mix in Engine Oil



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 Page | 30

b. Air leakage observed oil filler cape in one case- SEL c. Air leakage observed from dipstick one case – ASSEMBLY

A

B

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

Page | 31

||Observation of variation

Supplier wise contribution in problem KOEL

SEL

48% 52%

Project 1: Eliminating / Reducing Water Mix in Engine Oil

Analysis| discovery of main root causes The analysis of the problem lead to the formulation of theories and sub-theories in their logical Page | 32 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

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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 | 33

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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

Page | 34

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

|| Probable causes selected for testing |establishing root causes 1) Breather pipe not inserted fully in hole. Page | 35

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.

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

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

||Testing of hypothesis All the possible causes were tested after discussion with the team members and marked as a Page | 36

valid reason or invalid reason accordingly.

Sr. no.

Probable causes

Testing and observations

Conclusion

1

Breather Pipe Besides observation on defective tractors, for this not fully inserted defect ,100 engine assemblies were visually in hole 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. Gap between bush Outer Diameter and hole in Oil Filler Body

Failed in Air & Water leakage test

Hypothesis Valid.

I) Bush Outer Diameter Under Sized

Specification: Hole size 27+.033/+0 Bore Inner Hypothesis Diameter checked with plug gauge for 5 Defective invalid. engines and 25 engines from the latest supply of engines. All were found OK with plug gauge.

4

5

ii) Oil Filler Body hole U/S Sealant application not OK

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

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

photograph. Leaking water can be seen inside.

Page | 37

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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.

Page | 38

6

Sealant not applied

7

Oil filler cap assembly not tightened

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

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

Oil filler cap assembly Design inadequate.

Leakage observed in1 out of 5 cases when water was poured at this point.

Hypothesis valid.

9

I)Steel washer

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. Observation on defective cases & randomly audited 50 cases in two shifts in plant no case was found where the cap was not fully tightened.

Rubber material of failed parts were checked and found as per specifications.

Hypothesis invalid.

Hypothesis invalid.

There was metal to metal contact due to steel

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

10

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.

Filler body Gap between bush Outer Diameter & hole

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.

i )Bore Over Sized 11

Dipstick not fully seated.

12

Dipstick “O” ring sealing not effective.

Checked visually. No case was found among defective and 100 other cases observed.

Hypothesis invalid.

I)“O” Ring size & Specification: Diameter 5.0 mm, Thickness 2.0 +/- .08 thickness not OK

Hypothesis invalid.

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

Hypothesis invalid.

Observation on failed engine.

ii) Groove diameter under sized

Found OK. Actual

: OK with Plug gauge No case was found in 100 cases Checked.

iii) Hole diameter over sized in Crank Case

Specification : 5.3mm + 0.1 with plug gauge Actual

: OK with Plug gauge

Hypothesis invalid.

No case found in 100 cases checked Specification: Dia. 9.0±0.03

13

Dipstick design not adequate.

Dipstick looses in 10 out of 100 Cases. Water seepage was also observed .Thus Design needs

Hypothesis valid.

Page | 39

Project 1: Eliminating / Reducing Water Mix in Engine Oil

improvement. As per given tolerances on hole size, Maximum hole diameter. = 9.03mm Min. diameter over “O” ring after fitment in groove =9.04mm

Page | 40

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

Hypothesis valid

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.

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

Air leakage test||| Page | 41

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.

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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. 1

2

3 4

Root Cause

Remedial Action

Sealant not applied properly (breather pipe bush ) SOP provided and operators were educated as per SOP at the suppliers end Rubber plug eccentric and not perpendicular New welding fixture designed w.r.t. cap (oil filler cap) ( J68080 ). Alternate design for nut welding provided (vides drawing no. V085633/1) Rubber plug head diameter less Diameter changed from 61mm to 63.5 mm Steel washer ineffective in oil filter cap assembly Design changed 1 ) Steel washer replaced with “O” ring

5

Dipstick design inadequate

6

Flash over plastic molding (dipstick)

Dipstick head made cup shaped “O” ring thickness increased from 2mm to 2.15 mm Dye re-work schedule made (50,000 cycles )

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

Page | 42

Project 1: Eliminating / Reducing Water Mix in Engine Oil

Page | 43

Check| Confirmation of effectiveness of actions Week Wise Rejection for the defect - Water mix in Engine oil ( in PPM) 2300 2200

PPM

Target: 1000 PPM

2100

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

2000 1900 1800 1700 March WK1

March WK2

March WK3

March Wk4

Source of data : testing and PDI

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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

5.4

Adverse effects (If any)

----- 1) Engine life improved. 2) Waste oil disposal problem solved. 3) Timely dispatch of tractors. -------- Nil -----

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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 | 45

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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.

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

Page | 46

Project 1: Eliminating / Reducing Water Mix in Engine Oil

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

Page | 47

Project Resolution Format – Early Hour Failures M & M Swaraj tractors division. Title of Project: Reducing problem of water mix in engine oil.

OBJECTIVE COMPONENT(S) UNDER FOCUS

BACKGROUND / OBSERVATION OF FIELD DATA

DESIGN SPECIFICATIONS

Date of Implementation:

TO resolve PDI and early hour failure (R/1000) in the tractor before and after dispatch. Complete engine assembly 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/ Jan-09 Feb-09 March Total Month SEL 6 7 6 19 KOEL 2 1 1 4 No water ingress into the engine oil being used for lubricating the running various engine parts and components.

Project 1: Eliminating / Reducing Water Mix in Engine Oil 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:

Page | 48

ROOT CAUSE ANALYSIS

Air Leakage Test

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

Project 1: Eliminating / Reducing Water Mix in Engine Oil Sr. No.

SOLUTION IDENTIFICATION

Defect

1.

Oil filler cap not fully tightened.

1

2.

Breather pipe not inserted in the oil teller body; gaps remain left between the bush Outer dia. and Inner Dia. of the housing.

3

3.

Oil teller body not seated with gear casing.

2

4.

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).

2

5.

Push rod bottom rubber plug damaged during assembly.

3

Page | 49

6. Dip stick not fully pressed. 1 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

Frequency

 

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

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. 2. 3. 4. 5.

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

Page | 51

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

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

12000 10000

PPM

8000 6000 4000 2000 0

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

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

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

Observation| Recognition of the features of the problem Page | 53

||Observation of the process

Fuel cock Assembly fitment to the fuel Tank Assembly

Fuel tank assembly fit on the tractor along with fuel cock Assembly

Correction stage

Yes No

Roller Testing

Rework

Tractor advised to store

PDI at STD before Dispatch

OK Leakage

Dispatch

Sent to QP6 stage

Yes

OK

Rework and Correct

No

Road Testing

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

||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.

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

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

||Brief Description Fuel cock assembly is used in fuel line of the tractor assembly. Its main function is to cutoff 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 Page | 55 ring.Fuel pipe is fitted with fuel cock with banzo and aluminium washer.

Fuel Cock Assy

Upper leakage point AL washer

Diesel Off / On Knob leakage point

Banjo bolt

Bottom leakage point AL washer

Interface of Fuel Cock & Fuel Tank Assembly

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

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

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

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

Analysis| discovery of main root causes Page | 57

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. b. c. d. e.

Torque wrench not used Assembly not as per Standard Operating Procedure (SOP) SOP not adequate Wrong torque wrench used 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

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

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. b. c. d. e.

Grease not applied Sop not displayed SOP not made No holding device used ‘o’ ring setting Not OK

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

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

|| Cause and effect diagram| the cause and effect diagram gives a systematic overview of the problem Page | 59 MAN

METHOD

Torque wrench not used

SOP not display Person not skilled

SOP not made

Assy not as per SOP ‘O’ Ring setting not ok

SOP not adequate

Wrong torque wrench used

No holding device used

Grease not applied

FUEL COCK LEAKAGE Fuel Tank

Wrong impact no torque

Setting under

Face dented Setting Al. washer over Torque wrench setting High hardness Butting face not // to each other

MACHINE

Sealing mtg. ‘O’ Ring

‘O’ Ring seat depth excess

Damage/cut Material porosity

Face dent or damage MATERIAL

Knob ‘O’ ring damage Fuel Cock Assy

M14x1.5 mot ┴ w.r.t to face M5 hole through Thread inclined

Fuel pipe rejected Crimping not ok

O/D U/S

w.r.t face

Circular finish not ok

Thread portion length less or more Banjo bolt defective Concentricity of Ø14& M14x1.5 thread portion not ok

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

|| 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. Probable No. Causes 1 Banjo bolt under torque

Testing of hypothesis

Conclusions

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

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

Hypothesis Invalid.

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

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

dented

Page | 61

3

Al washer High hardness

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

4

Fuel cock M16x2 face not flat

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

5

Banjo bolt Five banjo bolts removed from the defective tractor and Ø 14 not checked with concentric gauge (J61405A). All were qualified the Hypothesis concentric gauge. ┴ =.05 max. invalid. with M14x1.5

6

Rubber sealing ring not seated in fuel tank groove

Hypothesis Invalid

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

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

7

Sealing ring (P395208) diameter undersize & hardness variation

15 Sealing ring were checked for diameter & shore hardness.

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 Hypothesis were qualified in the gauge No. J61408. invalid. Squareness checking gauge number Also 100 pieces at random were also checked on line with gauge all were qualified.

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

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.

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

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

other 10

Fuel pipe butting not parallel to each other

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

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

Page | 63

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

|| 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

S.NO 1.

Root cause Banjo bolt under torque

Why Torque wrench not used

Why workmen not aware about SOP

Why SOP not prepare

2.

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

Assembly not done properly

SOP not followed

SOP not made

3.

Air leakage performed

To find out leakage point

|| Final remedies Sr. no. 1.

Root Cause

Remedial Action

Banjo bolt under torque

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

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

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

Rubber sealing ring not seated in fuel tank groove.

3

Fuel leakage from fuel cock knob

Standard operation process (SOP) made and worker educated for adhering to this. System designed Page | 65

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