Eicher Project Report-SANAT

EICHER TRACTORS, MANDIDEEP (A unit of TAFE MOTORS AND TRACTORS LTD.)

A TRAINING REPORT ON 5150 POWER STEERING Training Duration: 05july2010 to 04 August2010

Training Co-ordinator Mr. RANJIT KUMAR SINHA V.D NO:0104ME071111

Submitted by: VIKASH KUMAR ENROLLMENT

Department of Mechanical Engineering RKDF INSTITUTE OF TECHNOLOGY AND SCIENCE, BHOPAL

-2-

DECLARATION

I hereby declare that the training entitled is an authentic record of my own work, carried out at EICHER TRACTORS as requirement of 30 days major training for the award of degree of B.E. (Mechanical Engineering), RKDF institute of technology and science, RGPV University, Bhopal, under the guidance of Mr. Ranjit Kumar Sinha during JULY 2010.

(Signature of student) Vikash kumar 0104ME071111

Date: ___________________

Certified that the above statement made by the student is correct to the best of our knowledge and belief.

RANJIT KUMAR SINHA VENDOR DEVLOPMENT

-3-

ACKNOWLEDGEMENT

I have learned a lot through this 30 days major training journey. Eicher tractors have proven to be so much fruitful and knowledgeable that it will help shape my career in future with least problems. I am grateful to Mr. Ranjit Sinha sir under whom I have been working in Eicher tractors. He gave me every opportunity to participate independently and freely in various projects and provided me with much useful recommendations and assistance. I was highly impressed with the way he use to keep hold of works going on in the department and the way he used his leadership qualities. Moreover his practical approach toward the works and his management qualities is something which makes him unique. He is mainly responsible for all the development going on in the company in matters of big projects such as 55 hp tractors. I really liked the way he negotiates with the supervisors for the projects. The way he impresses the person is absolutely different from a normal person. Their policies were very nice and taught me many things which is very much helpful for shaping my future.

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CONTENTS:  SUMMARY  TAFE PROFILE INTRODUCTION TECHNICAL TIE UP RESEARCH & DEVELOPMENT SALES & SERVICE NETWORK FINANCIAL STATUS: EICHER MARKETING EICHER WORK FORCE AND POLICY  EICHER SALES VARIOUS MODELS: AN OVER LOOK INTO THE SYSTEM OF EICHER TRACTORS 

EICHER TRACTORS ENGINEERING CENTER



FINANCE AND ACCOUNTS DEPARTMENT



SALES AND MARKETING DEPARTMENT



MATERIALS/VENDOR DEVELOPMENT



STORES DEPARTMENT



QUALITY ASSURANCE DEPARTMENT.



PRODUCTION DEPARTMENT



MAINTENANCE DEPARTMENT



ENGINEERING DEPARTMENT



SERVICES



HUMAN RESOURCES DEPARTMENT

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TAFE PROFILE Introduction Tractors and Farm Equipment Limited (TAFE) is a unit company of the Amalgamations group, one of India's largest light engineering groups with diverse interests in diesel engines, automobile

components,

tractors

and

related

farm

machinery,

lubricants,

panel

instruments, hydraulic pumps, engineering tools, storage batteries, paints, engineering plastics, automobile franchises and printing apart from interests in agribusiness, book selling and publishing. The group's leadership technology, built on foreign know how has been nurtured through indigenous efforts. TAFE was established in 1961 to manufacture and market a range of Massey Ferguson tractors and related farm equipment in India. One of the largest tractor manufacturers in India, TAFE's vision is to be the first choice of customers in India and to also move towards a growing presence in the international markets. TAFE has collaboration with AGCO Corporation, headquartered in Duluth, Georgia, which is one of the largest manufacturers, designers and distributors of agricultural equipment in the world. Its products are sold in more than 140 countries. With a network of more than 500 dealers, branches, service outlets as well as its own sales offices and depots covering the entire width and breadth of India, TAFE is committed to providing complete farming solutions to its customers and empowering them to work towards increased farm productivity, prosperity and profits. Tractors and Farm Equipment Limited (TAFE), has been a pioneer in the mechanization of the Indian farms. Beginning with the popularizing of tractors in agriculture in the early 60s, TAFE has many firsts to its credit. TAFE was the first company to market a total package of Tractors and farm equipment to not only provides farm power but also interfaces to transform the farm power to increased farm productivity. TAFE was also the

-6first to introduce the Direct Injection technology in India, thereby initiating considerable fuel saving and the resulting economies in tractor operations cost to its customers.

TAFE was also the first Indian manufacturer to launch a 75 HP tractor to cater to the emerging needs of very large farms and agri-businesses. With three manufacturing locations at Chennai (Sembiam), Madurai (Kallidaipatti) and Bangalore (Doddaballapur), TAFE has a large manufacturing base. Its Madurai plant, the latest and possibly the largest such plant in the country is specially tailored to take on short run production batches to the exacting standards demanded by advanced countries. All its plants and sales offices are linked by VSAT links providing fast and efficient communications and data linkage another first of its kind in India. Tractors and Farm Equipment Limited (TAFE), is also involved in the following areas, apart from its core business of manufacturing and marketing tractors. • TAFE has developed a range of matching trailers, implements and accessories. These are marketed through TAFE's dealer network by a totally owned subsidiary, • TAFE, through TAL is also involved in the marketing and distribution of lubricants and greases for tractors through its dealer network. • TAFE is also involved in the packaged power industry through its Power Source Division. • TAFE has in-house facilities for the manufacture of hydraulic pumps and gears for tractors. A related facility for the manufacture of panel instruments, not only for captive use but also for the growing automobile industry in India is an integral part of the company. • TAFE has also diversified into Engineering plastics and production of tools and dies for this industry. •

TAFE's vision of being the customer's first choice on offering to the customer’s quality

products engineered to perfection using technology that is contemporary and relevant to the market it serves. This approach to quality as being inherent to its existence has obtained for TAFE certification under ISO 9002. Recently, TAFE has also been recommended for ISO 9001:2000 certifications. The quality movement permeates through out the organization and is apparent from the various laurels won by quality circles from the company in national and international arenas.

-7•

TAFE's vision is not just wishful thinking but based on recognized engineering, marketing

and financial strengths, built up over the past four decades. In all that it does, TAFE pursues excellence. To achieve the distinction of the first choice among the farming community of India and ensure a growing presence in international markets through setting leadership standards of performance and customer care in the agricultural machinery business. "To us in TAFE, excellence is not some thing that we engineer, input or inspect into our products. It is an innate desire that inspires our hearts at work and at home and ripples out into the world around us. "

TAKE OVER EICHER TRACTORS: BIGGEST IN TRACTOR INDUSTRY

The Chennai based tractor major, Tractors and Farm Equipment Limited has been taking over of Eicher’s tractor division near Bhopal, engine division at Alwar and gears division at Parwanoo, in the biggest such acquisition in the history of the Indian tractor industry. TAFE, already the second largest manufacturer of tractors in India, with this approval, comes within striking distance of market dominance in the domestic tractor industry. Speaking at a media meet, TAFE’s Director, Mrs. Mallika Srinivasan said, “This move was a well-deliberated strategic move on our part. This acquisition will provide strong synergies of growth in the future to help achieve market dominance”. ‘Tafe motors and tractor limited’ company’s director Mrs. Mallika Srinivasan decided to take over Eicher tractors. She went on to add “TAFE has long held a significant presence in the 30-40 HP segment and the Eicher brand holds substantial market shares in the below 30 HP segment. The respective brands have a strong brand presence and equity in the customers’ minds. This coming together of the brands with strengths in individual segment forms a perfect fit to take on the tractor market which is currently on an upswing. It is in this scenario that this coming together of two major brands in the industry becomes highly significant. This also represents a giant leap for us in our vision to become the farmers’ first choice”.

-8With this acquisition, TAFE’s combined market share is 22 per cent and a combined volume of about 53,000 tractors. TAFE already has large number of products and variants to suit the changing demand patterns of tractor customers across the country. With the addition of the portfolio of products offered under the Eicher Brand, this new venture will offer to its customers the best in terms of product range, value for money, quality, and innovation in design and assured post sales product support. The move will also result in TAFE having a combined distribution network of over 2000 dealers, branches, service and parts outlets and customer contact points which is the largest in the industry. TAFE and Eicher tractors will retain their individually strong identities at the brand level and distribution level. The potential synergies of growth made possible by this move will translate into positive benefits to the employees, vendors and dealers and provide them ample growth opportunities. With its major focus being on the tractor business, TAFE aspires to be the number one player in the domestic market and the growing presence in the international market. TAFE buys Eicher's tractor,

engine & gear businesses for Rs 310 crore. The Eicher Motors board has cleared the sale of the company’s tractor, engine and gear businesses to Tractors and Farm Equipment’s, TAFE, for Rs 310 crore. TAFE will purchase the Eicher facilities through an SPV called TAFE Motors & Tractors.

The SPV, a 100% subsidiary of TAFE, will run the Eicher tractor unit and the gear & engine businesses as a separate entity with separate brand identity but operational financial control. The acquisition would improve TAFE’s geographical spread across markets like MP, UP and Bihar where Eicher is strong — alongside Rajasthan, Gujarat, AP and Karnataka where TAFE or stable mate Massey Ferguson are strong.

"In fact, the board of directors of EML granted approval for the sale on a going concern basis of the tractors, engines and gears divisions of the company at Manideep, Alwar and Parwanoo to TAFE Motors and Tractors for a total consideration of Rs. 310 crore," With the acquisition of the Eicher unit, Tafe — the second largest manufacturer of tractors in India — will eye market dominance. According to industry data available for the April-December 2004, Tafe registered sales of 24,191 units, while Eicher sold 13,670 tractors.

-9Brief description of the units of this take over is as follows: Eicher Tractors 

Pioneer Manufacturer in India since 1960.



Technology from GEBR Eicher, Germany & Valtra, Finland.



Over 3, 50,000 satisfied owners.



Market leader in <30 HP segment.



First Tractor Company to produce Air cooled as well as water cooled tractors.



Current range 24, 30, 35, 42, 51 & 61 HP - Annual capacity is over 35,000 numbers.



Two manufacturing plants – Faridabad and Bhopal



51, 61 and 70 HP-New products under introduction.



Exported to Europe, U.S.A., Africa & South Asia.



First Indian company to be awarded with ISO 9001 certificate

Fully integrated R&D Center Eicher Demm 

QS 9000, ISO 14000 & ISO 9002 certified facilities.



Two manufacturing units – Thane and Parwanoo



Manufactures a wide range comprising:



Spur Bevel & Helical Gears



Crown Wheel Pinion



Transmission Shift & Rear Axle Gears



Caters to OEM & Replacement Market.



Exports to Europe, Asia & US.

Eicher Engines



Manufacturers of automotive and stationery engines from 22HP to 42 HP



Genets from 12.5KVA to 30 KVS

Eicher Tractors Eicher Tractors is one of the newly added in the companies of the TMTL Group. Tractor operations are divided in Bhopal and Faridabad manufacturing facilities, Eicher Tractors Engineering (R&D unit) and Marketing functions. Mr. R. C. Banka is Chief Operating Officer of the Tractor Business Unit.

- 10 TECHNICAL TIE UP  Technology transfer from Ricardo of UK for developing air-cooled engines  Technology transfer from SISU (VELMET) Finland, for higher horsepower tractors. RESEARCH & DEVELOPMENT Comprehensive facilities for development of new tractor models including diesel engines. Facilities at ETE include - State of art Design officers with fully networked CAD / CAE environment, own Prototype / Tooling manufacturing facilities. Various Labs for Design verification, Field Simulation, Product Testing and validation and Information Center with facilities of Technical Library, Internet and Archives. EXPORT

- U.K., SRI LANKA, BANGLADESH, NIGERIA and NEPAL.

SALES & SERVICE NETWORK Gears are sold through a network of 16 distributors each having over 250 stockiest and retailers mainly entering to the replacement market. Company depots are located at Calcutta, Madras, Vijayawada, Bangalore, Ahmadabad, Indore and Delhi for supplying to distributors. FINANCIAL STATUS: EICHER TRACTORS had a turnover of 550 Crores in the last financial year which ended in 05. But for this financial year the proposed turnover is 750 Crores for EICHER Tractors. EICHER MARKETING The tractor operations are located at Bhopal plant. The combined production capacity is about 25000 tractors per annum. Eicher tractors manufacture and markets tractors from 24 HP to 50 HP range. Company has its own distribution network in most agrarian states and has 350 dealers. Marketing network is spread across the country and there are 35 area offices in smaller cities of the country. Eicher offers 2 years warranty on the tractors against any type of manufacturing defect & efforts are made to upgrade the service network by providing doorstep service to the farmers.

- 11 The Marketing team consists of 26 executives and staff members. The group shall strive to become truly global in its operations. Global does not merely mean exporting our products. It means being present in all relevant parts of the world for each product as seller and wherever practical & economical as manufacturer. It requires that we start thinking globally from now on while making any important decision. It necessary assumes that global competitiveness, sound financial health,

customer

orientation,

superior

technology,

global

brand

recognition,

outstanding employee motivation, as well as several other vital skills and attributes. It should result in rapid growth, both domestically and internationally.

EICHER WORK FORCE AND POLICY

The company gives high thrust to its employees, which are encouraged to acquire knowledge in their work area and are given ample freedom. There are about 1100 employees in Eicher Tractors. There are 100 executives, 350 staff and 550 operators in the company. Eicher offers equal opportunities to learn, perform and grow to all employees. Employees are encouraged to acquire knowledge are permitted for job diversity within organized units of work. Specific care is exercised for ensuring safety and health of the employees including contract employees.

TECHNOLOGY IN EICHER

Eicher has state of art R&D center at Bhopal facility, which has Pro/E, Adams, Hyper mesh work stations, simulation rigs, mechanical test beds and mock shop for developing new products. The manufacturing plants have very good paint shops and assembly lines, Co-ordinate Measurement Machines and conveyers for various product lines. These plants are very flexible to roll out any of 68 variants within a short time as low as one week after putting an order of customized tractor. Eicher puts a lot of emphasis on technology up gradation of its service network as well. Company uses IT as a business excellence enabler and its home portal EPIC is widely used for all in-house daily

- 12 management processes of information sharing, leave planning, performance appraisal and progress tracking etc . ERP package of SAP was established in 1999, which helps smooth transactions in supply chain management processes from supplier raw material planning to tractor delivery at sales outlets and demand forecasting.

EICHER SALES

Key customer groups of Eicher Tractors have typically included the small land holding farmer, which wanted a small tractor in past 3 decades. The company has changed its perception now and offers tractors from smaller 24 HP to premium segment of Valtra . The selling price of the products varies from Rs 2 lacs to 5.5 lacs depending upon the specifications. Today 50 % revenue comes from higher horsepower models. Customers specifically for the low cost of maintenance like Eicher’s tractors as Eicher’s tractors consume minimum fuel in Indian farming and driving conditions.

EICHER SALES AND SERVICES

Eicher Tractors Bhopal being basically tractor assembly operations, most items except a few critical engine parts are bought from out side suppliers to design made by Eicher. The heavy dependence on bought out items puts a very high focus on the supplier quality management processes, which we will discuss in detail later. Suppliers play a valuable role in the value creation process and Eicher R&D takes suppliers input on cost as well as manufacturability of new designs from the suppliers in concurrent engineering environment.

Eicher has a strong supplier and customer relationship and communication mechanism. Suppliers can access the ERP system on line and can get knowledge of their inventory levels, production schedule adherence and tentative future production levels apart from quality inspection status and bill payment processes. Customers have access to 24-

- 13 hour help line and special service desks spread across India to serve them better. Customer is assured of getting the tractor attended within 6 hours of his complaint. Company is also making some channel partners such as ITC & other grain buying houses, Fertilizer & Pesticides companies to enhance bonding with the customers and to increase loyalty towards Eicher.

VARIOUS MODELS: 241 XTRAC:

Engine Make & Model

Eicher

HP Range

24

Type

4 Stroke Air cooled

Cylinders

1

Bore/Stroke (mm)

115 / 150

Cubic Capacity (cc)

1557

Max engine torque kgm

10.5

Back up torque% Oil Bath Type

22

- 14 Transmission Type

Sliding Mesh

Clutch Type

dry, single plate

Gear Box

5 Forward & 1 Reverse Speeds

Rated PTO

495

Hydraulics Type

Automatic depth & draft control

Lifting Capacity at hitch point (kgf)

800(+/- 100)

Hydraulic pump

gear driven

Electrical Battery

12 V

Alternator

12 V

Tractor Fuel Tank Capacity

35

Tyre size

front 6.00x16, rear 12.4x28

Weight kg

1675

Wheel base mm

1885

Ground Clearence mm

375

Type of steering

Mechanical

Features: - Fuel efficient engine - Highest towing capacity in its class - Best output in field in its class - Strong Gear box for longer life - Easy and low cost maintenance - Efficient disc brakes - Live hydraulics with draft and position control

- 15 -

242 XTRAC:

Engine Make

Eicher

Type

4 stroked air cooled

HP Range

24

PTO hp

19.32

no of cylinder

1

Bore mm

115

stroke mm

150

SFC (gm/ptohp/hr)

176

Max eng torque kgm

10.5

Back up torque %

22

- 16 -

Electrical Battery

12 V

Alternator

12 V

Transmission Type

sliding mesh

clutch type

dry, single plate

Brake

dry disc

rated PTO rpm

1021

Gear box speed

8 forward, 2 reverse

Hydraulics Type

automatic depth & draft control

Lift capacity at hitch point (KGF)

1000 +/- 100

Hydraulic

gear driven

Tractor Fuel tank capacity

48

Tyre size

front 6.00x16; rear 12.4x28

Wheel base mm

1895

Ground clearance mm

395

Type of steering

Mechanical

Features - Fuel efficient. - Easy & low cost maintenance - Best output in field in its class - Attractive styling with ergonomic steering & dashboard - Higher towing capacity - Efficient disc brakes with easy serviceability - Live Hydraulics with draft and position control

- 17 -

312 SUPER DI:

Engine Make

Eicher

Type

4 stroked air cooled

HP Range

30

pto hp

30.5

No: of cylinder

2

Bore mm

100

Stroke mm

125

Engine capacity cc

1963

sfc (gm/ptohp/hr)

176

Max eng torgue kgm

12.13

- 18 Back up torque %

19.26

Electrical Battery

12 V

Alternator

12 V

Transmission Type

sliding mesh

Clutch type

dry, single plate

Brake

dry disc

Rated pto rpm

1331

Gear box speed


Hydraulics Type

automatic depth & draft control, mix mode, COR


1000 +/- 100

Hydraulic pump

gear driven


48

Tyre size

front 6.00x16; rear 13.6x28/12.4x28

Wheel base mm

1990

Ground clearance mm

370

Type of steering

Mechanical

Features - Fuel efficient. Engine with Ricardo technology - Easy & low cost maintenance - Best output in field in its class - Higher towing capacity - Life hydraulics with draft and position control - Efficient disc brakes

- 19 -

333 SUPER DI:

Engine Make

S 324 Simpson

HP Range

35

PTO hp

34

Type

4 Stroke, Water Cooled

P. T. O. H. P.

33.3

Bore & stroke (mm)

88.9 x 127

Engine rated rpm

2000

Displacement (cc)

2365

Max eng torque kgm

13.51

Electrical

- 20 Battery

12 V

Alternator

12 V

Transmission Type

sliding mesh

Clutch type

280 mm dry type (single plate)

Gear box

sliding & constant mesh gears

Gear box speed


Hydraulics Type



1000 +/- 100


48

Tyre size

front 6.00x16; rear 13.6x28/14.6x28

Turning radius with brake (m)

3.2

Turning radius without brake (m)

3.68

Type of steering

Mechanical

Features - Fuel efficient. 3 cylinder, Simpson engine - Easy & low cost maintenance - Best output in field in its class - Attractive styling with ergonomic steering & dashboard - Higher towing capacity - Completely water sealed for paddy operation - Mixed mode, live hydraulics suited for heavy duty applications - Efficient disc brakes with easy serviceability.

- 21 -

368 SUPER DI:

Engine Make

Eicher

HP Range

35

pto hp

34

Type

4 Stroke Air Cooled

No: of cylinder

3

Bore (mm)

100

Stroke (mm)

125

Eng. capacity (cc)

2945

sfc (gm/ptohp/hr)

183

Max eng torque kgm

13.51

Back up torque %

18.30

- 22 -

Electrical Battery

12 V

Alternator

12 V

Transmission Type

sliding mesh

Clutch type

dry, dual plate

Gear box speed


Brake

dry disc

Rated pto rpm

597/1331

pto speed

540

Hydraulics Type


Lifting Capacity at hitch point (KGF)

1200 +/- 100

Hydraulic pump

gear driven


48

Tyre size

front 6.00x16; rear 13.6x28/14.6x28


3.2


3.68

Type of steering

Mechanical

Features - Fuel efficient engine with Ricardo technology - Best haulage in its class - Easy & low cost maintenance - Efficient disc brakes - Mixed mode, live hydraulics suited for heavy duty

- 23 380 SUPER DI:

Engine Make

Simpson S325/E1

HP Range

35

PTO HP

36.5

Type

4 Stroke Water Cooled

No: of cylinder

3

Bore (mm)

91.44

Stroke (mm)

127

Cubic Capacity (cc)

2500

sfc (gm/ptohp/hr)

180

Max eng torque kgm

14.17

Back up torque %

15.94

Electrical Battery

12 V

Alternator

12 V

- 24 -

Transmission Type

sliding mesh

Clutch type

dry, single/double plate

Gear box speed


Brake

dry disc

Rated pto rpm

597

pto speed

540

Hydraulics Type

automatic depth & draft control, mix mode


1200 +/- 100

hydraulic pump

gear driven


48

Tyre size

front 6.00x16; rear 13.6x28/14.9x28

Weight kg

2010

Wheel base mm

1905


2.97


3.45

Type of steering

Mechanical

FAB FOR 380 SUPER DI Features - Fuel efficient engine 3 cylinders, water cooled - Easy & low cost maintenance - Best output in field in its class - Attractive styling with ergonomic steering & dashboard - Higher towing capacity - Completely water sealed for paddy operation - Mixed mode, live hydraulics suited for heavy duty applications - Efficient disc brakes with easy serviceability - Optional telescopic front axle suitable for various crops.

- 25 -

480 SUPER DI:

Engine Make

Simpson S325/E2

HP Range

45

pto hp

39.70

Type


no of cylinder

3

Bore (mm)

91.44

Stroke (mm)

127

Cubic Capacity (cc)

2500

sfc (gm/ptohp/hr)

180

Max eng torque kgm

15.61

Back up torque %

18.66

Electrical Battery

12 V

Alternator

12 V

- 26 -

Transmission Type

sliding mesh

Clutch type


Gear box speed


Brake

dry disc

Rated pto rpm

597

pto speed

540

Hydraulics Type



1200 +/- 100

Hydraulic pump

gear driven


48

Tyre size

front 6.00x16; rear 13.6x28/14.9x28

Weight kg

200

Wheel base mm

2075/1910

Draw bar pull unblallasted (kgf)

1612


3.05


3.45

Ground clearance mm

320

Type of steering

Mechanical

Features - Fuel efficient, 3 cylinder, water cooled engine - Easy & low cost maintenance - Best output in field in its class - Attractive styling with ergonomic steering & dashboard - Higher towing capacity - Completely water sealed for paddy operation - Mixed mode, live hydraulics suited for heavy duty applications - Efficient disc brakes with easy serviceability

- 27 -

485 SUPER DI:

Engine Make

Eicher

HP Range

41.1

Type


No: of cylinder

3

Bore (mm)

100

Stroke (mm)

125

Cubic Capacity (cc)

2945

sfc (gm/ptohp/hr)

177

Max eng torque kgm

16.9

Back up torque %

23.50

Electrical Battery

12 V

Alternator

12 V

- 28 -

Transmission Type

sliding mesh

Clutch type


Gear box speed


Brake

dry disc

Rated pto rpm

597

pto speed

540

Hydraulics Type



1200 +/- 100

Hydraulic pump

gear driven


48

Tyre size

front 6.00x16; rear 13.6x28/14.9x28

Weight kg

2045

Wheel base mm

2075

Draw bar pull un ballasted (kgf)

1612


3.2


3.68

Ground clearance mm

395

Type of steering

Mechanical

Features - Fuel efficient engine with Ricardo technology - Easy & low cost maintenance - Best output in field in its class - Attractive styling with ergonomic steering & dashboard - Best haulage capacity in its class - Mixed mode, live hydraulics suited for heavy duty applications - Completely water sealed for paddy operation - Efficient disc brakes with easy serviceability

- 29 -

AN OVER LOOK INTO THE SYSTEM OF EICHER TRACTORS There are following basic departments in EICHER Tractors. 1. EICHER TRACTORS ENGINEERING CENTER This department is responsible for designing the products to be manufactured by the different vendors. The department has been divided into different areas like transmission, which looks after the gear designing, tractor, which looks after general parts of the tractor, hydraulics, which is responsible for looking after the ADDC and the components related to hydraulics, product development, which looks after the various field issues and improving the present products.

2. FINANCE AND ACCOUNTS DEPARTMENT This Department is responsible for all the financial transforms that are carried out in the company such as payments for all the incoming material, salaries of all the employees, all the records for expenditures and Credits to the company are maintained by this department.

3. SALES AND MARKETING DEPARTMENT This Department is responsible for consolidating the position of the company in the market every year. Every year these people get some new strategies so as to increase the share of the company in the market. Most of the Sales of the company are dependent on the working of this department thus being one of the most important departments.

- 30 -

4. MATERIALS/VENDOR DEVELOPMENT This department is responsible for all the incoming material from the vendor. This department is further divided into two departments a) Vendor Development. All the new samples and in fact all the new components are developed by this department. All the components developed are not consumed as a part of the regular production but implemented as a trial only and consumed in regular production only after these components are regularized. b) Regular purchase Department This department is responsible for all the incoming material brought in that is used in regular production. 5. STORES DEPARTMENT This department is responsible for the handling of the incoming material, supplying the material on to the line and also the dispatch the rejected materials back to the vendors. Thus stores have got a huge task to do and that can’t be performed as a single association and thus has been divided into different sections as per the need such as Incoming Material Stores named as Group 1,2,3 Stores, main stores, ETE Stores, Rejection Stores etc. of 6. QUALITY ASSURANCE DEPARTMENT. This department is responsible for over all Quality Control of the incoming components and Assurance about the Quality of the Tractor to the customer. This department is further divided into Sub-Departments, which is discussed separately later on. Quality can be defined’ as ‘fitness for use’ when we talk of quality it means that product should be fit for use and it is the user who judges and decides what qualities he wants in the product. The quality characteristics can be grouped into 4 categories: 1. Quality of design

- 31 2. Quality of conformance 3. Availability 4. Customer service

Quality of design The design must meet all the requirements of the customer. If he wants a motor of say 5 HP, you can’t design your motor for 4.5 HP. The designer should aim at a design which fulfills all the qualities, or almost all the qualities desired by the customer. He should also make a product, which would become more competitive.

Quality of conformance The degree or extent to which a product actually conforms to in accordance with the specification and drawing is called the ‘Quality of Conformance’.

Availability This includes such characteristics as reliability, maintainability and length of life. All these indicate as to what extent the product will be available for use.

Customer Service This includes the extent to which customer can get assistance from the manufacturer or to keep the product in continuous use. The quality policy of Eicher tractor is to design, develop, manufacture and service products of such quality which ensure the customer satisfaction, this is achieved through.

- 32 -

 Continuously identifying customers needs communicating the same within the Organization.  Focus on design for reliability, ease of manufacture and cost effectiveness.  Production and delivery of zero defect products of competitive prices in the Mode l mix required by the customers.  Timely and responsive service after sales. The objective of a quality assurance system is to maintain the necessary standards of quality. The important components of the quality assurance system are:



Monitoring quality assurance program of suppliers.



Checking the accuracy of test measuring equipment.



Evaluating and controlling the quality of product in the field.



Establish a feedback link about the quality-related information to the management.



Evaluating, planning and controlling product quality.



Conducting special quality studies and managing the entire quality system.

The various sub departments of quality assurance department are: (a) Metallurgical Lab (b) Standard Room (c)

Development Cell

(d) Receipt Quality Control

- 33 (e) Manufacturing Quality Control

Sample validation If there are some changes to be made or any new component is to be install a lot of five samples is to be brought to the sample room for verification purposes. Then the sample

is

passed

on

depending

upon

its

dimensional

and

other

required

characteristics. The department purpose is to check the components of new vendor.

The objectives of sample validation department are  To

assure the dimensional and other characteristics of new sample are conforming to

the specification. 

To make quality standards along with materials department to ensure the

characteristics of components over long period of time.

Metallurgical Lab This lab has all facilities to determine the chemical composition of the raw material used for the production of various components. This lab includes Universal testing machine, Rockwell Machine, Brinell Hardness Tester, Rubber Testing Machine, Chemicals for determine the microstructure of the raw material, Rubber tensile testing equipment. The objectives of metallurgy lab To ensure all components should be free from any sort of non-conformance relate4d to physical chemical aspects per relevant standards. To ensure the quality of paints rubber items.

- 34 Standard room These departments house all the measuring instruments and their records. It is a fully air conditioned room with dust free environment. The room is specially made dust proof for avoiding any measurement anomalies. CMM machine is installed here which is used to check the components for better accuracy. Objectives of standard room •

To perform calibration of the various instruments in various department.

•

To demonstrate the confidence level of measurement system to the customer.

•

Gauge planning and procurement from the vendor for calibration. Design release department This department deals with product development of new tractors as was valtra when it was developed last year. Basically this department coordinates between design and various divisions.

Objectives of DR department •

New design implementation

•

To coordinate different department while new design is to be implemented

•

Review of components according to quality aspects and design review.

Receipt quality control RQC may be defined as the sum of the measures taken by the receivers to assure the quality or material offered by vendor. This department receives the components from the vendor and assures mainly the dimensional aspect and also the appearance of the component. This department has a very large list of gauges and instrument, which are duly calibrated according to date; adherence and tractability to the IS there. The clearing of components includes evaluating the sample size from each lot; the components are checked for various aspects and then send for confirmation or rejection.

- 35 Objective of RQC •

To assure the quality of a particular unit or group of units submitted

for acceptance. •

To assure quality characteristics over the long term will meet with the quality standards. The RQC department is sub divided into four sections as/materials these are a)

Sheet metal

b)

Casting

c)

Forging

d)

Bar stock Manufacturing quality control. This department deals with the manufacturing quality. To ensure this quality, various audits are conducted like FIFO (first in first out), tourqing, washing, sealant application, functional audit, settings and various alignments, bearing, final product audit etc. •

Judging the conformity/ of the process to the established standard and taking suitable action when deviations are noted.

•

To assure that these standards are implemented by conducting daily audits and upgrading the standards as and when required.

7. PRODUCTION DEPARTMENT This Department is responsible for carrying out all the assembly operations.

This

department is further sub-divided into some of the parts as per different assembly lines such as Hydraulics Assembly line, Transmission line, Pre-painting line, Paint10 kitchen, Post painting line, PDI etc.

(a) Maintenance department For regular & preventive maintenance of machines & any other equipment used for assembly this. Departments provide its services.

- 36 (b) Store Store assures regular and continuous supply to avoid line stopping. All the materials purchased are stored here systematically and items that can be rusted are applied with rust preventive oil once in a week and in season twice in a week. The assembly line has been categorized depending upon the operations they are performing. They are namely: •

ADDC line

•

Transmission line

•

Pre painting line

•

Paint shop

•

Post painting line

ADDC line ADDC stands for automatic depth and draft control. This is used for the operation of the agriculture implements like cultivator, MB plough, disc harrow, etc. ADDC system controls the depth of implement, depending upon the draft. Draft is resistance of the soil, which acts against the implement. ADDC system is based on the principle of sensing the forces on implement and hence using the hydraulic pressure to lift or lower the 3point linkage.

Transmission line In this line the gear box, differential assembly, final drive assembly and ADDC coupling is done. The gearbox assemble is called g1 and the differential assembly is called g2. The various gear mechanisms used in tractor are: •

Sliding gear mechanism

•

Synchro-mesh mechanism

Most of the models have sliding gear mechanism expect for the Eicher Valtra 6100 and power 6100, which have got synchromesh gear and mechanism. There are 8 speeds in forward direction- 4 in high speed and 4 in low speed, 2 gears are in reverse direction. The high low speed is engaged by lever high-low. With the high low provision we can increase the torque since at low speed the torque generated is

- 37 more. Transmission assembly also consists of PTO (power transmission output) that is used to run the pump for drawing out water and some implements like rotavator, etc. Pre Painting line This line includes the coupling of engine and fly wheel to the transmission assembly. For this purpose there is a machine which ensures that proper coupling is done. Then brakes, clutch, steering mechanism are assembled along with the other items like front weight, pressures pipe suction pipe etc.

Paint shop This shop is basically in 2 categories one line itself and second sheet metal paint shop. On the line, the chassis of the tractor is painted and is then baked in over. In sheet metal paint shop consist of thirteen tank systems, which include first cleaning of the material, de-rusting, descalling, surface activation for better paint adhesion.

Post painting line The post painting line involves the assembly of bonnet, dashboard, electrical air cleaner, water radiator, tyres, etc. This also involves the filling of oils like steering, air cleaner, gear box oil and diesel oil. 8. MAINTENANCE DEPARTMENT This department is responsible for carrying out all the maintenance work to be carried out in the plant. Any kind out of repair work or maintenance such as electrical maintenance, this department carries out working of equipment on the assembly line etc. 9. ENGINEERING DEPARTMENT

- 38 This Department is responsible for launching new technologies in the plant such as any kind of new testing machine, implementation of new machines, layout of the plant and reducing the overall expenditures of the plant by desiccating etc.

10. SERVICES This department is responsible for providing all the services and repair works to the customers after tractors have been sold. Many new methods and strategies have been adopted in the past to provide need full service to the customers and full care has been taken to take care of their valuable suggestions and feedback. 11. HUMAN RESOURCES DEPARTMENT: This is the most important department of any organization. As we all know that 3 M’s are most vital for any production unit. These 3 M’s are Men, Materials, and Machines. Out of all the, Men or Human Resource is the most complicated or important resource for any organization, the department which performs all the functions relating to the human resources is known as HUMAN RESOURCE MANAGEMENT. Human resource department is divided into 3 parts:  Corporate HR  Plant HR  Marketing HR The department is responsible for each and every function regarding the Human resources.

- 39 PLANT LAYOUT 5. Plant Layout & Departments

Component Washing

Addc line

Rework Area

Pre painting

Samples room

Inspection

Transmission

Store

Pre painting store (right)

PRV ROOM

Washing

Production house

Painting and Baking

Engg. Deptt. And SHQ

Test rig

Post painting Sub assy

Sheet metal washing and painting

R.Q.C

Transmission

Pre painting store (left)

Post painting store

P.D.I. and Final Inspection

Air filling station

Post painting store

- 40 -

I am here in Eicher tractor, mandideep for knowing about 5150 pwer steering and also knowing about its mechanism.

- 41 -

- 42 -

- 43 -

COMPONENTS OF 5150 PS 1.Gasket gear pump 2.Pipe mounting braket 3.Tandem pump 4.Filter 5.Hex bolt

Eicher Project Report-SANAT

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