Internship Report @ Millat Tractors Limited (MTL) 2013

33 %
67 %
Information about Internship Report @ Millat Tractors Limited (MTL) 2013
Education

Published on February 15, 2014

Author: azlanchaudhry

Source: slideshare.net

Description

6 week Internship Report @ Millat Tractors Limited (MTL), Lahore, Pakistan.

Millat Tractors Limited 2013 INTERNSHIP REPORT Azlan Zahid Millat Tractors Limited 4/1/2013 to 5/16/2013 University of Agriculture Faisalabad Page 1

Millat Tractors Limited Acknowledgements We are pleased to acknowledge Mr. Naseem A. SandhuGM(Admin) and Mr. Azhar Noor Dy.GM (Mktg.) Millat tractors limited who helped us to work here as internee. We have learned a lot during my period of internship in MTL. We have observed our theoretical knowledge being converted to practical processes. We also acknowledge Mr. Khawaja Ali Hassan AM (Mfg.) from manufacturing department, Mr. Hafiz Faheemand Abdul MannanfromEngine Assembly Plant (EAP), Mr. Athar GM (QA) and especially Mr. Muhammad AkmalDy. Manager (Production) from Tractor Assembly plant (TAP), and all others for their help and support in instructing and giving us sound knowledge about their respective plants. University of Agriculture Faisalabad Page 2

Millat Tractors Limited Executive Summary Millat Group is Pakistan’s leading engineering concern in automobile sector & has a history that spans almost half a century. MillatTractors Limited MTL is market leading industry of agricultural tractors & holds above 50% market share. We carried our work according to the given schedule. The activities assigned to us were very precise and intellectually challenging. The activities include are; complete visit to market and dealership network to know about the market policy of MTL, the current demand of tractors & market position of MTL, after sales services provided to the customers, visit dealer’s workshop to know about the quality of the Product. Viewing of machining of different parts, Engine assembly, Tractor assembly and different operations after which the real product comes out. The course of action adopted to complete these activities was to first understand the Assembly machines and then the assembly of the parts .These activities were done in the supervision of the assigned engineers. Our activity also includes to keep an eye on how QA dept. is working and how this dept. make it possible the best quality product. The response we got from market dealers about the quality of the product is fairly satisfactory. We also conducted many survey in different departments during our internship at MTL regarding material flow, health and safety conditions and mishandling of tools and parts. According to our observation and analysis the reason behind the poor quality of the product is due to the poor materials supplied by the vendors and inefficiency of QA dept. We found that customer’s perception about MASSEY FERGUSON is good and irrespective of the quality customer is always willing to purchase MASSEY FERGUSON. Currently, high price is the major factor for decrease in the tractors demand. As Pakistan is an agriculture country, Govt. should implement such policies in agriculture sector that favors farmer. Govt. should right off the tax on tractor on immediate basis in order to provide support to this falling sector. University of Agriculture Faisalabad Page 3

Millat Tractors Limited Report on Internship at Millat Tractors Limited (MTL) We, thegroup of 07 students of B.Sc. Agricultural Engineering form University of Agriculture Faisalabad (UAF) got an opportunity to do internship in a professional engineering environment at Millat Tractors Limited (MTL). Our aim was to get training and experience about the processes happening in this industry. Name 1. 2. 3. 4. 5. 6. 7. Uni. Reg. #. 2009-ag-3108 2009-ag-3109 2009-ag-3084 2009-ag-3100 2009-ag-3092 2009-ag-3150 2009-ag-3204 AzlanZahid Muhammad Ali Usman Hassan Tanzeel-ur-Rehman NadeemAkram Haseeb Bilal Muhammad Aamir Our training schedule was as under Sr. #. 1 DATE DURATION DEPTT: REPORT TO 27-03-2013 to 09-04-2013 02 Week Marketing Division GM (Marketing) 2 15-04-2013 to21-04-2013 01 Week Manufacturing Dept. GM (Production) 3 22-04-2013 to29-04-2013 01 Week Engine Assembly Plant GM (Production) 4 02-05-2013to 09-05-2013 01 Week GM (Production) 5 10-05-2013to 16-05-2013 01 Week Tractor Assembly Plant (TAP) Quality Assurance (QA) GM (QA) Supervisor University of Agriculture Faisalabad Page 4

Millat Tractors Limited Internship Program Date 01-04-2013 Period Full Day Department Engine Assembly Plant 02-04-2013 Full Day Tractor Assembly Plant 03-04-2013 Full Day Dealership & workshop visit Sheikhupura and Ferozewala SajjadHussain& Imran Ayub 04-04-2013 1st Half 2nd Half Field Marketing Services Role of dealership network After sales Service network Physical inspection of specs of tractor Khalid Sandhu (SM-FM) Ali Akhtar (SM-Svc) 05-04-2013 Full Day Lahore market & customer Survey Current tractor demand & factors Azhar Noor (DGM-Mktg) Marketing 09-04-2013 Activity Responsibility Abdul Mannan KhurramA.Warraich (SM-P) Report completion from 06-04-2013 to 08-04-2013 Report Submission M. Akram (GM-Mktg.) 15-04-2013 Full Day Manufacturing Cylinder Block Line Khawaja Ali Hassan 16-04-2013 Full Day Manufacturing Cylinder Block Line (Ext) Khawaja Ali Hassan 17-04-2013 1st Half 2nd Half Full Day Manufacturing Transmission Line CNC Cylinder Head Line (Ext) Khawaja Ali Hassan 19-04-2013 1st Half 2nd Half Manufacturing Central Housing Line Lub Oil line Khawaja Ali Hassan 22-04-2013 Full Day Engine Assembly Segregation & Washing Section Engr. Hafiz Faheem 23-04-2013 Full Day Engine Assembly Engine Assembly Section Engr. Hafiz Faheem 24-04-2013 Full Day Engine Assembly Engine Test Section Engr. Hafiz Faheem 25-04-2013 Full Day Engine Assembly Rectification Section Engr. Hafiz Faheem 18-04-2013 Report completion from 26-04-2013 to 28-04-2013 HR Dept. Report Submission 29-04-2013 02-05-2013 Manufacturing Full Day Tractor Assembly Plant (TAP) Visit of Assembly Lines University of Agriculture Faisalabad Khawaja Ali Hassan SaeedIkram Muhammad Akmal Dy. Manager (Production) Page 5

Millat Tractors Limited 03-05-2013 Full Day Tractor Assembly Plant (TAP) Mishandling Survey 06-05-2013 Full Day Tractor Assembly Plant (TAP) Material Flow Analysis 07-05-2013 Full Day Tractor Assembly Plant (TAP) Paint section survey Muhammad Akmal Dy. Manager (Production) 08-05-2013 Full Day Tractor Assembly Plant (TAP) Rear AxleBuild Line Muhammad Akmal Dy. Manager (Production) 09-05-2013 Full Day Tractor Assembly Plant (TAP) Chassis Build Line Muhammad Akmal Dy. Manager (Production) 13-05-2013 Full Day Quality Assurance (QA) Introduction to QA dept. and its different sections Mr. Athar GM (QA) 14-05-2013 Full Day Quality Assurance (QA) Testing Labs visit Mr. Mansoor 15-05-2013 1st Half Quality Assurance (QA) CMM and UMM Said Noor 16-05-2013 2ndHalf HR Dept. Report completion from 15-05-2013 to 16-05-2013 Report Submission Muhammad Akmal Dy. Manager (Production) Muhammad Akmal Dy. Manager (Production) SaeedIkram (HR Manager) Office Stamp University of Agriculture Faisalabad Page 6

Millat Tractors Limited Contents Page Section Page Number Acknowledgements Executive Summary Organization Structure 02 03 11 1. Introduction 1.1. Millat Tractor Ltd 1.2. Bolan Castings Ltd 1.3. MillatEquipment Ltd 1.4. Millat Industrial Products Ltd 2. About The Company 2.1. Hierarchy Of Strategic Intent 2.1.1. Company’s Vision 2.1.2. Company’s Mission 3. History 4. Products of Millat Tractors Limited 4.1. Tractors 4.1.1. Tractor Types and Comparison 4.2. Agriculture implements 4.3. Multi-Products 5. Marketing Division MTL 5.1. Different Sections of Marketing Division 5.2. Internship Activities 1st and 2nd week 5.2.1. Day 1 Activity 5.2.2. Day 2 Activity 5.2.3. Day 3 Activity 5.2.4. Day 4Activity 5.2.4.1. Free Services details 5.2.5. Day 5Activity 6. Machining Division of MTL 6.1. Lines in Machining Division 6.2. Major Vendors 6.3. General Operations in Machining 6.4. Details of Machining Lines 7. Internship Activities 3rd Week (Machining) 7.1. Day 01 Activity 7.1.1. Cylinder Block Machining Operations 7.2. Day 02 Activity 10 10 10 10 10 12 12 12 12 14 15 15 15 17 21 23 24 31 31 31 31 32 32 32 35 35 36 37 38 46 47 47 51 University of Agriculture Faisalabad Page 7

Millat Tractors Limited 7.3. Day 03 Activity 7.4. Day 04 Activity 7.5. Day 05 Activity 8. Engine Assembly Plant 8.1. Segregation Section 8.2. Engine Assembly Line 8.2.1. Sub‐Assembly or Pre‐Assembly 8.3. Engine Test Section 8.4. Rectification Section 8.5. Finished Engine store 9. Internship Activities 4th Week (EAP) 9.1. Engine Build Operations 10. Tractor Assembly Plant (TAP) 10.1. Tractor Assembly Shop 10.2. Tractor Assembly Shop seven stages 10.3. Sections of TAP 11. Internship Activities 5th Week (TAP) 11.1. Task 01 11.1.1. Introduction 11.1.2. Detail Data of Mishandling Survey 11.1.3. Reasons of Mishandling 11.2. Task 02 11.2.1. Introduction 11.2.2. 1st Group Questionnaire (Segregation Section) 11.2.3. 2nd Group Questionnaire (Assembly Lines) 11.3. Task 03 11.3.1. Introduction 11.3.2. Questionnaire (Painting Section) 12. Internship Activities 6th Week (QA) 12.1.Introduction 12.2.Different types of gauges 12.3.Inspection and Testing Facilities in Labs 12.3.1. Oil and Grease Testing 12.3.2. Paint and Coating Testing Lab 12.3.3. Rubber Testing 12.3.4. Material Testing 12.3.5. Mechanical Testing 12.3.6. Metallographic and Microstructure 12.3.7. Metrology 12.4.Coordinate Measuring Machine 13. Target Setting At Millat Tractor University of Agriculture Faisalabad 51 51 51 53 54 55 58 58 61 63 63 66 71 71 72 74 81 81 81 81 82 83 83 84 85 88 88 88 91 91 91 91 91 91 91 92 92 92 92 92 93 Page 8

Millat Tractors Limited 14. Internal Problems Analyzed At Millat Tractors Limited 14.1.Product Development (Operational Level Problem) 14.2.Weak in Aggressive Marketing 14.3.Unsatisfied Delivery Procedure 14.4.Lack of Proper Survey 14.5.Delay Tractor Delivery 14.6.No Team Work 14.7.Centralized Decision Making 14.8.Time Consuming Procedure 14.9.No Customer Dealing Department in Real Meaning 15. Market Analysis 15.1.Problems regarding the quality 16. Reasons for Market Downfall 17. Suggestions 18. Conclusions 19. References 94 94 95 95 95 96 96 96 96 96 96 96 97 97 101 101 List of Tables & Graphs Table.1. Internship Schedule Table.2. Internship Program Table.3. Marketing Network Table.4. Customer Survey details Table.5. Production and Sales Table.6. Production against Workers Table.7. Different Ranges for Engine testing Table.8. Production and Sales (engine) Table.9. Data of Mishandling Survey 04 05 22 33 33 52 59 65 82 Graphical Representation of Production and Sales Volume Graphical Representation of Market Share across Pakistan Graphical RepresentationProduction against Workers Graphical Representation of Daily Engine Assembling Graphical Representation of Production and Sales volume (engine) Graphical Representation of Weekly Production in TAP Graphical Representation production and Sales Volume 34 34 52 64 65 90 90 Line Diagram of Material Flow Line Diagram of Engine Assembly Plant 46 64 University of Agriculture Faisalabad Page 9

Millat Tractors Limited 1. Introduction Millat Group is Pakistan’s leading engineering concern in automobile sector & has a history that spans almost half a century. Millat Group encompasses four major companies MILLAT TRACTOR LIMITED, MILLAT EQUIPMENT LIMITED, MILLAT INDUSTRIAL PRODUCT LIMITED and BOLAN CASTINGS LIMITED. Today the group manufacturers: Tractor under licensing agreement with Massey Ferguson, UK (owned by AGCO, USA), Diesel Engine, Diesel Generating Sets and Prime Movers, Forklift Trucks under license from M/s Anhui Heli Co. LTD. China, a range of Agriculture Implements, Gears, Batteries and Automotive castings. The company is also dedicated to customize its products as per customer’s requirements Millat Group has played a pivotal role in transfer of technology & transformation of the fledging local light engineering sector into a robust, vibrant, quality conscious Auto Vending Industry. The fact that Millat Tractor has a market share of more than 50% and indigenization level of 90% is a testament to the efforts of Millat Group over that last 47 years. 1.1. Millat Tractors Ltd Millat tractors Ltd MTL- an ISO 9001 :2008 certified company for its assembly & material testing & gauge control laboratory-is Pakistan’s leading engineering concern in automobile sector. It manufactures MF-240, MF-350, MF-260, MF-375, MF-385, MF-385 4WD, Implements, Prime movers, Forklift Truck & Power Generation Sets www.millat.com.pk 1.2. Bolan Casting Ltd In 1993, the Company in collaboration with the employees of Bolan Casting Limited (BCL) acquired the management control of Bolan Casting Limited by purchasing 51% of the Company shares offered by the government as part of the process of privatization. BCL provides major casting for Automobile Industries and also 50% of the Company requirements are met from it. Since acquisition of the control by MTL, BCL has also performed very well and has been on a growth pattern. www.bolancastings.com 1.3. Millat Equipment Ltd Millat Equipment Limited is an associated Company and was incorporated in 1993 as a private limited Company under the Companies Ordinance, 1984, and was converted in to unquoted Public Limited Company on April 20, 2004. The Company is engaged in the business of manufacturing of automotive, agricultural and industrial vehicles, parts and components thereof. www.millatgears.com 1.4. Millat Industrial Product Ltd Millat Industrial Products is a subsidiary of the Millat Tractors Limited. The Company is engaged in the business of manufacturing and sales of vehicular, industrial and domestic batteries. www.millatbatteries.com University of Agriculture Faisalabad Page 10

Millat Tractors Limited University of Agriculture Faisalabad Page 11

Millat Tractors Limited 2. About The Company Millat Tractors Limited is a Pakistan‐based company engaged in the assembly and manufacturer of agricultural tractors, implements and multi‐application products. Millat Tractors Limited (MTL) is an ISO 9002 certified company for its Assembly Plants (Tractor Assembly, Engine Assembly, and Industrial/Agricultural Products), Material Testing and Gauge Control Laboratory. It is Pakistan’s leading engineering concern in the automobile sector, that manufactures; Tractors, under licensing agreement with Massey Ferguson, UK (AGCO, USA) Diesel Engines Diesel Generating Sets and Prime Movers Forklift Trucks, under license from Anhui Heli Forklift Trucks China and A range of Agricultural Implements. The company is also dedicated to customize its Diesel Generating Sets and Prime Movers asper requirement of its Customers. The company has spread its products throughout the length and breadth of the country. Today the number of MF tractors made by MTL exceeds 250,000 while the total number of tractors in the country is approximately 500,000, giving it a market share of above 50%. In other words every second tractor in Pakistan is MF. This achievement has been made possible only through the Company’s commitment to Quality, After Sale Service, and competitive Prices. During the fiscal year ended June 30, 2010, the Company delivered 40,140 tractors. In fiscal 2010, it produced 40,178 tractors. And in this year 2013, their target is to achieve production of about 32,000 tractors. 2.1. Hierarchy Of Strategic Intent 2.1.1. Company’s Vision “Millat to be global group of companies, recognized for a range of quality products with innovative design capabilities”. 2.1.2. Company’s Mission “Millat to be market leader in agricultural tractors and machinery, building companies image through innovation and competitiveness, grow by expanding market and investing into group companies, ensuring satisfaction to customers and stakeholders and to fulfill social obligations.” University of Agriculture Faisalabad Page 12

Millat Tractors Limited Proposed Company’sVision: vision of Millat Tractors should be: 1. “To improve and maintain the leadership position” 2. “Millat Tractors Limited is dedicated to provide quality innovative products with the best package of guaranty and warranty for its customers whenever they are” 3. “To make Millat Tractors as leaders all the way” Proposed Company’s Mission:Mission Statement of Millat tractor should be: “ To retain and improve Millat Tractor good will, profit ability and market leadership by manufacturing the quality Tractors and machinery and making human capital more committed, productive and efficient.” 3. History Millat Tractors Limited (MTL) was established in 1964 to introduce and market Massey Ferguson (MF) Tractors in Pakistan. An assembly plant was set up in 1967 to assemble tractors imported in semi-knocked down (SKD) condition. The company was nationalized under Economic Reforms Order in 1972 and started assembling and marketing tractors on behalf of Pakistan Tractor Corporation (PTC) which was formed by the Government for import of tractors in SKD condition. In 1980 the Government decided on indigenization of the tractors and entrusted this task to PTC (Pakistan Tractor Corporation). PTC transferred this role of indigenization in 1981 to MTL. This was the turning point in the Company’s history and it went about the task methodically and rapidly. The Company undertook this new role with enthusiasm and in the spirit of national development and proved its engineering capabilities by surprising the deletion targets set by the Government. Just in one year’s time, the company took a giant step towards self-reliance by setting up the first engine assembly plant in Pakistan. In 1992, the company was privatized. The employees joined hands and took over the management by winning an open bid. To maintain its leadership role in tractor manufacturing in the country, MTL continues to look toward future, to identify and exploit new opportunities and to consolidate existing ones. The Tractor Assembly Plant is part of this philosophy. This plant started its production in 1992. The establishment of this modern plant not only increased production capacity to 16000 tractors per year on a single shift basis, but also provided a quantum jump to the quality of the assembled tractors and pushed MTL into ranks of the major tractor manufacturing companies of the World. The Company made a strategic decision right in the beginning to bring those manufacturing facilities in-house for which capabilities did not exist in the country and for parts which required high precision and investment. Therefore, in 1984, sophisticated manufacturing facilities for the machining of intricate components were set up. These were previously not available in Pakistan. Currently, critical components like Engine Blocks, Sump, Transmission Case, Axle Housing, University of Agriculture Faisalabad Page 13

Millat Tractors Limited Hydraulic Lift Cover, Front Axle Support and Centre Housing are all being machined most successfully in-house at MTL from locally sourced castings. At MTL, we firmly believe that producing to International quality standards is the key to our continued success and growth, and our quality control department converts this belief into reality. In 1992, the company was privatized. The employees joined hands and took over the management by winning an open bid. To maintain its leadership role in tractor manufacturing in the country, MTL continues to look toward future, to identify and exploit new opportunities and to consolidate existing ones. The Tractor Assembly Plant is part of this philosophy. This plant started its production in 1992. The establishment of this modern plant not only increased production capacity to 16000 tractors per year on a single shift basis, but also provided a quantum jump to the quality of the assembled tractors and pushed MTL into ranks of the major tractor manufacturing companies of the World. After successful takeover, MTL also acquired the management control of Bolan Castings Limited (a Public Limited Company specializing in intricate automotive castings) in partnership with employees of the company, in 1993. In 1992, the production of Millat Tractors was just 8,000 units per annum with variety of only 2 main products, now the annual production is reached from 8,000 units to 45,000 units with variety of 8-different main models. Moreover, the company looks to the future with optimism and plans to broaden its customer base. Consequently the opportunities are being explored in multi-application of engines and tractors in areas other than farming sectors. Mass Production of Generating Sets was started in 1994, while a 3-Ton Fork Lift Truck branded as Millat, based on TCM technology was launched in the year 2002. In addition, Millat Tractors Limited has been the regular recipient of the Corporate Excellence Award of Management Association of Pakistan and the Top Companies Award of Karachi Stock Exchange, since early eighties. MTL’s Annual Report has been acknowledged as the Best Annual Report by the Institute of Chartered Secretaries and Admin Association of Pakistan for several years. A wide range of Massey Ferguson Tractors from 50 HP to 85 HP is available to cater to the needs of farmers. These Tractors can be procured against Cash, as well as through Bank Financing. Brief Specifications of each of the Tractors are available under Tractors In Industrial Products, a wide range of Generating Sets 15 KVA to 40 KVA, Forklift Trucks (3 ton) and Prime Movers (Power packs) from 50 HP to 85 HP. Also deals in range of Generating Sets from 27 kVA to 2000 kVA. A wide range of Agricultural Implements is also available like Chisel, Disc &Mould Board Plough, Tine Tillers, Offset Disc Harrow, Ridger, Front Blade, Multi‐purpose Rear Blade, Agricultural Loader, Farm Trailer, Hydraulic Tipping Trailer, Jib Crane, Post Hole Digger, Lawn Mover, and Pneumatic Pruning Set etc. University of Agriculture Faisalabad Page 14

Millat Tractors Limited The biggest Spares Network ensures the availability of Genuine Parts, for the complete range of products throughout the country. Now HOLOGRAM SEAL backed by oneyear warranty ensures its genuineness. Millat also ensures to provide prompt after‐sales service to its valued customers through spread network of main and rural workshops throughout the Country. Products of Millat Tractors Limited 4. Millat Tractors Limited is manufacturing a large variety of agriculture equipment. The major share of its product is of tractors.Some of the major products of Millat Tractors Limited are as follow: 4.1. Tractors       MF-240 MF-260 MF-350 MF-350+ MF-375 MF-385  MF-385 (4WD) 4.1.1. Tractor Types and Comparison University of Agriculture Faisalabad Page 15

Millat Tractors Limited University of Agriculture Faisalabad Page 16

Millat Tractors Limited University of Agriculture Faisalabad Page 17

Millat Tractors Limited University of Agriculture Faisalabad Page 18

Millat Tractors Limited University of Agriculture Faisalabad Page 19

Millat Tractors Limited University of Agriculture Faisalabad Page 20

Millat Tractors Limited University of Agriculture Faisalabad Page 21

Millat Tractors Limited University of Agriculture Faisalabad Page 22

Millat Tractors Limited Marketing Network of MTL University of Agriculture Faisalabad Page 23

Millat Tractors Limited University of Agriculture Faisalabad Page 24

Millat Tractors Limited University of Agriculture Faisalabad Page 25

Millat Tractors Limited University of Agriculture Faisalabad Page 26

Millat Tractors Limited University of Agriculture Faisalabad Page 27

Millat Tractors Limited University of Agriculture Faisalabad Page 28

Millat Tractors Limited University of Agriculture Faisalabad Page 29

Millat Tractors Limited University of Agriculture Faisalabad Page 30

Millat Tractors Limited 5.2. Internship Activities of 1st and 2nd week 5.2.1. Day 1Activity On day 1 (01-04-2013)as per schedule we had avisit to Engine Assembly Plant where we reported to Mr. Abdul Mannan. He briefed us all the engine assembling stages & engine testing system. We spent full day over there & observed things closely. Firstly we went to segregation section where all parts are received. After that these parts go through the process of De-greasing (Trichloroethylene) & Washing (Redline). Then we moved to main assembly line where all the parts are assembled on its turn as given in Engine Build/Test Card. The workers were doing necessary quality checks where required. When the engine was completely assembled it was ready for test run. In engine testing section the engine was attached to the testing machine for a duration of 40min. The engine was tested against the different rpm & loads. The pressure in the oil galleries was tested by a software operated testing machine. If the engine passes the test it is ready to go to the Tractor Assembly Plant. 5.2.2. Day 2 Activity On day 2 (02-04-2013) as per schedule we had a visit to Tractor Assembly Plant where we reported to Mr. Khurram A Warraich. He brieflydescribes all the operations happening in Tractor Assembly Plant&also told us that the Plant is ISO certified. During this brief introduction we came to know the production capacity of the plant which is normally 58 tractors per shift. There are 2 shifts per day & one shift can produce max of 97 tractors. Around 112 persons work there in 1 shift. There are 3 assembly lines (Rear Axle Build line, Chassis Paint Line, Final Build Line).We closely observed all the assembling stations turn by turn.Whenever we found it difficult we consulted with the station supervisor. When the tractor is fully assembled it is passed to QA. Then the QA issues the fitness certificate to that tractor & if it does not match the standards it is sent back to remove the fault. If it clears all the required tests it is further passed to marketing department. 5.2.3. Day 3 Activity On third day (03-04-2013) we visited the Sheikhupura and Ferozewala dealers and their workshops. Our major concern was to know about the market share of MTL and its competitors, quality of the brand, dealership network and commissions. In these regions MTL occupied the maximum market and the share is about 100%. The dealership network is very extensive to facilitate the farmer at his doorstep and workshops are available at every 10 km distance. From today’s visit we concluded some points that are listed below. According to the dealers, the overall quality of the tractors is not satisfactory because of the reasons like the performance of Fuel Injection Pump is not good as it consumes more fuel due to University of Agriculture Faisalabad Page 31

Millat Tractors Limited the greater rotor clearance. The major problem is of Differential System (Crown Wheel).There is also a problem of Rear Rim distortion in shape and early rusting of the rims.Pressure is not maintained in the Hydraulic System under loaded conditions due to the manufacturing fault.The chassis is not properly painted due to which sometimes it rusts. We collected this information by visiting the dealer’s workshop by interviewing the fore-man there on duty. 5.2.4. Day 4 Activity On 4th day (04-04-2013) we dealt with after sales services regarding warranty and its terms and conditions,claim details, IFS software, rejection section and material management department.Warranty of tractor is 1 year or 1200 hours from the date of delivery. Accidental case is not accommodated. Parts can be claimed from nearby dealer’s workshop. Within first 24 hours any problem in engine the whole tractor is replaced. Within 100 hours any problem in engine the whole engine is replaced.MTL does not debit any claimed part in its account until it is anassembling fault. Claim is not provided if it is driver’s fault the team assures either it is a driver fault, manufacturing fault or assembling fault. Claims are entered through IFS software (International finance solution) which is inter connected with MMD (Material Management department), MIR (Material Issuance Requisition) and Material Rejection Department. 5.2.4.1. Free Services The free service accommodates the tuning, labour, oil filters and primary diesel filters. MTL provides 138 Rupees per hour as repair time schedule to the labour. First free service at 30 hours Second free service at 200 hours Third free service at 600 hours 5.2.5. Day 5 Activity On day 5 (05-04-2013) we had a meeting with Sir Azhar Noor (DGM-Mktg) he briefed us about marketing tactics, need of marketing and customer survey. Then we went to the Lahore market and visited the customers to know their opinion about MTL, current tractors demand, customer satisfaction level, brand equity, company’s repute, and future demand of tractors. The production of MTL is 42000 in 2011-2012 and is now reduced to 32000. The details of the customer survey are given below. University of Agriculture Faisalabad Page 32

Millat Tractors Limited Name M.Hanif Location Noshehra Cont.# Model 0344-6084451 MF-240 MF-375 0333-7914614 MF-240 M. Raza Khan Ziarat Muzafar Rahim Shamkay 0307-4444274 MF-240 GT Road, Lahore Area 8 Acre 5 Acre 50 Acres Remarks Fiat Engine is better than Massey. Easy starting in cold weather, brand trust and after sales services are good. problem of hydraulic pump. 2nd gear fault, no quality of tractor, paint, seals and nut bolts are not of good quality. Suggestions Improve fuel consumption Sheet metal should be of good quality Improve overall quality rather than focusing on quantity. Customer Survey details Graphical representation of the total production and sale of last five years is given below Total production and Sale per Annum Year Units Produced Units Sold 2007 27081 27127 2008 27506 27260 2009 30244 30677 2010 40178 40140 2011 42188 42011 2012 32004 32006 Production and Sales University of Agriculture Faisalabad Page 33

Millat Tractors Limited 45000 40000 35000 30000 25000 Units Produced 20000 Units Sold 15000 10000 5000 0 2007 2008 2009 2010 2011 2012 Graphical Representation of Production and Sales volume 70 60 50 40 Millat tractors Al-Ghazi Tractors 30 Others 20 10 0 2010 2011 2012 Graphical Representation of Market Share across Pakistan University of Agriculture Faisalabad Page 34

Millat Tractors Limited Machining Division 6.1. Lines in Machining Division There are nine lines in the machining division listed below 1. Axel Housing Line (Right and Left) 2. Cylinder Block Line (old) 3. Cylinder Block Line (Ext) 4. Cylinder Head Line (Ext) 5. Center Housing Line 6. CNC Line 7. Lub Oil Sump Line (240) 8. Lub Oil Sump Line (385) 9. Transmission Case Line We visited each of these machining lines in 5 days and studied the process of machining ofcasted components. In all the components the first operation was usually a milling operation to provide University of Agriculture Faisalabad Page 35

Millat Tractors Limited a flat surface to locate component. And then all the fixtures throughout the machining line used inside diameter for locating part also known as dowel holes. 6.2. General Operations in Machining 1. Drilling 2. Rimming 3. Boring 4. Counter Boring 5. Spot Facing 6. Counter Sinking 7. Milling 8. Tapping 9. Facing 10. Turning 11. Honing University of Agriculture Faisalabad Page 36

Millat Tractors Limited 6.3. Major Vendors 1. 2. 3. 4. 5. 6. 7. Bolan Casting Millat Equipment Ltd. KSB Pumps Chenab Castings Sino Diesel Sturlings Millat Electric Ltd. University of Agriculture Faisalabad Page 37

Millat Tractors Limited Cylinder block It is foundation of the engine. All other engine parts are assembled in or attached to cylinder block. There are two cylinder block machining lines. Old Manual machining line New Automatic machining line Old Machining line Capacity of old line is 48 parts per shift. It uses casted cylinder blocks from Karachi and machines them through a number of operations. These include Drilling, boring and reaming holes for attaching various parts such as crank and cam bores, water jacket holes etc Cylinder bores are machined and then provided surface through process of honing. Since overhead camshafts are used in the engines manufactured here, camshaft bearings holes are bored. Surfaces to which parts are attached are milled, machined and surface finished. Oil passages are drilled. Coolant passages are cleaned out. Then all seal plugs are fixed and then the cylinder block is tested for any leakages through pressure test. There is an automatic hooter attached with the test bench. If the pressure drops inside the submerged cylinder block, it indicates a leakage and automatically buzzer starts sounding. Engine cylinder liners are then fitted inside the cylinder. They save the cylinder walls from getting damaged due to continuous reciprocating motion of piston against cylinder wall. Cylinder liners are again bored and honed for smooth and accurate surface finish. New Automatic Machining line It has got a capacity of 72 parts per shift which is quite faster than the old machining line as it uses different transfer systems that perform different machining operations in a single plant thus decreasing the cycle time and increasing productivity. Cast iron blocks used here are casted in china. All the 22 operations performed are same as old line but in different sequence. Different plants and machines used in this process are i. Plant 6269 University of Agriculture Faisalabad Page 38

Millat Tractors Limited ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. xvi. xvii. xviii. xix. Plant 1554, a PLC operated plant and it can take 10 components at a time for machining Machine 1676 Machine 730 Machine 5307 Plant 1623 Machine 762, rear and front face finish operation Plant 5939, can have 5 cylinder blocks machined at a time. Plant 1617 oil bearings supply and bearing notches, it divides different operations thus increasing work efficiency Machine 3940, milling machine Plant 1647 this plant does 6 different operations Machine 763, plug stage M/C 6270 boring and finishing of liner bores M/C 6400 cylinder bores and honing process M/C 5202, pressure test, water gasket test M/C 1779 liner fitting M/C 747 liner boring M/C 4676 liner honing Final stage, here machined cylinder block is given a final inspection Transmission Case Machining Line Transmission case is a very important component of a tractor and it has got one semi‐automatic line. That line had been shut down for some maintenance work so the 3 CNC i.e. computerized numerical control machines were being used for its production. CNC machines were being operated by specialized operators who would enter a part program into the machine and then close the door for CNC to work. At a time, 3 components could be loaded into the CNC machine which would be machined one after the other.After machining the total weight is 77.8 Kg with grade 14 and hardness of 179‐203 BHN. University of Agriculture Faisalabad Page 39

Millat Tractors Limited Operations  Triplex Milling Machine This is the first operation on transmission case. Cast transmission case is fitted in machine fixture and mills the three side’s top, rear and end face of transmission case by the help of triplex milling machine.  Radial Drilling Machine In this operation top face of the transmission case is drilled by the help of radial drill machine and in this operation two dowel holes are also making for other machining purposes.  Front Face Drilling In this operation 17 drills are used to make holes on the front face of transmission case by the help of front face drilling machine.  Horizontal Milling Machine In this operation horizontal milling machine are used to finish the surface where the fly wheel rotates.  Vertical Gangue Drill Machine In this operation 18 holes are made at the rare end of transmission case by the help of vertical gangue drill machine.  Horizontal Milling Machine In this operation bottom face of the transmission case is faced by the help of horizontal milling machine.  Radial Drilling Machine It is also used to make the hole at the rear end of transmission case. These holes are made for some other purpose.  Vertical Boring Machine This operation is used to make rough bore in the transmission case holes where the different types of shafts are passed for power transmission.  Rimming Machine In this operation all the holes of transmission case are rimmed or finished by the help of rimming machine.  Horizontal Milling Machine In this operation both right and left side of the transmission case are finished by milling machine. University of Agriculture Faisalabad Page 40

Millat Tractors Limited  Radial Drilling Operation Machine In this operation holes are made on the both faces of transmission case by the help of radial drilling machine and drilling, boring and taping operation can be performed. After these operations final product is ready Design Office The main purpose of design office is to design the different parts of machine which is broken .It also make the different types of Jigs and Fixtures which are used on different machine to hold the work piece and guide the cutting tool. Bushes are also used on jig plates to guide the cutting tools. If any jig, fixture and machine part is broken at operation time it send to the design office where it’s designing is performed. After designing it forwarded to the tool room. Jig Jig is used to guide the cutting tool and it may or may not be used to hold the work piece. Fixture Fixture is only used to hold the work piece on machine table. Lubrication Oil Sump Line Sump is a part of a tractor engine in which Lubrication oil is present. It is filled with the bottom face of block where the Crankshaft is present. It is also called Lubrication oil pan. Material for cutting tools Carbide Operations Different types of operations performed on sump by the help of different machines according to our desire. Operation No 1 In this operation the upper face of Sump is finished by single spindle vertical Milling machine. We use any milling operation is only for level the surface to prevent leakage of oil. University of Agriculture Faisalabad Page 41

Millat Tractors Limited Operation No 2 In this operation side face of the sump is leveling or finishing and rear and of the sump is also milling by single spindle horizontal milling machine. Operation No 3 In this operation front face of sump is milled by the help of double spindle horizontal milling machine. Operation No 4 In this operation the other side of sump is milled by 6the help of single spindle horizontal Milling machine. Operation No 5 In this operation 5 holes are made at the front end of sump and 8 holes are made at rear end of sump by the help of double sided multispindle drilling machine. Operation No 6 In this operation holes are made at the upper face of sump by the help of vertical gangue drill machine. Operation No7 In this operation the surface where the bearing shell is placed is first bore and then finish by the help of horizontal boring & facing machine. Operation No 8 In this operation the front face holes of sump is tapped and also make ream dip hole where the quantity of lubrication oil checked by the help of two stages tapping and drilling machine. After these operations final shape of the sump is ready. Center Housing Line Centre housing is a part of a tractor which is attached to the rare end of transmission case. It is also called gear box. With the center housing right and left axle are also fitted. The casting of the center housing is made Bolan casting limited Karachi. Operations Different operations are performed on center housing to get desired shape .These operations are divided in to four sections. University of Agriculture Faisalabad Page 42

Millat Tractors Limited Section 1 Sr. # M/c Name Op. No Op. Description 1 2 3 4 Milling Vertical Milling Double head milling Multi spindle Drilling 20A&B 30 40 50&60 Lug facing and drain hole Mill the joint face Bolton and strainer milling Dowel hole drilling and rimming 5 Multi spindle Drilling 70,80&90 Drilling bottom and strainer faces Drilling joint face Section 2 Sr. # M/c Name Opine Op. Description 1 2 3 4 Duplex Milling Horizontal Milling Face milling Radial Drilling 140 150 160 185 Mill side cover face Mill the crown wheel clearance Mill pinion side and end face Tapping joint, Drain hole and bottom hole Section 3 Sr. # M/c Name 1 2 Face Milling Drilling Four Way Boring 3 4 Two way Boring Four Way Boring Op. No and 200,210 220&230 240 290&320 Op Description Facing front end.PTO, Drilling side cover faces and Pump pin Drill front end dowel roughing Axle bore axle faces main sleeve Bore lay shaft and PTO bore. Facing sleeve bore and pump pin Finish Axle bore. Axle bore sleeve Bore ream facing for Dowel Lay shaft and PTO bore Section 4 Sr. # M/c Name Multi spindle 1 head Multi spindle 2 head Op. No index 330&350 index 360 Op. Description Drilling Axle face Pump pin stud for holes Drilling the faces University of Agriculture Faisalabad Page 43

Millat Tractors Limited 3 4 Face Milling Milling 380 400 Lug sided faces Lug cutting 5 Radial drilling 410 Taping Axle and sleeve faces Axle Housing An axle is a central shaft for a rotating wheel or gear. In some cases the axle may be fixed in position with a bearing or bushing sitting inside the hole in the wheel or gear to allow the wheel or gear to rotate around the axle. In other cases the wheel or gear may be fixed to the axle, with bearings or bushings provided at the mounting points where the axle is supported. The box wing type housing is used to place the axle is called axle housing. Operations Caste axle housings take from Bolan Casting Limited after these different types of operations perform on axle housing to get its desired shape by the help of different types of machines which is shown in table given below. Sr.No 1 M/c Name Double End horizontal Boring Machine. Op.No 10 2 20 3 Double End Horizontal Boring Machine. Lathe Machine. 4 Lathe Machine 40 5 Lathe Machines. 50.Lh/Rh 6 Lathe Machines 60,Lh/Rh 30,Lh/Rh OP.Description Rough Bearing Bore Large End Rough Oil Seal Bore Small End Rough Retainer Bore Small End Finish Bearing Bore Large End Finish Oil Seal Bore Small End Finish outer Dias Of Large End, Small End Finish End Back Side Finish Small End Face Rough Large End Back Side Finish Large End Finish Spigot dia rough Small End Face Finish End Flange University of Agriculture Faisalabad Page 44

Millat Tractors Limited 7 Duplex Milling Machines 70 Fender Boss Mills 8 Multi Drilling Machine 80 Make Hole On Large End And Small End 9 Vertical Drilling Machine. 90 Make Hoes On Fender Face. 10 Horizontal Milling Machine. 100 Thrust Face Mills 11 Radial Machine. 110.L/H 12 Radial Machine 110.R/H 13 Radial Machine 120 Brake Shaft Holes Counter hole Shaft Lower Link Brake Shaft Hole Counter Hole Shaft Lower Link Hole And Finish Finish Of shaft Lower End Holes LH/RH. Cylinder head Cylinder heads machined here are first casted out of Cast Iron for 3 cylinder engines. They are machined to take various parts that are attached or installed in the head such as valves. Cylinder head forms the top of the combustion chamber while piston and ring form the bottom. Then they are bought in this plant to be accurately machined to be used in the engine assembly. There is one machining line for cylinder heads and its capacity is 90 components per day shift. After machining, the final weight of cylinder head is 25kg and it’s a grade 17 with hardness of179‐235 BHN. There are 2 transfer systems in cylinder head machining line. Cooling jackets, intake & exhaust manifolds are casted inside the cylinder head. Exhaust Manifold It is a set of tubes. It carries exhaust gas from cylinder head to the exhaust system. The manifold attaches to the head so the exhaust ports in head align with the tube openings. An in‐line engine has 1 exhaust manifold. Inlet manifold It is set of tubes that carry air or air‐fuel mixture from throttle valves to the intake ports in the cylinder head. On in‐line engines, the intake manifold attaches to the side of cylinder head. At the start of the machining operations casted parts are fed into a PLC operated transfer system where milling, drilling and taping of cover plate occurs. Then it is fed into 2nd plant which is also PLC operated where cover plate is drilled and reamed. Also, inlet and exhaustmanifold milling occurs here and it takes 3 min times approximately. The parts are then fed into an RLC University of Agriculture Faisalabad Page 45

Millat Tractors Limited based transfer system where operations like drilling, counter boring, taping, reaming and sub‐drilling occurs. Then valve seats are accurately machined so that valves accurately fit in them. Inlet hole is larger than exhaust hole to make more air come into the cylinder for combustion. 7.Internship Activities 3rd Week(Machining) Machining Division (15-04-2013 to 21-04-2013) Quality starts with machining. It is the backbone of an industry. In MTL there are two machining sections Old and Extension. In old, all components are machined expect head. In Extension Cylinder Head and Block aremachined.Machining Extension was made in order to enhance the production capacity of the plant. In old section, the operations are done manually and in Extension, all the operations are done automatically. We visited all Assembly lines and observed all operations happening on these lines. CMM Quality MM store Casting Feed on line Line inspection Gauges Quality inspector Machining Not Ok Lot Ok Engine Assembling Plant Washing Pallet Tractor Assembling Plant Line Diagram of Material Flow University of Agriculture Faisalabad Page 46

Millat Tractors Limited 7.1 Day 01 Activity On day 01 (15-04-2013), we went to Machining division and reported to Khawaja Ali Hassan. He gave us the general overview of machining division i.e. what is happening here, what kind of machinery we are using, what operations being carried out here and how it is happening and told us the infrastructure of the machining division. He also introduced us to the supervisor of Cylinder Block Line. Supervisor guided us and gave us all the information regarding the machines and operations being carried out at the given Machine Line. He said to us if you have any questions regarding any operation or machined part, don’t hesitate to ask me. We took a complete round of the Machine line and observed each and every operation very carefully. At the end of the day, we reported to Mr. Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined.Our objective was to understand the assembling procedure and all the operations performed. We keenly observed all the operations in the cylinder block line.The list of the operations is given below. 7.1.1. Cylinder Block Machining Operations OP 10 Machine type: Radial Drill Machine. Tools: Core Drill, Rimier, Spot face and Counter Sink OP 20 Machine Type: Milling machine Function: Head face and sump face milling OP 30 Machine Type: Radial Drill machine Function: Dowel hole (Reference hole) and sump face. University of Agriculture Faisalabad Page 47

Millat Tractors Limited OP 40 Function: Drilling at Sump face OP 50 Function: Chamfering at the sump face. OP 60 Function: Threading at sump face. OP 70 Function: Bearing cheeks (finishes the bearing sides of block). OP 80 Function: Rough boring of the Liner. OP 90 Function: Milling at opposite cam side. OP 100 Function: Rough milling at front and rear end. OP 110 Function: Drilling Head face, rear end and front end. OP 120 Function: Drilling and tapping at head face and sump face. OP 130 Function: Drilling and reaming head face and opposite cam side(Plug fitting). OP 150 Function: Bearing cap fitting with torque 110lb. OP 160 Function: Final milling rear and front end. University of Agriculture Faisalabad Page 48

Millat Tractors Limited OP 170 Function: Rough boring cam and crank bore. OP 180 Function: Finishing of crank and cam bore with tolerance 25 micron. OP 190 Function: Drilling and reaming of front end. OP 200 Function: Drilling and reaming at rear end. OP 220 Function: Milling at cam side. OP 230 Function: Notch making in crank bore for shell bearing fitting. OP 240 Function: Drilling at cam side. OP 250 Function: Drilling at opposite cam side. OP 270 Function: Drilling in crank bore and filter face. OP 280 Function: Tapping at rear end, front end, cam side and opposite cam side. OP 290 Function: Plug fitting in reference holes (Dowel Holes). OP 300 Function: Final milling at Head face . University of Agriculture Faisalabad Page 49

Millat Tractors Limited OP 310 Function: Final boring in Liner bore. OP 320 Function: Honing to give cross hatching. OP 340 Function: Pressure test machine to test oil leakage. OP 350 Function: Liner press machine. University of Agriculture Faisalabad Page 50

Millat Tractors Limited 7.2. Day 02 Activity On day 02 (16-04-2013)as per schedule we went to Cylinder Block Line (Ext). We reported to supervisor there. He gave us a brief introduction about the part being machined and told us about the production and man power at his line. We visited the Line with him and he gave us the general overview about the operations being performed there. He told us that the plant is automatic, finishing is better and production is higher than old Cylinder Block Line. We observe each and every operation there and took help from the workers. Line consists of Plant rather than OP. We observed less man power is required there as the plant is automatic. At the end of the day, we reported to Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined. 7.3. Day 03 Activity On day 03 (17-04-2013) as per schedule we went to Transmission Line, where we reported to supervisor there. He gave us the complete info about the part being machined and brief us about the operation being performed at his Machine line. He gave us info about the machines and man power of the Line. We visited each and every OP with him and observed the things carefully. In 2nd half we went to CNC line. We visited the whole section. On that day only 1/3 CNC was operated. We had a good observation of the operation of CNC. At the end of the day, we reported to Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined. 7.4. Day 04 Activity On day 04 (18-04-2013) as per schedule we went to Cylinder Head Line (Ext) and there we reported to supervisor there. He gave us a brief introduction about the part, he told us about the daily production which was 90parts/day. He told us that the plant is automatic, man power requirement is less and finishing is much better. Then we took a complete round of the Cylinder head line with him. He briefed us about all the operations being performed at the Line. We spent whole day there and observed all the operations. At the end of the day, we reported to Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined. 7.5. Day 05 Activity On day five (18-04-2013), as per schedule we went to Center Housing Line. We reported to supervisor of the line. He guides us about his line and then he took a complete round of the line with us and gave us all the information regarding the part and operations being performed at the Line. We visited the Line and observe all the operations closely and got all the reqd. information by interviewing the supervisor. In 2nd half we went to Lub Oil Sump Line. Supervisor there gave us a general overview of the part and Machine line. We visited each and every station of the Line and observed the things closely. At the end of the day, we reported to Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined. University of Agriculture Faisalabad Page 51

Millat Tractors Limited Components Production/Shift Workers Transmission case Cylinder Head Axel housing Block(old) Block(Ext) Central Housing Sump(240) Sump(385) 48 90 56 48 75 55 59 19 33 15 21 38 15 33 12 12 Production against Workers Production against Workers 100 90 80 70 60 50 Production/Shift 40 Workers 30 20 10 0 Transmission case Cylinder Head Axel housing Block(old) Block(Ext) Central Housing Graphical Representation of Production against Workers University of Agriculture Faisalabad Page 52

Millat Tractors Limited Receiving of Engine components from the vendors Material management dept. Quality check Engine Assembly line Both 3 and 4 in‐line cylinders are assembled here. In 3 cylinder type there are engines MF240, MF260, MF350, MF350+ which are used in tractors as well as fork lifters, generator sets and prime movers. 4 cylinder Engines of MF375, MF385, MF385‐4WD are assembled which are used in big tractors. Engine build card is followed in the engine assembly plant. Each type of engine has its own colored card.All the operations listed on the build card are duly followed and each worker signs in the build card corresponding to each job that he performs. So any fault could be traced back to that worker. There are total 10 operations on the main assembly line for building up an engine. Production Capacity of EAP plant is 59 engines of 3 cylinder type and 36 engines of 4 cylinder type per shift and there is double shift for the engine assembly plant. Production is increased on demand. Engine assembly plant (EAP) has been divided into 4 sections which are as follow 1. Segregation 2. Engine Assembly Line 3. Engine testing or Test shop 4. Rectification Section University of Agriculture Faisalabad Page 53

Millat Tractors Limited Vapor degreasing is a surface finishing process. It involves solvents in vapor form to cleanse the workpiece in preparation for further finishing operations. The acting principle behind the vapor degreaser process is that the solvents will dissolve the contaminants on the workpiece and remove them by dripping off the part. A basin of solvent is set up with a heating coil to bring the solvent to boil. As the solvent evaporates it rises to the fill‐line in the chamber, above this is air with a much lower density than the solvent. This contains the vaporized solvent in a closed space where the workpiece is placed. The solvent condenses on the more frigid workpiece and the now liquid solvent dissolves the greases on the part. With the impurities contained in the liquid beads, the solvent runs off the part. Some systems are designed to capture and reclaim this solvent, making the process much more economical. University of Agriculture Faisalabad Page 54

Millat Tractors Limited 8.2. Engine Assembly line Engine Assembly line is a line in which all the parts of engine is fitted with Engine block. This line starts with block and complete on full engine. The assembly line is divided in to different operations which are given below. The operation line starts from operation 10 and completes on operation 100. Operation No 10 Operation No 10 is divided in to three main steps. 1. In this step Head Studs, Shells, Crankshaft, Bearing caps and Thrust washers are build on engine block . 2. In this step Main Bearing caps is fitted with bolts and give torque, Tightening the Head Studs and Sump Studs, Bearing Shells, Drain plug and Water Plug build in the block. 3. In this step Oil Gallery Plug, Main Oil Seals Dowels and Water Plug fits, Tightens the bolts of Main Bearing caps and after this block is fitted on trolley. Operation No 20 Operation No 20 is divided in to two main steps 1. In this step Punch the Engine No,Tight and fits the Oil Pump and fits the Timing Case with the help of bolts. University of Agriculture Faisalabad Page 55

Millat Tractors Limited 2. In this step Hub Dowel, Idler Gear Hub, Timing case Gasket, Oil Pump Gear and lock is fitted. After this align the Timing Case and tight the all bolts and give torque Operation No 30 Operation No 30 is divided in to two main steps. 1. In this step fit the Main Oil Seal with Gasket, fit and tight the Water Connection,fit the connecting rod shells and fit the Piston in the Block. 2. In this step tight the Connecting Rod and give torque, fit and tight a stress pipe and fits the Main Oil Seal bolts. Operation No 40 Operation No 40 is divided in to two main steps. 1. Fit the idler gear, Came Shaft with gear and Elbow, fit the Fuel Injection Pump,lock the Idler gear and “D” mark align the came and gear. 2. Fit and align the Timing mark, tightening the Fuel Pump and Came bolts and give torque and check the Back Lash of gears. Operation No 60 Operation No 60 is divided in to three main steps. 1. Fit and tight the Cylinder Head, alignment of Sump, joint the Front over Rear Half moan and fit and tight the drain Plug 2. Torque the Cylinder Head bolts, compounding the Sump and tighter the bolts of Sump. 3. Fit the Sump and torque the bolts of sump. Operation No 70: Operation No 70 is divided in to two main steps. 1. fit the Rocker Shaft assembly and torque and adjust the tappet, fit the Dip Stick and Dip Stick Tube and oiling the Rockers Levers. 2. Fit the Induction many fold and Lift Pump and tight the bolts and give torque, fit the Oil Pressure Pipe. Operation No 80: Operation No 80 is divided in to two main steps. 1. Joint the Timing Case, fit the Screws, fit the Bracket and Levers and tight the all Screws. 2. Fit the Injector, Pressure Pipes and Hose Pipe with clamps, tightthe Timing Case Screws and give torque. University of Agriculture Faisalabad Page 56

Millat Tractors Limited Operation No 90: Operation No 90 is divided in to two main steps. 1. Fit the Oil Filter Assembly, Exhaust Many Fold and Returning Pipe , tight the Injectors Nuts and fit the Front Lifting Hook. And also fit the Thermo state Valve. 2. Fit the Crank Pipe and Breather Pipe, tighten the Hose Pipe Clamps, Fit and tight the Tappet Cover and tighten the oil filter. Operation No 100: Operation No 100 is divided in to three main steps. 1. Open the Engine Fit the Water Outlet Plugs and Fit the Transmission Studs. 2. Fit and tight the Adopter Plates bolts, Fit the Fly Wheel Bolts and torque and also tight the Crank Pulley bolts. 3. Fit the Adopter Plates bolts and torque and also fit and torque the Fly Wheel bolts. University of Agriculture Faisalabad Page 57

Millat Tractors Limited Sub‐Assembly or Pre‐Assembly On one side of the main assembly line there is a sub‐assembly section that assemblesdifferent key components together and then these assembled components are installed inthe engine on main assembly line. This speeds up the process, reduces cycle time andincreases efficiency of the process. After these operations the Engine is ready.Now after these operations Engine is forwarded to the Test Shop. Engine Test Section: University of Agriculture Faisalabad Page 58

Millat Tractors Limited There is a complete testing setup for every engine that comes out of the main assembly line.Here engine is thoroughly checked for its working and any possible faults such as enginenoise, rpm, loading, leakages, exhaust smoke etc. Different ranges are given below . Tester 1st Time 2ndTime Time R.P.M Brake Power (minutes) (NM) (K.W) Low Idling R.PM 750 750 5 1000 50-55 5.8 Low Idling Oil Pressure 5 1500 60-65 9.4 High Idling Oil Pressure 2470 2470 5 1500 90-95 14.9 Tappet setting .010” .010” 20 2250 146-160 35-37 Different Ranges for Engine testing In the Test Shop there are different types testing beds which are used for testing the Engine R.P.M, Oil leakage and tappet setting University of Agriculture Faisalabad Page 59

Millat Tractors Limited In engine build card different performance factors of every engine are entered after testingand if there is an error found then engine is referred to the rectification section.This table shows the ranges of testing values. If the engine below this values then the engine is passed but if the values greater than the engine is rejected and forwarded to the Rectification. University of Agriculture Faisalabad Page 60

Millat Tractors Limited Rectification Section In this section the fault in any tested engine is removed using standard procedures. If thereis any part that needs to be replaced or any adjustment in existing component is neededthen it is carried out here and then again sent to engine testing shop for final inspection. Fuel Leakage: Check Fuel injection pump, Fuel injection pressure and Fuel lift pump. University of Agriculture Faisalabad Page 61

Millat Tractors Limited Water Leakage: Check Cylinder Head rear plate. water pump, Head Gasket, Water Plug, Drain Plug and Oil Leakage: Check Tappet Cover , Cylinder Head Gasket , Front rear half moan joint , Sump joint , Timing Case cover , Rear end oil seal , Oil filter , Drain plug , PTO plate , Pressure pipe and elbow pipe and Timing case cover seal. Any type of sound: Check Timing gears and Knocking. Appearance: Check Missing and Vibration. Or any types of disturbance which create in engine are rectifying in the Department and forwarded to the Test Shop. University of Agriculture Faisalabad Rectification Page 62

Millat Tractors Limited Finished Engine Store All the engine that passes inspection test are sent to Finished engine Store and further moved to Tractor Assembly Plant according to production requirement 9.Internship Activities 4th Week (EAP) Engine Assembly Plant (22-04-2013 to 29-04-2013) Engine is the prime mover for power generation. And during its assembling it has to undergo 5 sections namely Segregation, washing and cleaning, assembly line, test shop and rectification sections. Several quality checks are performed during assembling by line inspection gauges to ensure the quality.In 4th week of our training, according to our schedule we went to Engine Assembly Plant, where we reported to Hafiz Faheem. He gave the general overview of Engine Assembly Plant. We visited each section on Engine Assembly Plant with him. He gave us the brief introduction about Segregation, Washing and Cleaning, Engine Assembling Line, Test Shop and Rectification Sections. Our objective was to study and examine all the operations keenly. We completed our objective that was assigned to us. University of Agriculture Faisalabad Page 63

Millat Tractors Limited Not Ok Washing and Degreasing Segregation OP.10 OP.20 components OP.30 OP.40 OP.50 OP.60 OP.70 Tractor Assembling Plant Ok EngineTest section Fed to Line OP.80 OP.90 Line Diagram of Engine Assembly Plant Weekly Production in Engine Assembly Plant 57 60 54 53 51 50 46 40 30 21 17 20 10 9 11 11 13 9 9 6 3 0 23-04-2013 24-04-2013 25-04-2013 MF 240 MF 375 26-04-2013 29-04-2013 Gen Set Graphical Representation of Daily Engine Assembling University of Agriculture Faisalabad Page 64 OP.100

Millat Tractors Limited Graphical representation of the total production and sale of last six years is given below Total production and Sale per Annum Year Units Produced Units Sold 2007 27081 27127 2008 27506 27260 2009 30244 30677 2010 40178 40140 2011 42188 42011 2012 32004 32006 Production and Sales (Engine) 45000 40178 40140 42188 42011 40000 35000 32004 32006 30244 30677 30000 27081 27127 27506 27260 2007 2008 25000 20000 15000 10000 5000 0 2009 Units Produced 2010 2011 2012 Units Sold Graphical Representation of Production and Sales volume (Engine) University of Agriculture Faisalabad Page 65

Millat Tractors Limited Our main objective was to understand the assembling procedure and all the operations performed. We keenly observed all the operations in the assembly plant the list of the operations is given below. 9.1. Engine Build Operations 1. OP 10 The major functions performed in this are Build card Crank shaft Bearings Caps and thrust washers installation. Punching of block number Main bearing caps Bearing shells Trolley support University of Agriculture Faisalabad Page 66

Millat Tractors Limited 2. OP 20 The major functions performed in this are Bench the engine number Fit the idol and cam shaft gears and torque them Tighten the Timing Case and bolts along with alignment Build the Water-Let and Hub Build the FIP and Burge Piece Timing Case and bolt them 3. OP 30 The major functions performed in this are Build the Main Oil Seal and Bearing Shells Insertion of piston in cylinder hole Tighten the Cone Rod and torque it Bolt the Main Oil Seal 4. OP 40 The major functions performed in this are Build the pipe of Balancer section Alignment of Balancer Fit the Balancer and Balancer Section Pipe Build the Fuel Pump Stud the Sump Build the Fuel Pump Gear Make a timing mark on gear and torque it Tighten the balancer and torque it Check the Back-Lash 5.

Add a comment

Related presentations

Related pages

Internship Report @ Millat Tractors Limited (MTL) 2013 ...

6 week Internship Report @ Millat Tractors Limited (MTL), Lahore, Pakistan. Text. RECOMMENDED
Read more

A legacy unmatched

A legacy unmatched Since our foundation ... 2008 2009 2010 2011 2012 2013 Annual Report & Financial Statements ... Millat Tractors Limited (MTL) ...
Read more

millat tractors specifications of millat tractor 360

Home » millat tractors specifications of millat tractor ... Internship Report @ Millat Tractors Limited ... Report @ Millat Tractors Limited (MTL), ...
Read more

MILLAT TRACTORS LIMITED( MTL ) - Habib Ullah Sheikh (Pvt)Ltd

millat tractors limited( mtl ) ... annual general meeting will be held on 30/09/2013 : 8/16/2013 : ... millat tractors limited detail:
Read more

Tractors | LinkedIn

Millat Tractors Ltd at Millat Tractors Limited, ... Internship at Millat Tractors Limited (MTL) ... Internship Report @ Millat Tractors Limited (MTL) 2013.
Read more

MILLAT TRACTORS LIMITED | Millat Group

Millat Tractors Limited (MTL) ... the production of Millat Tractors was just 8,000 units per ... MTL’s Annual Report has been acknowledged as the Best ...
Read more

Haseeb Hassan | LinkedIn

Report submitted to General Manager Operations. Summer Internship Millat Tractors Limited (MTL) ... Millat Tractors Limited.
Read more

final millat 2014

Annual Report 2014. ... 2014 1. 2 Millat Tractors Limited 50 years of Delivering ... We at MTL have been proud contributors to the farming community at ...
Read more