INDUSTRIAL TRAINING REPORT ON

KERALA AUTOMOBILES LIMITED,

THIRUVANANTHAPURAM, KERALA

TRAINING DONE FROM 14/05/2015 TO 20/05/2015

Submitted by

Akhil D

Sarath K.M

Hari Krishnan Thampi

Ayyappan R

INDUSTRY PROFILE

The automobile industry in India has undergone drastic changes in terms of consumer perception

as well as technology since its inception. Automobile industry development provides necessary

infrastructure for economic development. Automobile industry in India has its beginning in

1950s; at that time generally carriage vehicles, tractors and other agricultural vehicles were

produced. In 1960s commercial vehicles available were very expensive and only the rich could

afford them. In between 1960-1970 manufacturing of commercial vehicles took shape.

Three wheeler industries in India had its beginning in early 1970s. The first three-wheeler

industry in India was API (Automobile Products of India) in 1971. But it was virtually

monopolized by Bajaj Auto Ltd., which was established in early 1970s.

KAL was incorporated in 1978 and was making losses in early years of its operations. Now

Kerala Automobiles became one of the profit making industries under the Government of Kerala

with a significant market share.

KAL is one of the major three-wheeler producers in India occupying about 10 acres of land.

Incorporated, as fully Government owned company on 15-3-1978 and production started in

February 1984. Initial technology was procured from Automobile Products of India (API)

Mumbai, but the collaboration terminated in 1987. Initially only petrol three wheelers were being

produced, but from 1988 onwards, KAL started producing diesel three-wheeler, which was1st of

its kind in India. At present, KAL produces five models of petrol three-wheelers and eight

models of diesel three-wheelers. KAL produces approximately 7200 vehicles per annum.

Recently KAL introduced three-wheeler tipper, exports to Sudan, Bangladesh, Sri Lanka,

Nigeria, Mexico, Iran, Nepal, etc.

Initially KAL was at loss, and hence it was registered with SIC Act, 1985 and Board of Industrial

Finance Re-construction (BIFR). In 1993-94, company, for the first time in the history, earned an

annual profit of 7.71 lakhs. Since then it has been registering profits every year.

PLANT LAYOUT

The plant consists of an assembly unit, a fabrication unit, and workshop. The store room is

placed near to Inspection and testing unit. The layout resembles to a process layout, but it also

had the features of a line layout. But the machine in the plant placed according to the

convenience of the workers.

PLANT DETAILS

MACHINE SHOP

The machine shop contains many machines for performing various operations. They include

semi automatic and fully automatic machines. Some of the machines include.

The bulk of operations for converting the metal parts into useful components to be used in three

wheelers are done at the machine shop. This section is the biggest section at KAL having the

largest share of qualified work force. This section ensures the quality standards at the

organization. The section has a large number of sophisticated machinery both automatic as well

as semiautomatic to produce the components at fast pace and satisfying stringent quality

standards. At each level of operation inspections are done to take appropriate action.

The raw materials used here at the machine shop includes those fabricated at the fabrication shop

and also castings and forgings imported from other factories. The machine shop also does jobs

for the space program of the VSSC.

CNC Lathes

CNC Milling Machines

Drilling Machines

Conventional Lathes Turret Lathe

Capstan Lathe Grinding Machine

Angular grinding Machine

Power Hacksaw

Tube bending machine etc

CNC Milling Machines

CNC milling is a specific form of computer numerical controlled (CNC) machining.

Milling itself is a machining process similar to both drilling and cutting, and able to achieve

many of the operations performed by cutting and drilling machines. Like drilling, milling uses a

rotating cylindrical cutting tool. However, the cutter in a milling machine is able to move along

multiple axes, and can create a variety of shapes, slots and holes. In addition, the work-piece is

often moved across the milling tool in different directions, unlike the single axis motion of a

drill.

CNC milling devices are the most widely used type of CNC machine. Typically, they are

grouped by the number of axes on which they operate, which are labeled with various letters. X

and Y designate horizontal movement of the work-piece (forward-and-back and side-to-side on a

flat plane). Z represents vertical, or up-and-down, movement, while W represents diagonal

movement across a vertical plane. Most machines offer from 3 to 5 axes, providing performance

along at least the X, Y and Z axes. Advanced machines, such as 5-axis milling centers, require

CAM programming for optimal performance due to the incredibly complex geometries involved

in the machining process. These devices are extremely useful because they are able to produce

shapes that would be nearly impossible using manual tooling methods. Most milling machines

also integrate a device for pumping cutting fluid to the cutting tool during machining.

Computer numeric controlled machining centers are used to produce a wide range of

components and tooling costs involved have continued to become more affordable. In general,

large production runs requiring relatively simple designs are better served by other methods,

although machining can now accommodate a wide range of manufacturing needs. CNC milling

centers are solutions to everything ranging from prototyping and short-run production of

complex parts to the fabrication of unique precision components.

CNC Lathe

Computer numerical controlled (CNC) lathes are rapidly replacing the older production

lathes (multi spindle, etc.) due to their ease of setting, operation, repeatability and accuracy.

They are designed to use modern carbide tooling and fully use modern processes. The part may

be designed and the tool paths programmed by the CAD/CAM process or manually by the

programmer and the resulting file uploaded to the machine, and once set and trialled the machine

will continue to turn out parts under the occasional supervision of an operator.

The machine is controlled electronically via a computer menu style interface the program

may be modified and displayed at the machine, along with a simulated view of the process. The

operator needs a high level of skill to perform the process, however the knowledge base is

broader compared to the older production machines where intimate knowledge of each machine

was considered essential. These machines are often set and operated by the same person, where

the operator will supervise a small number of machines (cell).

The design of a CNC lathe varies with different manufacturers, but they all have some

common elements. The turret holds the tool holders and indexes them as needed, the spindle

holds the work piece and there are slides that let the turret move in multiple axis simultaneously.

The machines are often totally enclosed, due in large part to occupational health and safety

(OH&S) issues.

With rapid growth in this industry, different CNC lathe manufacturers use different user

interfaces which sometimes make it difficult for operators as they have to be acquainted with

them. With the advent of cheap computers, free operating systems such as Linux, and open

source CNC software, the entry price of CNC machines has plummete).

These machines where used to a verity of operations. Some of them include

Facing

Drilling

Turing

Grinding

Threading etc.

Virtually every type of material that can be drilled or cut can be machined by a CNC mill,

although most of the work performed is done in metal. As with drilling and cutting, the proper

machine tools must be selected for each material in order to avert potential problems. The

hardness of the work-piece material, as well as the rotation of the cutting tool must all be

factored before beginning the machining process.

Drilling Machines

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section

in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed against

the work piece and rotated at rates from hundreds to thousands of revolutions per minute. This

forces the cutting edge against the work piece, cutting off chips (swart) from the hole as it is

drilled.

Exceptionally, specially-shaped bits can cut holes of non-circular cross-section; a square

cross-section is possible.

Salient Features:

Massive and rigid construction

Ergonomically grouped controls for operating convenience.

Light centering of spindle

Precise depth release.

Electro-hydraulic clamping provided for drill head, arm & sleeve

Shock-free engagement of taps through clutch and spindle reverse for

withdrawals.

Machine with drilling capacity 80 mm / 100 mm also available

Turret Lathe and capstan lathe

Turret lathes and capstan lathes are members of a class of lathes that are used for

repetitive production of duplicate parts (which by the nature of their cutting process are usually

interchangeable). It evolved from earlier lathes with the addition of the turret, which is an

indexable tool holder that allows multiple cutting operations to be performed, each with a

different cutting tool, in easy, rapid succession, with no need for the operator to perform setup

tasks in between (such as installing or uninstalling tools) nor to control the tool path. (The latter

is due to the tool-path being controlled by the machine, either in jig-like fashion [via the

mechanical limits placed on it by the turret's slide and stops] or via IT-directed servomechanisms

[on computer numerical controlled (CNC) lathes]).

There is a tremendous variety of turret lathe and capstan lathe designs, reflecting the variety of

work that they do.

Conventional Lathes

A metal lathe or metalworking lathe is a large class of lathes designed for precisely machining

relatively hard materials. They were originally designed to machine metals; however, with the

advent of plastics and other materials, and with their inherent versatility, they are used in a wide

range of applications, and a broad range of materials. In machining jargon, where the larger

context is already understood, they are usually simply called lathes, or else referred to by more-

specific subtype names (tool-room lathe, turret lathe, etc.). These rigid machine tools remove

material from a rotating work piece via the (typically linear) movements of various cutting tools,

such as tool bits and drill bits.

Surface grinder also includes wash grinder. A surface grinder has a "head" which is lowered to a

work piece which is moved back and forth under the grinding wheel on a table that typically has

a controllable permanent magnet for use with magnetic stock but can have a vacuum chuck or

other fixturing means. The most common surface grinders have a grinding wheel rotating on a

horizontal axis cutting around the circumference of the grinding wheel. Rotary surface grinders,

commonly known as "Blanchard" style grinders, have a grinding head which rotates the grinding

wheel on a vertical axis cutting on the end face of the grinding wheel, while a table rotates the

work piece in the opposite direction underneath. This type of machine removes large amounts of

material and grinds flat surfaces with noted spiral grind marks. It can also be used to make and

sharpen metal stamping die sets, flat shear blades, fixture bases or any flat and parallel surfaces.

Surface grinders can be manually operated or have CNC controls.

Tool and cutter grinder and D-bit grinder can usually perform the minor function of the drill bit

grinder, or other specialist tool room grinding operations.

Jig grinder, which as the name implies, has a variety of uses when finishing jigs, dies, and

fixtures. Its primary function is in the realm of grinding holes and pins. It can also be used for

complex surface grinding to finish work started on a mill.

Gear grinder is usually employed as the final machining process while manufacturing a high-

precision gear. The primary function of these machines is to remove the remaining few

thousandths of an inch of material left by other manufacturing methods (such as gashing or

hobbing).

Die grinder, which is a high-speed hand-held rotary tool with a small diameter grinding bit. They

are typically air driven (using compressed air), but can be driven with a small electric motor

directly or via a flexible shaft.

Grinding Machine

A grinding machine, often shortened to grinder, is any of various power tools or machine tools

used for grinding, which is a type off-machining using an abrasive wheel as the cutting tool.

Each grain of abrasive on the wheel's surface cuts a small chip from the work-piece via shear

deformation.

Grinding is used to finish work-pieces that must show high surface quality (e.g., low surface

roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in

grinding is on the order of 0.000025 mm, in most applications it tends to be a finishing operation

and removes comparatively little metal, about 0.25 to 0.50 mm depth. However, there are some

roughing applications in which grinding removes high volumes of metal quite rapidly. Thus,

grinding is a diverse field.

TYPES

Belt grinder, which is usually used as a machining method to process metals and other

materials, with the aid of coated abrasives. Sanding is the machining of wood; grinding is

the common name for machining metals. Belt grinding is a versatile process suitable for

all kind of applications like finishing, deburring, and stock removal.

Bench grinder, which usually has two wheels of different grain sizes for roughing and

finishing operations and is secured to a workbench or floor stand. Its uses include shaping

tool bits or various tools that need to be made or repaired. Bench grinders are manually

operated.

Cylindrical grinder, which includes both the types that use centers and the center-less

types. A cylindrical grinder may have multiple grinding wheels. The work piece is

rotated and fed past the wheel(s) to form a cylinder. It is used to make precision rods,

tubes, bearing races, bushings, and many other parts.

Vertical machining centre

Salient Features:

Bed type machine configuration

Preloaded linear re-circulating guide-way system

AC Spindle motor

AC Servomotors for feed drive of all axes.

Automatic cyclic lubrication system for ball-screws and guide-way system.

Chip collection arrangement with chip conveyor.

Guide-way protection through telescopic covers/bellow covers.

Machine work lighting.

Cam driven high speed armless auto tool changer.

External coolant

Head counter balance

Power Hacksaw

A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered either by its

own electric motor or connected to a stationary engine. Most power hacksaws are stationary

machines but some portable models do exist; the latter (with frames) have been displaced to

some extent by reciprocating saws such as the Sawzall, which accept blades with hacksaw teeth.

Stationary models usually have a mechanism to lift up the saw blade on the return stroke and

some have a coolant pump to prevent the saw blade from overheating.

Power hacksaws are not as commonly used in the metalworking industries as they once

were. Bandsaws and cold saws have mostly displaced them. While stationary electric hacksaws

are not very common, they are still produced. Power hacksaws of the type powered by stationary

engines and line shafts, like other line-shaft-powered machines, are now rare; museums and

antique-tool hobbyists still preserve a few of them.

Pipe and Tube bending machine

Tube bending is the umbrella term for metal forming processes used to permanently form pipes

or tubing. One has to differentiate between form-bound and freeform-bending procedures, as

well as between heat supported and cold forming procedures.

Form bound bending procedures like "press bending" or "rotary draw bending" is used to

form the work piece into the shape of a Straight tube stock can be formed using a bending

machine to create a variety of single or multiple bends and to shape the piece into the desired

form. This process can be used to form complex shapes out of different types of ductile metal

tubing.) Freeform-bending processes, like three-roll-push bending, shape the work piece

kinematically, thus the bending contour is not dependent on the tool geometry.

Generally, round stock is what is used in tube bending. However, square and rectangular

tubes and pipes may also be bent to meet job specifications. Other factors involved in the tube

bending process is the wall thickness, tooling and lubricants needed by the pipe and tube bender

to best shape the material and it is also used in different ways e.g.( tube, pipe wires).

FABRICATION

Fabrication when used as an industrial term, applies to the building of machines, structures and

other equipment, by cutting, shaping and assembling components made from raw materials.

The plant also contains a fabrication department. All the fabrication works were

performed here. Fabricator's shops vary both in the size of the facility and weight of material that

they can handle. The sophistication of the available equipment will also vary. Increasingly,

where investment is available, operations are being automated and computer-controlled.

Fabricators facilities may range from a very small operation, through to a large factory

involving many departments responsible for material procurement, material allocation, drawing

office, planning, welding, quality control, stockyard, preparation, fabrication, treatment, storage

and dispatch. Fabrication may also involve a number of fabrication shops each resourced with

different cranes, welding and other equipment to suit different product ranges.

In addition to the shop floor for the main production areas, areas may be set aside for the

trial assembly of certain elements. The remainder of the fabricator's premises will usually include

design and drawing offices, a template shop, and planning, administrative and estimating

departments.

Materials can be ordered direct from the producer where significant quantities of steel

are required; smaller quantities of a limited range of sections can be obtained from stakeholders.

Steel products are only sourced direct from the rolling mill if the quantity of a given size and

grade is sufficient. Otherwise they are sourced through steel stockholders who offer a wide range

of off-the-shelf profiles. As these are generally in standard lengths there may be some

additional cutting wastage, but a steelwork contractor may have a long-term partnering

arrangement with a stakeholders whereby: the stakeholders takes the risk of cutting wastage by

delivering materials that are cut-to-length. The materials are delivered to the fabrication works

on a "just-in-time" basis to reduce the steelwork tractors need for working capital. The materials

may be pre-treated or pre-prepared in other ways (e.g.:- plates profiled and drilled).

Hydraulic Press

Presses are used in industrial settings for a wide variety of uses, including squeezing,

forming, and pressing. There are many different types of presses. Among the most popular these

days are pneumatic presses and hydraulic presses. These two models of presses are very similar

in function and can be used for a lot of the same things. However, there are some specific

differences between them to consider when attempting choosing between them. Hydraulic

presses are fundamentally chambers filled with some sort of liquid, usually oil. A piston presses

into the chamber, causing the oil to shift position. Since the chamber is sealed, the oil exerts

pressure on another, larger piston or base-plate, which is in turn pressed downwards.

Pneumatic Presses

Pneumatic presses are controlled by the manipulation of pressurized air. The air is forced

into a tube which fills with the air and applies pressure that causes the press to move downwards.

Once the press' stroke is finished, the air is evacuated through valves, and mechanical springs

cause the pump to move upwards again.

Hydraulic presses and pneumatic presses can provide many of the same functions

with equal quality. They can both be adjusted to changed the stroke length or the

stroke pressure. They both have full tonnage and any position along their stroke,

making them preferable to mechanical presses. They can both perform

complicated pressing and forming tasks with the proper modification as you go

along.

The main difference between them is their speed. Pneumatic presses are much

faster than hydraulic presses, and that means there are many jobs they can

perform faster and more efficiently. However, this makes them ill-suited for

hydro-forming or other jobs where the hydraulic press' slower speed is an

advantage.

There are also differences as far as maintenance. Hydraulic presses require more

care, and have more components attached to them for this purpose, making them

more complicated. Pneumatic presses require less time and energy for

maintenance.

WELDING

Welding is defined as a process where two or more pieces of metal or thermoplastics are fastened

together by use of heat and pressure. The process of applying heat softens the material and

enables it to affix together as one in a joint area when an adequate amount of pressure is applied.

The concept of welding first developed in the middle ages, though it did not form into the

process of welding as it is today until the latest years of the 19th century. Before this, a process

known as "forge welding" was the only means of joining two metal objects together. Forge

welding consisted of using a flame to heat metal to extremely high temperatures and then

hammering each piece together until they became one. This method was replaced around the

time of the industrial revolution. Electric and gas flame heating methods proved to be much safer

and faster for welders. Practically every material that has made society what it is today, was

created by welded construction tools or has been welded itself. Because of this, welders have a

wide range of areas for employment; many welders specialize in pipe welding or automobile

welding while others specialize in machinery. The possibilities are endless for welders seeing as

welding can be performed in a diverse range of locations, including underwater, though not all

forms of welding are the same. Some forms of welding use gas, while others use electric and the

newest forms involve use of a laser. The process of welding that is used depends on a variety of

factors but the form and thickness of the material is usually the deciding factor for which method

is most effective. Arc, Electro slag, Flux-Cored, Gas Metal-Arc, Gas Tungsten-Arc, Metal Inert

Gas, Plasma Arc, Shielded-Metal Arc, Submerged Arc and Tungsten Inert Gas are the most

widely used welding methods.

Arc welding machine

Arc welding is a popular form of welding due the low cost of the process. The process begins

with a device that gives off an electric current. This device can differ greatly from process to

process yet it always enables electric current to move through materials that without the

device, would be considered non-conductive. It is called 'arc welding' because an electrical

current is created between the welding device and the materials to be welded which at times

gives an arch like appearance. The first basic form of arc welding was invented in the year

1802. Today, many other subcategories of arc welding exist.

Butt welding machine

Butt welding is a welding technique used to connect parts which are nearly parallel and don't

overlap. It can be used to run a processing machine continuously, as opposed to having to restart

such machine with a new supply of metals. Butt-welding Is an economical and reliable way of

joining without using additional components.

Usually, a butt-welding joint is made by gradually heating up the two weld ends with a weld

plate and then joining them under a specific pressure. This process is very suitable for

prefabrication and producing special fittings. Afterward, the material is usually ground down to a

smooth finish and either sent on its way to the processing machine, or sold as a completed

product.

This type of weld is usually accomplished with an arc or MIG welder. It can also be

accomplished by brazing. With arc welding, after the butt weld is complete, the weld itself needs

to be struck with a hammer forge to remove slag (a type of waste material) before any

subsequent welds can be applied. This is not necessary for MIG welds however, as a protective

gas removes any need for slag to appear. Another with a MIG welder is that a continuous copper

coated wire is fed onto the stock, making the weld virtually inexhaustible.

Spot welding machine

Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in

the 0.5 to 3 mm (0.020 to 0.118 in) thickness range. The process uses two shaped alloy

electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the

sheets together. Forcing a large current through the spot will melt the metal and form the weld.

The attractive feature of spot welding is that a lot of energy can be delivered to the spot in a very

short time (approximately 10100 milliseconds). That permits the welding to occur without

excessive heating of the remainder of the sheet.

The amount of heat (energy) delivered to the spot is determined by the resistance between the

electrodes and the magnitude and duration of the current. The amount of energy is chosen to

match the sheet's material properties, its thickness, and type of electrodes. Applying too little

energy will not melt the metal or will make a poor weld. Applying too much energy will melt too

much metal, eject molten material, and make a hole rather than a weld another feature of spot

welding is that the energy delivered to the spot can be controlled to produce reliable welds.

Metal Inert gas welding machine

Metal Inert Gas Welding is a process of welding that uses a gas to shield the weld metal. The gas

keeps the metal being welded from being effected from natural elements in the environment,

such as oxygen. This allows the welder to operate at a continuous rate, making the process fairly

quick. Operation of the equipment does not require an extreme level of skill by welders,

however, the equipment used in MIG Welding can only be used indoors due to the gas involved

in the welding process. MIG Welding was originally released in the 1940's but underwent many

upgrades until being perfected in the 1960's.

HEAT TREATMENT

Heat treatment is a critical and complex element in the manufacturing of gears that greatly

impacts how each will perform in transmitting power or carrying motion to other components in

an assembly. Heat treatments optimize the performance and extend the life of gears in service by

altering their chemical, metallurgical, and physical properties. These properties are determined

by considering the gear's geometry, power transmission requirements, stresses at different points

within a gear under load, load cycling rates, material type, mating part designs, and other

operating conditions. Heat treatments improve physical properties such as surface hardness,

which imparts wear resistance to prevent tooth and bearing surfaces from simply wearing out.

Heat treatments also improve a gear's fatigue life by generating subsurface compressive stresses

to prevent pitting and deformation from high contact stresses on gear teeth. These same

compressive stresses prevent fatigue failures in gear roots from cyclic tooth bending. Physical

properties such as surface hardness, core hardness, case depth, ductility, strength, wear resistance

and compressive stress profiles can vary greatly depending on the type of heat treatment applied.

For any given type of heat treatment the results can be tailored by modifying process parameters

such as heating source, temperatures, cycle times, atmospheres, quench media, and tempering

cycles to meet specific application requirements.

IMPORTANT STEPS ARE

CARBURIZING

Carburizing is the most widely used form of surface hardening, is the process of diffusing carbon

into surface of low carbon steel at elevated temperatures. This results in a high carbon case

forming just inside the surface of a low carbon component. During quenching from austenitizing

the austenite will transform to martensite, and the higher carbon case will have a high hardness

while the lower carbon core material will have a lower hardness. The goal of this process is to

produce a hard, strong, wear resistant outer surface while retaining a softer, ductile tough core.

HARDENING

There are two general classifications of heat treatments used for hardening steels: neutral

hardening, and case hardening. Neutral hardening refers to maintaining the carbon potential of

the atmosphere at the same percentage as the carbon in the steel during the hardening cycle. This

means that carbon is entering and leaving the surface of the steel at the same rate, and no net gain

or net loss of carbon atoms inside the surface of the steel occurs. Many gears are neutral

hardened, but for the most demanding applications case hardening processes, such as carburizing

and nitriding, are the preferred methods due to their improved wear characteristics and

mechanical properties.

QUENCHING AND TEMPERING

Oriented toward carbide steels such as carbon-moly, this process is designed to enhance

toughness as well as controlling yield strength and ultimate tensile strength of steel. The steel is

heated to above its upper critical temperature and quickly immersed in fresh water or brine to

achieve rapid setting of the desired metallurgical structure. Oil quenching is sometimes used.

The usual practice is to quench until cooling reaches around 8000F, quickly followed by a

tempering period in a fired furnace in order to soften the martensitic structure and achieve the

desired mechanical properties in the material including a desired measure of ductility. The

tempering process is, in effort, a stress relieving process.

ASSEMBLY SECTION

The Kerala Automobile has got separate assembly unit, where the assembly operations are

performed. This section mainly deals with the assembly of gearbox and gearbox-engine. The

engine is fitted to the chassis and them to the drive mechanism. After this the body is assembled

to the chassis. The electrification stage succeeds the above operations. The assembly operations

were aided by following machines, Hoists, universal Toll kits, fixtures, painting booths.

Wheels & Tyres

KAL vehicles use pressed steel disc wheels of divided type. The two halves are securely fastened

to form a rim having two fixed flanges. The tyre with tube is then fixed onto the wheel. KAL

uses MRF-savari brand of tyres for its vehicles.

Back plate Assembly

The drum brake system used consists of two brake shoes with friction material actuated by a

wheel cylinder. The parking brake is actuated by a cam. Retractor springs used for release of

brakes. Tension springs are placed beneath the brake shoes.

Differential Assembly

Matching planet and sun gears are selected and fixed on the seats provided in the differential

cage. Then the cross pin is inserted .the meshing of the gears are checked to see if there is any

backlash.

Propeller Shaft Assembly

The propeller shaft consists of two universal joints and sliding joint. Bevel pinion is attached to

one end via the universal joint .flexible ring type universal joint is used.

Handle Bar Assembly

Handle bar consists of mechanisms for actuating clutch, accelerator and front brake it also

houses the switch assy. for light and other accessories.

QUALITY CONTROL

KAL uses computerized design system and testing equipment to ensure the international

standards. Quality assurance achieved through satisfied quality control methods has helped KAL

to achieved ISO 9001 Certification.

Verification inspection are done on each step of manufacturing and assembled to provide the

required specification and stranded. This has been made possible using equipments such as

Universal testing Machines, Dynamometers, Exhaust Analyzer, Digital Height Master, Eddy

Current Tester etc.

The QC system is designed to provide routine and consists checked to ensure data integrity,

correctness and completeness. QC activities includes general such as accuracy checks on data

acquisition and calculation and the use of approved standardized procedure for emission

activates Include a planned system of review procedures conducted by personal not directly

involved in the inventory development process.

CONCLUSION

The Industrial Training we had at KAL gave us an insight into the operation of an

automobile industry. We had a first-hand experience with the various departments in an

automobile industry, and also of the various operations done in those departments. We also came

to know the various challenges faced by an industry and how it overcame that adverse climate

through the strong determination of management and employees.

INDUSTRY PROFILE