Presentation.... Internship at Millat Tractors Limited (MTL)

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

Transcript of Presentation.... Internship at Millat Tractors Limited (MTL)

Page 1: Presentation.... Internship at Millat Tractors Limited (MTL)
Page 2: Presentation.... Internship at Millat Tractors Limited (MTL)

Presented By:

Presentation on Internship at Millat Tractors Limited (MTL)

1. Usman Hassan 2009-ag-30842. Nadeem Akram 2009-ag-30923. Tanzeel-ur-Rehman 2009-ag-31004. Azlan Zahid 2009-ag-31085. Muhammad Ali 2009-ag-31096. Haseeb Bilal 2009-ag-31507. Muhammad Aamir 2009-ag-3204

Submitted To:Dr. Manzoor Ahmad

Page 3: Presentation.... Internship at Millat Tractors Limited (MTL)

1. Primary Objective:

To get training in a professional environment by engaging ourselves in one of

leading automotive company Millet Tractors Limited and to highlight the problems

and suggesting the suitable solutions.

Objective of our Internship

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Objective of our Internship

2. Secondary Objective:

To know about the market structure.

To get training at Engine Assembly Plant.

To get training at Tractor Assembly Plant.

To get familiar with all machining processes.

To get familiar with the operations of Quality Assurance Department.

To analyze different problems in industry.

To give suitable suggestions regarding problems.

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Introduction of Millet Tractors Limited

•Millet Group is Pakistan’s leading engineering concern in automobile sector & has

a history that spans almost half a century, Millet Tractors Limited is market leading

industry of agricultural tractors & holds above 50% market share.

•Millet 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.

• Millet Group encompasses four major companies

MILLAT TRACTOR LIMITED

MILLAT EQUIPMENT LIMITED

MILLAT INDUSTRIAL PRODUCT LIMITED

BOLAN CASTINGS LIMITED

•Millet Tractors Limited manufactures MF-240, MF-350, MF-260, MF-375, MF-

385, MF-385 4WD, Implements, Prime movers, Forklift Truck & Power

Generation Sets.

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Features of MTL

1. Millet Tractors Limited turnover is Rs.2300 crore.

2. Export market comprises of countries like Afghanistan, China, Namibia,

Uganda, Somalia and other African countries.

3. Highest market share in Pakistan of 64%.

4. Biggest assembly line in Pakistan.

5. Extensive dealership network and after sale services all over Pakistan.

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Products of Millat Tractors Limited

• Tractors MF-240 MF-260 MF-350 MF-350+ MF-375 MF-385 MF-385 (4WD) MF-455

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Multi Products

Forklift Truck

Generators

Prime Mowers

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Task 1:Field Market Survey

Marketing Division

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Our objective was to conduct an analysis on

Marketing Tactics Market share of MTL and its competitors Quality of the brand Dealership network and commissions Marketing regions Customer and dealer satisfaction level Current tractors demand Brand equity Future demand of tractors

Objective of Field Market Survey

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2010 2011 20120

10

20

30

40

50

60

70

Millat tractorsAl-Ghazi TractorsOthers

Graphical Representation of Market Share across Pakistan

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Internal Problems Analyzed At Marketing Division

1. Product development

2. Weak in aggressive marketing.

3. Unsatisfied delivery procedure.

4. Lack of proper survey (Market research).

5. Delay in tractor delivery.

6. No team work.

7. Totally centralized decision making.

8. Time consuming procedure.

9. No customer dealing department in real meaning.

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According to the dealers, the overall quality of the tractors was not found satisfactory the reasons are summed up below.

1. The performance of Fuel Injection Pump is not good it consumes more fuel due to the rotor clearance.

2. The major problem was of Differential System (Crown Pinion).3. There is a problem of Rear Rim distortion in shape and early rusting of the rims.4. Pressure is not maintained under loaded conditions in the Hydraulic System due to

the manufacturing fault.5. Turbo charger oil kit leakage in MF-260.6. The chassis is not properly painted due to which sometimes it rusts.7. When the temperature reaches near 400C the seals of tractors standing in

showroom leaks.

Problems Regarding The Quality

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Reasons for Market Downfall

The downfall pattern shown graphically below in local market due to the following reasons:

1. 10% Tax increase the prices.2. Green Tractor Scheme and Sindh Government tractor scheme3. High price of tractors.4. High fuel price.

2007 2008 2009 2010 2011 20120

5000

10000

15000

20000

25000

30000

35000

40000

45000

Units Produced

Units Sold

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Suggestions and Recommendations

1. The delivery time period at MTL is 21-days, arrangement should be made to decrease the delivery time so that service level can be improved.

2. There is some need to change the working environment of organization. HR should be the most valuable person in the marketing department.

3. Do not just use newspaper or conferences for advertisement but there should be proper publicity of the product so that people should be aware of Millat.

4. There should be complete R & D development department in company. This department should do market research and providing guideline for developing new products and modifying existing ones.

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Machining Division

Task 2:

To Practically Experience The Machining Operations

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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 (old) 5. Cylinder Head Line (Ext) 6. Center Housing Line7. Transmission Case Line 8. Lub Oil Sump Line (240)9. Lub Oil Sump Line (385)

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General Operations in Machining

1. Drilling 2. Rimming3. Boring4. Counter Boring(⌴)5. Spot Facing6. Counter Sinking(⌵)7. Milling8. Tapping9. Facing10. Turning11. Honing

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Cylinder Block Line

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.

1. Old Manual Machining Line (48 Parts per shift )2. New Automatic Machining Line (72 Parts Per Shift )

Cylinder Block line consist of 35 different machines performingdifferent machining operations.

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Milling at Head Face

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Honing Operation in Cylinder

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Water Jackets and Oil Galleries Testing Operation

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Oil Sump

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

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Transmission case Cylinder Head Axel housing Block(old) Block(Ext) Central Housing0

10

20

30

40

50

60

70

80

90

100

Production against Workers

Production/Shift

Workers

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Suggestions and Recommendations

1. Different machines performing the same operation must be checked and their number must be reduced.

2. The production efficiency could be increased by increasing worker’s efficiency. This can be done by giving some kind of incentives to the worker.

3. Old machines must be replaced by automatic plants. It will enhance the rate of production, better finishing quality, reduce the labor cost, consume less energy and would be space efficient as well.

4. CNC machine is required in OP‐53 on lube oil sump line because 0.064 tolerance cannot be controlled by manual Mill machine.

5. An alternate source is required for casting of lube oil sump due to casting problems.

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Engine Assembly Plant (EAP)

Task 3:To know about the operations happening in Engine

Assembly Plant.

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Engine Assembly line is a line in which all the parts of engine are fitted with Engine block and this line starts with block and complete on full engine.

There are 10 operational sections for complete engine assembly and the operations are given on engine build card.

There are sub-assembly sections in which small parts like Engine Head, Rocker Arm Assembly, Piston etc. are assembled.

In 3 cylinder type there are engines MF-240, MF-260, MF-350, MF-350+ which are used in tractors as well as fork lifters, generator sets and prime movers.

4 cylinder Engines of MF-375, MF-385, MF-385(4WD) are assembled which are used in big tractors.

Production Capacity of EAP plant is 95 per shift per day. Production can be increased on demand.

Engine Assembly Plant

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Engine build card is followed in the engine assembly plant

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Line Diagram of Engine Assembly Plant

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Sections of Engine Assembly Plant

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

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Engine Test Section

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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 engine noise, rpm, loading, leakages, exhaust smoke etc. Different ranges are given below:

Tester 1st Time 2ndTime Time(minutes)

R.P.M Brake(NM)

Power(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

Engine Test Ranges

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Engine Test Bed

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23-04-2013 24-04-2013 25-04-2013 26-04-2013 29-04-20130

10

20

30

40

50

60

53

57

54

46

51

9

11

9

17

21

11

9

6

13

3

Weekly Production in Engine Assembly Plant

MF 240 MF 375 Gen Set

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Assignment Task

To suggest the possible problems of excessive engine noise

during testing which is the big problem and can cause engine

rejection.

We found following problems which are given below:

1. Excessive Back Lash between the gears

2. Excessive End Float in the idler gear

3. Improper fitting of timing case

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Suggestions and Recommendations

1. Gauges should be calibrated timely and properly and worn out gauges should be replaced on time.

2. The company should put more effort in taking care of its workers especially daily wages and contractual workers so that they are satisfied with their jobs and give more quality output.

3. Another area which demand attention is that of job rotation. Employees are not so much productive, motivated and efficient because of their routine job.

4. They are allowed the operational level employee in decision making process especially when the decision are taken about the labor force because most of the time they better know about what is beneficial and suits to them.

5. The Quality Circles should be introduced among workers so that their participation in the improvement process increases.

6. Worker safety should be taken under consideration at the EAP (Engine Assembly Plant).

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Tractor Assembly Plant (TAP)

Task 4:

• To conduct an analysis on Mishandling• To analyze the problems in Material Flow• To analyze Painting Section and Painting Quality

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Tractor Assembly Plant

This is the main plant of Millat Tractors. All the components of tractor carried from different locations are assembled here. In this plant all the parts of the tractor are assembled on assembly lines.

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There are three assembly lines in TAP: Initial Build Assembly Line Chassis Paint Assembly Line Final Build Assembly Line

Sections of TAP

These are as follows:• Segregation and Degreasing• Assembly line• Sheet Metal Washing and Paint Shop• Test shop/Rectification area

Assembly Lines of TAP

Tractor Assembly Plant

Page 45: Presentation.... Internship at Millat Tractors Limited (MTL)
Page 46: Presentation.... Internship at Millat Tractors Limited (MTL)

Analysis on Mishandling

• Mishandling can be narrated as the miss use of the tool or the miss use of the component to be assembled both are under the issue of mishandling.

• Mishandling is a very big issue in any industry and its cost is always beard by the industry thus the profitability is decreased.

• Millat lost 2.5 million as mishandling expenses in Tractor Assembly Plant only which is a big loss.

We the internees were asked to conduct the survey in Tractor Assembly Plant on Mishandling. Our main concern was to know about three main questions and to help understand the reasons and to give suggestions to limit the mishandling losses.

Q.No.1. Do the worker know about what is mishandling?Q.No.2. Why mishandling occurs?Q.No.3. Suggestions by the workers i.e. how we can minimize this mishandling.

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    Sr. #.

  

Worker familiar with the concept of mishandling

Reasons why mishandling occurs

Lack of Expertise of the laborers

way of Rejection of the component

Inspector bias to vendor or sincere in rejection

Press machine malfunctioning

Timely Rejection of the component Inspector Availability

Worker Inspector

01 Yes Yes Improper Sincere No Yes Yes Yes

02 Yes Yes Improper Sincere Yes Yes Yes Yes

03 Yes Yes Proper Sincere No No Yes Yes

04 No Yes Improper Sincere Yes Yes Yes Yes

05 Yes Yes Proper Sincere Yes No Yes Yes

06 Yes Yes Proper Sincere No Yes No No

07 Yes Yes Proper Sincere Yes Yes Yes Yes

08 Yes Yes Proper Sincere Yes Yes Yes Yes

09 No Yes Proper Sincere Yes Yes Yes Yes

10 No Yes Proper Sincere Yes Yes Yes Yes

11 No Yes Proper Sincere Yes Yes Yes Yes

12 No Yes Proper Sincere No Yes Yes Yes

13 No Yes Proper Sincere Yes No Yes No

14 Yes Yes Improper Sincere Yes Yes Yes Yes

15 Yes Yes Improper Sincere No Yes Yes Yes

Survey Questionnaire

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The following are the main reasons of mishandling.

Above all the reasons one thing in common was that newly appointed worker always do

losses as he is unfamiliar with the system, so less expertise of the laborer is the main

reason in mishandling. We also came to know that some appointments of workers on

reference are not right some of those workers are not fit for the job hence they greatly

mishandle tools and components as they are not eligible.

QA should not allow the bad quality piece fed to assembly line, once it is assembled it

becomes mishandled willingly or unwillingly.

Due to over burden of production mishandling occurs.

Duties changing again and again cause mishandling as every worker best knows his work.

Reasons of Mishandling

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While making fun at working time, sometime tools become the part of their fun.

It occurs due to low quality of tools used.

By the worker i.e. use of improper tool for specific function.

By the negligence of the worker like sometimes the threads of the nut and bolt mismatch

and it is tightened so both the parts become waste.

Millat Tractors Limited purchases low quality parts which breaks during working so it

also becomes the case of mishandling.

Reasons of Mishandling

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1. It is the duty of the QA department that not to allow the bad quality part fed to the

assembly line.

2. The inspector should be on line for timely rejection of parts.

3. Supervisor should always focus on new workers and he should instruct them properly.

4. There should be optimum production load on the workers so the mishandling should be

limited.

5. Good quality tools should be used so components can be saved.

6. Proper tools should be used for proper jobs. Like to align the stud by hitting on the

threads should not be done this action was seen on line while visiting.

7. Training workshops should be conducted.

Suggestions for Mishandling

Page 51: Presentation.... Internship at Millat Tractors Limited (MTL)

To Analyze The Problems In Material Flow

The overall productivity of the plant depends on both input resources and output of the plant. The productivity can be increased either by increasing the output or decreasing the input resources.

Input resources includes:• Man• Material• Machine• Tools & Equipment• Method

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Material Flow Line Diagram

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Problems of Material FlowStorage Bins Storage Bins are not enough in every section. Some line facing severe shortage of bins. Due to this, parts are placed on the floor that results in damaging of parts.Delivery of PartsDue to the non-availability of the fork lifter or Stillage parts are not delivered at station on time.Handling of ComponentsHandling of components is done manually which require labor power and more time.Placement of the parts in bins and racksThe parts are not properly placed in the bins and racks by Segregation sectionColored bins for different model’s partsThere are no separate bins for different parts of different tractor models.Rejection Bins Rejection Bins are enough in number but placed far apart so time consuming and tiresome job.

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Problems of Material Flow• For higher productivity, the number of bins should be increased. This

will reduce Mishandling and time of production.• Workers from Segregation section just throw the parts in the bins that

might results in damage of some parts. This results in poor production cost.

• It would be great to add more bins but it could never be happened in this scenario because presently the space available is not enough to accumulate many bins at each station.

• Workers from segregation section don’t drop or deliver the parts to each station. They just throw in into the Storage bins.

• Usually on time delivery doesn’t happen but sometimes it does happen. The production rate is very fast, for this, material flow should also be fast but the quantity of fork lifters and stillage doesn’t respond to the number of work stations.

• Shortage of racks is also another factor for the delay of parts. Station having only one rack of each part suffers the most.

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1. An electronic Fork lifter should be provided because it is compact in size and produce no smoke.

2. Proper training should be given to workers to give them awareness to avoid the piling of segregated material at work stations.

3. The number of bins should be increased. This will reduce Mishandling and time of production.

4. Proper training should be given to worker to avoid mishandling 5. Material Management (MM) store should not be there within the plant area. It

should be in a separate building. This will release some space and it could be utilized in a better way.

6. Fork lifters and stillage should be increased in number to make sure that each part should reach its station on time.

7. Racks should increase in number in order to minimize the time lost in movement.

8. Rejection Bins should be increased to avoid wastage of time. It should be provided in easy reach of each worker or station.

Suggestions and Recommendations

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To analyze Painting Section and Painting Quality

• To know about the current painting quality, instruments used, processes carried out, problems regarding the worker’s health and safety and to find out the weaknesses and reasons behind poor worker health in that section.

• Painting section is very critical section regarding the worker’s health. Two of the workers are already suffering from Lungs infection.

• Our task was to find out the reasons behind that. We prepared a questionnaire regarding the painting processes, equipment used and prevailing health and safety conditions. The questionnaire is below

Red Gray SilverFender, Fender Plate, Fender Support Shroud  

  

Wrapper

Dash board, Dash board path Tank clampTop hood, Side hood  

Channel Strip Side panel

Q.1. What are the components painted in this section?

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Q.2. Either spray paint guns are available or not in this section?Yes, guns are available in this section. In fact are surplus in number.

Q.3. Either spray paint guns are of good quality or not in this section?Yes, guns are of good quality made by Bashir Sons.

Q.4. Either safety nasal mask are available or not?Yes, the masks are provided by MTL keeping in view the safety of the

workers.Q.5. Either worker wears safety nasal mask or not?

No, Workers don’t wore. Masks in summer but in winter they often wore it.Q.6. What is the effect of paint on the health of worker if the safety measures are not taken into account?

Workers have no sound knowledge about their safety. Recently two cases are reported in which the workers are suffering from lungs infection.Q.7. Either quality of the paint is good or not?

MTL is using ICI Paints according to prescribed standards of Massey Ferguson and it is of good quality

Questionnaire

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Q.8. Either work load for worker is manageable or not?Yes, work load is very much manageable. After every 70 hangers the worker in the paint booth is replaced.

Q.9. Either the worker are sufficient or not?Yes, man power in this section is enough in number. Total 24 workers are

available in each shift including supervisor and housekeeping staff.Q.10. Either paint is available on time or not?

Paint is available at paint booth and there is no delayQ.11. what are the major problems faced by workers regarding the painting?

No problem at all. Workers consider themselves that they are highly skilled in their respective job and can dealt with the problemQ.12. Either proper temperature is there or not?

Stove oven temperature ranges from 140-150◦C. stove oven doesn’t start till the temperature reaches to 140◦C. Dry oven temperature is 130◦C

Questionnaire

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1. Training workshops should be carried out in TAP to give awareness to the workers about their safety and health.

2. It should be made mandatory for the workers to wear safety nasal masks during painting.

3. Training workshop should be carried out time to time in order to improve the worker’s skills in order to enhance the painting quality.

4. Painting precision and accuracy should be improved in order to minimize the paint losses.

5. The painting quality must be improved to avoid rusting.

Suggestions and Recommendations

Page 60: Presentation.... Internship at Millat Tractors Limited (MTL)

Task 5:

To Know The Working Of Quality Assurance

Quality Assurance Department

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What is Quality?

Product or service that fulfills or completes its task or work effectively for specified period of time is referred as quality.

QA has three sectionsBought Out Finished (BOF)In House Quality ManufacturingProduction Lines Quality

To ensure the quality of the components to be assembled MTL have different types of gauges, fixtures and jigs, micro gauges, dial gauges, height gauges, depth gauges and many others.

Quality Assurance

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Different types of Gauges

Snap gauge: To determine the outer diametersPlug gauge: To determine internal diameter or boreSlip gauge: To determine the gaps between two componentsRing gauge: To determine the thread outer diametersDial gauge: To determine the multiple dimensions (ovality,

tapperness, bore, length, clearances) in microns.

• In every department of Millat Tractors Quality Assurance section is present which assures the quality of all the processes happening there.

• At every step of manufacturing there are gauges present to check the quality of the product at every step.

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Quality of precision machined parts both in house manufactured and vendors supplied is ensured by the use of CMM, CMM caters for precise measurement of linear and geometrical size and assures the dimensional integrity of complex parts with high speed. CMM can measure up to half micron.

CMM can measure:

• Intricate sizes • Positions• Angles • Diameters • Squareness• Flatness

Coordinate Measuring Machine (CMM)

• Parallelism• Concentricity• Roundness• Straightness• Co-axial ties

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Inspection and Testing Facilities in Labs

• Oil and Grease Testing

• Paint and Coating Testing Lab

• Rubber Testing

• Material Testing 

• Mechanical Testing

Page 65: Presentation.... Internship at Millat Tractors Limited (MTL)

What is Quality?

Product or service that fulfills or completes its task or work effectively for specified period of time is referred as quality. What is Quality Assurance?The Quality assurance department attempts to improve and stabilize the production and associated processes to avoid or to at least minimize the issues which leads to the defects. To ensure the quality of the Tractors and other multiple products that are assembled in MTL is the main task of the quality assurance department.

Quality Assurance

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Quality Assurance

Quality Assurance(QA) Department has 3-sections:

• Bought Out Finished (BOF)• In House Quality Manufacturing• Production Lines Quality

Page 67: Presentation.... Internship at Millat Tractors Limited (MTL)

Bought Out Finished

• This section is incoming inspection center that basically deals with the inspection of incoming parts that were manufactured by different Vendors.

• It utilizes different types of instruments, gauges, micro gauges, fixtures and jigs for measuring the different dimensions of different parts.

• Random sampling technique is adopted to collect the sample out of the total lot and the dimensions are then measured and compared with the standard one.

• Massey Ferguson(England) has predefined the acceptable quality level for the different parts according to which lot is either rejected or accepted depending upon the nature and sensitivity of the part, e.g. The acceptable quality level is 2 for the lot of 100 pieces if a sample of 8 pieces is to be taken.

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In-House Quality Manufacturing

• It basically deals with the quality of the components, parts or accessories that are manufactured o machine d within the fences of MTL.

• There are the drawings for the different parts that allows only the specific level of tolerance in the machining or finishing of these parts, this section has basically the concern with that level of tolerance and has to maintain,

• This section utilizes very delicate and sensitive equipment's such as Co-ordinate measuring machine(CMM) for the assurance of quality.

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• This section has to dealt with the problems encountered on production or assembling lines and is responsible for meting and maintaining the set standards of the final products.

• There are pre-defined methods of assembling the different components and sub components to get a final finished products.

• This section assures that these predefined methods of assembling should be adopted by the different workers in order to met the standard

• Furthermore it resolves the problem encountered in following the specific procedure of assembling.

Production Lines Quality

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Gauges• At every step of manufacturing there gauges are present to check the

quality of the product.• These gauges are provided to help out the Engineers of Production

lines quality to check the various parameters during assembling.

Different types of Gauges:

Snap gauge: To determine the outer diametersPlug gauge: To determine internal diameter or boreSlip gauge: To determine the gaps between two componentsRing gauge: To determine the thread outer diametersDial gauge: To determine the multiple dimensions (ovality,

tapperness, bore, length, clearances) in microns.

Page 71: Presentation.... Internship at Millat Tractors Limited (MTL)

Quality of precision machined parts both in house manufactured and vendors supplied is ensured by the use of CMM, CMM caters for precise measurement of linear and geometrical size and assures the dimensional integrity of complex parts with high speed. CMM can measure up to half micron.

CMM can measure:

• Intricate sizes • Positions• Angles • Diameters • Squareness• Flatness

Coordinate Measuring Machine (CMM)

• Parallelism• Concentricity• Roundness• Straightness• Co-axialties

Page 72: Presentation.... Internship at Millat Tractors Limited (MTL)

Coordinate Measuring Machine (CMM)

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Detailed Report of CMM

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Inspection and Testing Facilities in Labs

• Oil and Grease Testing

• Paint and Coating Testing Lab

• Rubber Testing

• Material Testing 

• Mechanical Testing

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Inspection and Testing Facilities in LabsOil and Grease Testing: • Flashing point apparatus• Different viscometer and viscosity bath

Paint and Coating Testing:• Salt spray testing machine• Thickness meter

Rubber Testing:• Durometer rubber hardness tester• Ovens and weighing balance

Mechanical Testing• Universal testing machine UTM (50 Tons)• Rockwell hardness testing machine• Brinell hardness testing machine• Vicker hardness tester with micrometer• Impact tester

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• MTL should be quality conscious rather than quantity conscious.• It is the duty of the QA department that not to allow the poor quality part fed

to the assembly line.• Good quality tools should be used so components can be saved.• Bought out Finished(BOF) section should work more precisely and

accurately to ensure the best quality of the vendor’s product.• CNC machine is required in OP‐53 on lube oil sump line because 0.064

tolerance cannot be controlled by manual Mill machine.• To improve the quality, change the operating machines gradually.• Vendors should be treated properly.

Suggestions and Recommendations

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Thank You…