L&T CASE EQUIPMENT PVT. LTD.

Pithampur (M.P.)

Industrial Training Report

Central Material Department

Submitted By:

Jyoti Chouhan,

Kuldeep Thakur

B.E. 2nd Year,

Mechanical Engineering.

S.G.S.I.T.S. Indore (M.P.)

Submitted To:

Mr. Sameer Sharma

Central Material Department

L&T CASE EQUIPMENT PVT. LTD. Pithampur (M.P.)

Date: 3-06-2010

DECLEARATION NOTE

We hereby declare that, all the work done in the Project is not copied from any other

source. The Drawings or any other data is not reviled among other peoples, which were

provided to us by the company.

DATE:

03-06-2010

TABLE OF CONTENTS

CONTENTS

Abstract……………………………………………………………....

Introduction…………………………………………………………..

Organizational information…………………………………….......

Company overview……………………………………..

Overview of the plant…………………………………..

The Training project……………………………………………

Objective…………………………………………………

Duration of the Project…………………………………

Project Scope……………………………………………

Methodology…………………………………………….

Data Collection………………………………………….

Manufacturing Processes………………………………

Data Analysis and Interpretation……………………...

Recommendations………………………………………

Conclusion……………………………………………………….

Appendix…………………………………………………………

ABSTRACT

Today in the Industrial world competition is at its peak. Each industry wants to increase its

production according to the demands of its customers and their needs and thus to make more

& more profit. To increase the profit in production as well as in satisfaction of their customers

from the products produced by the company the best way is to reduce the production cost with

significant increase in quality and service life of the product.

Products may be a single part or they may be an assembly of many constituent parts. The

Production cost includes cost of raw material, processing cost, transportation cost etc. So as to

reduce the production cost options available are to select the material having all the properties

for the required purpose at the lowest price. Sometimes there is a condition of availability of

the material at low cost which does not have the properties for the required purpose, but it can

be processed to make it suitable for the purpose thus second thing one can do is to select the

proper manufacturing and finishing processes. At the same time the manufacturer also needs

to control the quality and service life of the constituent parts of a product so as for satisfaction

of his customers.

Quality of the part depends on the manufacturing processes by which it is made as they decide

the properties of the product according to its application. Service life of a part depends on the

working circumstances, and on its maintenance. Thus to increase the production to fulfill the

demands of the customers and to make profit these aspects needs our considerations.

INTRODUCTION

This report is on the Minor Summer Industrial Training I received in the company “L&T

CASE EQUIPMENT PVT. LTD”. Pithampur (M.P.), during dates 19/05/2010 to 31/05/2010.

The Industrial Training in the company enabled me to widen my theoretical knowledge with

the practical exposure. The LTCEPL is a Construction division company of private sector in

India. It manufactures and sells construction and road building equipment such as Loader

Backhoes and Vibratory Compactors.

During my training I was associated with the Material Department of the company, under the

Training in-charge Mr. Sameer Sharma. Basic objective of my training is to be familiar with,

and to understand about how an industry works and to implement the theoretical knowledge I

have received during our studies in college, in the practical field to serve the company. I was

assigned a project by our training in-charge related to some spare parts such as pins & bushes

used in Wheel Tractor Loader Backhoe (WTLB). The project was about to study the

production drawing of those parts and to suggest a better material as their substitutes. I

worked on the project on the basis of our Material Science, and Engineering Drawing studies.

The method I adopted to study the drawings of the components, and material properties to

withstand the conditions they are subjected to, are given in this report. Also the suitable

materials available for the purpose are also suggested.

ORGANIZATIONAL INFORMATION

L&T CASE EQUIPMENT PVT. LTD. is an Engineering & Construction division company of

Larsen & Toubro (L&T) group, which itself is a technology, engineering, construction and

manufacturing USD 9.8 billion company. It is one of the largest and most respected

companies in India's private sector. L&T was founded in Bombay (Mumbai) in 1938 by two

Danish engineers, Henning Holck-Larsen and Soren Kristian Toubro. Both of them were

strongly committed to developing India's engineering capabilities to meet the demands of

industry. Now Mr. A. M. Naik is the Chairman & Managing Director of Larsen & Toubro

Limited.

Today L&T Group has following worldwide Operating Divisions:

Engineering & Construction Projects (E&C)

Heavy Engineering (HED)

Engineering Construction & Contracts (ECC)

Electrical & Automation (EBG)

Machinery & Industrial Products (MIPD)

Information Technology & Engineering Services (InfoTech)

Finance and Banking Solutions (BFS)

COMPANY OVERVIEW :

L&T CASE EQUIPMENT PRIVATE LIMITED (LTCEPL) was formed in November 1998

and is a 50:50 Joint Venture between Larsen & Toubro Limited (L&T) and Case New Holland

(CNH) Global N.V., for manufacturing and selling construction and road building equipment

such as Loader Backhoes and Vibratory Compactors. It is situated at Pithampur (near Indore)

in Madhya Pradesh. Now Mr. C.V. Alavandi is the Chief Executive Officer of the company.

The LTCEPL is ranked 1st in production of Vibratory Compactor in India and it’s Loader

Backhoe market share is 11%.

Larsen & Toubro Limited (L&T) is a technology, engineering,

construction and manufacturing company. Seven decades of a

strong, customer-focused approach and the continuous quest for

world-class quality have enabled it to attain and sustain

leadership in all its major lines of business.

Case New Holland (CNH) Global N.V. is a Netherlands based

USD 13 billion company engaged in the manufacture and

distribution of agricultural and construction equipment

worldwide. The company operates in three segments:

Agricultural Equipment, Construction Equipment, and Financial

Services.

 

OVERVIEW OF THE PLANT :

L&T Case Equipment manufacturing facility is located at Pithampur near Indore in Madhya

Pradesh. It is ISO 9001 certified for design, manufacture, sells and supply of construction and

road building equipment such as Loader Backhoes and Vibratory Compactors. These products

are used primarily for the country’s infrastructure development, irrigation, mining. A small

quantity is also exported to neighboring SAARC countries.

The estate is spread over 40 acres with over 12,000 sqm. built-up space, assembly shops

equipped with state of the heart facilities like:

Welding Robots.

Laser Gas-cutting Machines.

CNC Boring Machines.

Powder Coating Painting facility.

WELDING ROBOT POWER COATING PAINTING

FACILITY

LASER GAS-CUTTING MACHINES

ASSEMBLY SHOP FOR ASSEMBLY SHOP FOR VIBRATORY COMPACTOR LOADER BACKHOE

The state-of-the-art Quality Assurance Laboratory in the company is equipped with sophisticated measuring equipment such as:

Digital Height Gauge,

Hydraulic Oil Contamination Tester,

Spectrometer,

Metallurgical Microscope,

Electronic Comparator,

Ultrasound Flaw Detector,

DIGITAL HEIGHT GUAGE METALLURGICAL MICROSCOPE

which ensure every manufactured component meets the exacting standards required for

robust, reliable products.

SUPPORT & SERVICES:

L&T Case Equipment Private Limited has nationwide Sales Offices, which provide technical

and commercial support and effective service backup to Customers for machines and spare

parts. The company provides field service support for its range of construction and road

building equipment. Service Engineers based near large machine population sites render

prompt and efficient after-sales support. LTCEPL also conducts training programmers round

the year for customers and dealers on equipment sales, operation and maintenance, and spare

parts management.

L&T Case has 8000 sq.ft. Central Ware House located in Indore to support the spare parts

operations. Inventory of over 4500 items is maintained. Dealers place their orders on-line

through the SAP ERP network.

DIAGNOSTIS TOOL-KIT

TRAINING HALL OF L&T CASE PARTICIPANTS UNDERGOING TRAINING CENTRE HANDS-ON TRAINING

SPARE PARTS

LTCEPL at Pithampur, manufactures 3 models of Vibratory Compactors and 3 models of Loader Backhoes:

VIBRATORY COMPACTORS

NAME SPECIFICATION VIEW

L&T 752 Double Drum Asphalt Compactor

Type Tandem Roller

Horse Power 74

Weight 8.8 T

Amplitude 1.0/0.4 mm

Frequency 33.3/ 50 Hz

L&T-CASE 1107 Single Drum Soil Compactor

Type Single drum

Horse Power 112

Weight 10.30 T

Amplitude 1.8/0.8 mm

Frequency 30/33 Hz

Options ‘PD’ version

L&T-CASE 450 Double Drum Mini Compactor

Type Tandem Roller

Horse Power 46.5

Weight 3000 kgs

Amplitude 0.6 mm

Frequency 55 / 66 Hz

THE TRAINING PROJECT

LOADER BACKHOES

NAME SPECIFICATION VIEW

L&T-CASE 580-3S

Horse Power

76

Weight 7.1 T

Bucket size Backhoe: 0.08 – 0.30 cu.m

Loader: 0.63-1.5 cu.m

Options

Bottom dump bucket, Rockbreaker, Ripper tooth, Lifting arrangements, Extending type

dipper, Backfill blade, 14x25 -20 PR Heavy Duty Tyres, Dozer blade, Limestone scraper.

L&T-CASE 770

Horse Power

76

Weight 7.1 T

Bucket size Backhoe: 0.243 cu.m

Loader: 1.00 cu.m

Options

4-wheel drive (4x4 Traction), Rockbreaker, Lifting arrangements, Extending type dipper, Bottom

dump bucket, Ripper tooth, Backfill blade, Heavy duty tyres: 14x25 -20 PR, Dozer blade, Limestone

scraper.

L&T-CASE 851

Horse Power

96

Weight 7.1 T

Bucket size Backhoe: 0.243 cu.m

Loader: 1000 L

Options

Bottom dump bucket, Rockbreaker, Ripper tooth, Lifting arrangements, Extending type

dipper, Backfill blade, 14x25 -20 PR Heavy Duty Tyres, Dozer blade, Four wheel drive.

During my working days in the Material department I was given Production drawings of four

components of the Loader Backhoe. Those components were two pins and two bushes used in

the backhoe assembly. Since an assembly of the machine is made of thousands of component

parts therefore to identify each component separately the components are assigned some

identification numbers, known as Part Numbers.

OBJECTIVE :

The objective of my project was to study the details of those Production drawings, with

estimation of production cost, and to recommend various ways to reduce the production cost

to increase the profit.

Components given are:

1) Hinge Locking Pin, Part No. - BU2720172.

2) Stabilizer Pin, Part No.- BU2720169

3) Bush End Pivot (Lift), Part No.- BU2870047

4) Bush End Pivot (Lift), part No.- BU2870046

NOTE: The components above are related to Loader backhoe only.

DURATION OF THE PROJECT :

The total duration of my industrial training was of 15 days. During those days I spent 4 days

in visiting the plant, and in understanding working of departments, manufacturing and

production processes. I worked 4 days (16 hours) on the Project assigned to me during my

working schedule in the company.

PROJECT SCOPE :

In the project assigned to me the concerned components are related to WTLB (Wheel Tractor

Loader Backhoe) only. It does not include any component from the Vibratory Compactor.

According to the objective of the project I was needed to study all the essential elements of

Production Drawings of the components in detail.

Generally a production drawing incorporates following information about the machine

component:

Quantity to be produced.

Raw material Type, Kind and Size.

Geometrical & Dimensional Tolerances.

Surface Roughness.

Manufacturing Methods.

Applicable National Standards.

Special Instructions.

The study includes aspects related to Selection of suitable raw material to meet the demands

of the purpose, efficient manufacturing methods, study of special secondary processes such as,

Case Hardening, Heat treatment etc. to improve the mechanical properties of the component.

The study also includes the exploration of various options available as a substitution for the

material being used, to increase the service life of the machine part of concern, and to select

the effective manufacturing methods to reduce the production cost and to increase the profit.

METHODOLOGY :

To study the Production drawings of all the 4 machine parts of interest in my project, first I

acquired their Part Numbers for their identification from Mr. Vineet in the Material

department. Then I went to the Engineering department to get the blue prints of the drawings

of the components designated by their part numbers. After getting the drawings I went to my

training supervisor to get an advice over primary steps that I should follow to complete the

project. After consulting with him I acquired the books & notes which can provide me full

details about the Production drawings and its elements. I studied the elements given in the

drawings thoroughly and understood their importance. Then I went in the Assembly shop

where I inspected where those parts are assembled in the WTLB. I discussed with the workers

there about the installation of those components.

After watching the assembly, I analyzed various loads to which the components are subjected

to. Then I studied about the material used to produce those Pins and Bushes and their

properties. I also studied the manufacturing methods and requirement of secondary operations

to produce the required mechanical properties to withstand at the field. After completing the

study I went for exploration of substituent, which has better mechanical properties and

comparatively less manufacturing costs. I studied about the estimation of manufacturing costs

and planning to control it to make profit for the company without compromising the quality of

the product.

DATA COLLECTION :

The material used in production of the components is Alloy Steel. Alloy steel is steel alloyed

with a variety of elements in amounts of between 1 and 50% by weight to improve its

mechanical properties. Various elements generally alloyed in steel and their effects on the

properties are given below:

Carbon (C): is the most important element in the majority of steel, affecting hardness

and strength by heat treatment. The ductility and weldability decreases with increasing

carbon content.

Manganese (Mn): contributes to strength and hardness with variable carbon content.

It is an austenite forming element in some steels and has a significant effect on

hardenability.

Nickel (Ni): is an important element which increases hardenability, tensile and impact

values of steels. Added to high chromium stainless steels in amounts of over 8% it

produces austenitic structures which gives high temperature strengths and resistance

to oxidation and corrosion.

Chromium (Cr): is added to steel to increase corrosion and oxidation resistance. It

also increases hardenability and combined with high carbon improves wear and

abrasion resistance

Molybdenum (Mo): is added to nickel chrome alloy steels to improve strength and

hardness and also in chromium nickel austenitic steels it improves corrosion

resistance. Molybdenum is used in some high speed steel grades.

NOTE: 1. Molybdenum (0.15 - 0.50%) is used in carburizing steels to simultaneously

increase the hardenability of the low carbon core and toughen the high carbon case. It

is especially effective in large cross sections, such as in gears. Molybdenum is not

oxidized during carburization, making it an effective hardening agent which does not

cause increased surface cracking and spalling.

2. 0.22% C in alloy steel provides low stress components, 0.35% C provides standard

stress components.

VARIATION IN YIELD STRENGTH OF THE ALLOY STEEL

DISCRIPTION OF MATERIAL USED

S No. PART No. COMPONENT MATERIAL COMPOSITION

NAME

1. BU2720172 Hinge Locking Pin 20Mn2 – IS:1570 0.17-0.24%C,1.40-1.80%Mn

2. BU2720169 Stabilizer Pin 39NiCrMo4-

IS:3930-1966

0.35-0.43%C, 0.70-1.0%Ni,

0.60-1%Cr, 0.15-0.25%Mo

3. BU2870047

BU2870046 Bush End Pivot (Lift) 20MnCr5- IS:4432

0.17-0.22%C, 1.10-1.40Mn,

1.0-1.30% Cr

MANUFACTURING PROCESSES :

1. First step is to collect the raw material available in the market in suitable form, such as in

rod form for pins, and bushes.

2. Processes applied for converting the raw material into useful piece and finding the

finished product of required dimensions. For example:

For Hinge Pins, piece of rough dimensions undergoes turning, facing, upset forging and

surface grooving. And for Stabilizer Cylinder Mounting Pin, rough piece undergoes

turning, facing, drilling and chamfering.

For Bushes rough dimensioned piece undergoes Drop forging and internal grooving, and

chamfering.

3. Secondary operations applied to primarily processed parts to improve their mechanical

properties and appearance. For example:

For Pins (IS:3930-1966): Induction Hardening to harden its case of depth 2.5-5.0mm to HRC

55-60, stress- relief annealing, and Black Oxide coating for corrosion resistance. For

achieving required surface roughness of 1.6µm on length operation performed can be planning

or disc grinding. And for 3.2µm on faces operations can be planning, milling or disc grinding.

For Bushes (IS:4432): Case Carburizing for hardening outer case of depth 0.8-1.2mm to

HRC 55-60, after case carburizing Tempering is done to remove residual stresses, then to

achieve the required surface roughness of 0.8µm Burnishing or Honing operations can be

performed.

NOTE: 1. Grooves should be cut before heat treatments.

2. Remove all burrs and sharp edges.

Sno. Process Advantages

1.

Induction Hardening

1. Automated process can be carried out

with unskilled labor.

2. Operating time is sharply reduced.

3. No scaling and distortion of workpiece.

4. High core strength and good impact

properties.

2.

Case Carburizing

1. Labor cost is lower.

2. Uniform case depth and carbon content.

3. Rapid heat transfer.

4. High wear resistant.

5. Resistant to shock loads and longer

service life.

REASION BEHIND SELECTING THESE PROCESSES

DATA ANALYSIS & INTERPRETATION :

LTCEPL requires about 400 Pins and 300 Bushes per month for its production. The

company orders the stock of these products to some manufacturer who supplies them

within the time provided by the company. Manufacturer first buy the raw material then

perform manufacturing operations on them and then supply it to the company at some

reasonable prize including the manufacturing cost and his profit.

Production Cost Calculation for Stabilizer Pin:

No. of quantity ordered = 400 per month.

Price of the raw material per piece = 40 Rs/kg.

Total raw material required = 1300 kg.

RAW MATERIAL COST:

Total cost of raw material = 40×1300 = 52000 Rs.

PROCESSING COST:

S. No. PROCESS

TIME CONSUMED

IN PROCESS

PER PIECE

(in min.)

PER PIECE

COST

(in Rs.)

TOTAL COST

(PER

MONTH)

1. Turning 10 6.6 2670

2. Facing 5 2.5 1000

3. Drilling 5 5 2000

4. Chamfering 5 1.5 600

5.

Induction Hardening

(1.6 kg per piece)

- 12 (per kg) 8000

6. Surface Coating - 8 (per kg) 6000

TOTAL 20270 Rs.

TOTAL PRODUCTION COST:

S. No. TYPE OF COST AMOUNT (Rs.)

1. Raw Material 52000

2. Processing 20270

3. Profit (10%) 7227

TOTAL 79,497

FINAL COST PER PIECE:

Cost per piece = Total amount/ No. of pieces.

79,497/400 = 199 Rs. Per piece.

Production Cost Calculation for Bush End Pivot (Lift):

No. of quantity ordered = 300 per month.

Price of the raw material per piece = 40 Rs/kg.

Total raw material required = 330 kg.

RAW MATERIAL COST:

Total cost of raw material = 40×330 = 13200 Rs.

PROCESSING COST:

S. No. PROCESS

TIME CONSUMED

IN PROCESS

PER PIECE

(in min.)

PER PIECE

COST

(in Rs.)

TOTAL

COST

(PER

MONTH)

1. Turning 5 3.3 1000

2. Forging - 17 (per kg) 5100

3. Grinding 10 1 3000

4. Internal Grooving 10 6.6 2000

5. Chamfering 5 1.5 450

6.

Case Carburizing

(0.5 kg per piece)

- 12 (per kg) 1500

TOTAL 13050 Rs.

TOTAL PRODUCTION COST:

S. No. TYPE OF COST AMOUNT (Rs.)

1. Raw Material 13200

2. Processing 13050

3. Profit (10%) 2625

TOTAL 28,875

FINAL COST PER PIECE:

Cost per piece = Total amount/ No. of pieces.

28,875/300 = 97Rs. per piece.

RECOMMENDATIONS :

1. In case the material 20MnCr5 for manufacturing the Bushes is not available so other

substitute materials available to fulfill the same purpose can be 20MnCr1,

15NiCr1Mo12, 15Ni2Cr1Mo15, 16NiCr2Mo20 because they have the same

mechanical properties as the 20MnCr5 has.

2. Similarly in place of 39NiCrMo4 for Pin substitute materials can be 40Ni2Cr1Mo28,

50Cr1, 50Cr1V23.

3. To manufacture a component the processes that are applied can be replaced by other

production and machining processes which cost lower. For example: Forging process

for production of Bushes can be replaced by Drilling and Boring process to form

inside cavity.

4. We can replace the alloy material of the components by plastic products or reinforced

polymers, such as Nylatron, Carbon fiber as they have less weight but same strength as

the metallic alloys have.

5. Another way to get more profit is to increase quantity and types of components in

order to the manufacturer.

CONCLUSION

The opportunity to work at L&T CASE EQUIPMENT PVT. LTD. provided the chance to

experience the variety of types of activities both in field and office and enabled me to get an

exposure to industrial world. Many thanks are extended to LTCEPL for allowing me to

undertake my training with them and to use the details of my theoretical knowledge in

practical field during my project work.

The project of selecting the correct material for the correct purpose regarding to its

physiochemical and mechanical properties and its effecting production cost estimation was the

ideal job for an undergraduate mechanical engineering student.

It is the task that opens the doors for progress in the next stage and which in turn is an area

where many of my skills are utilized. The most significant part of my industrial training is that

I was able to experience variety of works, all of which are typical of the job, I will be

undertaking in my carrier. This project provided me a way to co-relate the knowledge of

different subject which I gathered in my college studies and to implement the mixed up

knowledge to tackle practical problems.

APPENDIX

Reference Books:

1. Material Science …………………………………O.P.Khhana.2. Material Science…………………………………..Callister.3. Production, Planning and Control with SAP…........Jörg Thomas Dickersbach.

Production Drawings provided by the company LTCEPL:

5) Hinge Locking Pin, Part No. - BU2720172.

6) Stabilizer Pin, Part No.- BU2720169

7) Bush End Pivot (Lift), Part No.- BU2870047

8) Bush End Pivot (Lift), part No.- BU2870046

Websites:

1) www.LnTCASE.com .

2) www.Larsentoubro.com .