SML ISUZU Training Report 0009
SML ISUZU Training Report 0009
OF
SIX WEEK INDUSTRIAL TRAINING UNDERTAKEN
AT
“PRODUCTION DEPARTMENT”
SUBMITTED IN PARTIAL FULFILLMENT OF THE SIX
WEEK INDUSTRIAL TRAINING
IN
MECHANICAL ENGINEERING
Department:Production
1ACKNOWLEDGMENT:
Any endeavour cannot lead to success unless and until a proper platform is
provided for same.This is the reason I find myself very fortunate to have
undergone my industrial trsining of six weeks at SML ISUZU,ROPAR.
The persons of my department and all other departments have extended a a
warm and helping hand.
I am very fortunate to have had a chance to feel the gravity of what role
mechanical engineering plays in the industry.It was a golden opportunity for
me to get a chance to experience what was feel to be in a company where
discipline,quality and hard work are motto.This training helped me a lot in
bridging the gap between the theoretical and the practical aspects of my
knowledge.
5
1.0 OBJECTIVES OF TRAINING:
1. To study the various processes which are done on various parts of
LCV,MCV and HCV.
2. To study about 5s technology.
3. To study the function of different departments.
4. To study about the defects in vehicles.
5. To study about management.
6. To study about human resource management and their beheviour about
employees.
6
1.1 AN EASY TRAINING BUT A TUFF JOB:
A - Active Participation
I - Interact To Clarify
G - Gain Knowledge
7
1.2 TPM MANAGEMENT:
JISHU HOZEN
PLANNED MAINTAINANCE
KOBETSU KAIZEN
EDUCATION AND TRAINING
QUALITY MAINTAINANCE
TOOL MANAGEMENT
OFFICE TPM
8
1.3 COMPANY PROFILE:
SML ISUZU was promoted in 5th October 1984 in technical and financial
collaboration with Punjab tractorts limited,Mazda motors corporation and
sumitomo motors corporation,Japan for manufacturing of light commercial
vehicles (LCV’S).SML ISUZU represents two powerful brands:SWARAJ-
symbolizing best Indian technology and engineering.
The assembly unit of SML ISUZU limited is located at village Asron district
Nawanshahar(PUNJAB) near the city of Ropar at a distance of 40kms from
the capital city of Chandigarh the plant has a captivating site.It spread over a
quaint,sprawling 100 acres of land ringed by shiwalik hills on the three of its
sides and river satluj on the other.The desolate slit hill has been leveled for
construction.The construction at this Rs5.0 crores plant,commenced on 16th
January 1985.Work mat the plant at a great tempo and the first vehicles rolled
out the production line in a record time of one year of laying the foundation
stone.
4 Wheels drives
Extend wheel base long chassis mini buses which carry up to 44
passengers
Deluxe buses carries up to 44 passengers
Ambulance developed with active involvement of senior specialist from
post graduate institute of medical science and research,Chandigarh
Hydraulic operated dumpers
Dual cabin load carriers
Integrated garbage collection and disposal system for urban centres
COMPANY LOGO
10
MFNB 9.10%
FLL’s 5.85%
Public 25.08%
Public 25.08%
Sumitomo
corporation
FLL’s 55.85% Japan
55.96%
MFNB
9.01%
ISUZU motors
limited 4.00%
Pie chart for share holding pattern
Fig 1.0
11
Vice President
Associate Vice President
General Manager
Deputy General Manager
Assistant Manager
Fig no 1.0
12
4WD TRUCK:
Fig no-1.2
13
AMBULANCE:
Fig no-1.3
14
ENGINESHOP:
The engine is a device that is used to convert chemical energy of fuel into
heat energy and this energy is then converted into useful work.The engine
provides the motive power for the various functions which the vehicle and any
part of it may be required to perform.
15
EURO-1
EURO-2
EURO-3
EURO-4
C.N.G.
16
17
FEED Operated by Operated by Have CRDI N.A
9. PUMP FIP engine
18
The components received from the vendors end cannot be used directly in the
engine assembly.For this purpose ,all components are washed properly and
burr,grease and cutting fluids strains effectively removed.
1. Magnetic Separator:
Magnetic separation is a process in which small magnetically
susceptible burrs are extracted from engine components using a low
intensity magnetic force.
2. Degreasing zone:
Solvent degreasing is a process in which a cleaning agent is applied
directly to the suface by spraying,brushing and wiping.This process
removes oil,grease,dirt, loose particles and any other contaminants that
may exist on the surface of the material.
4. Drying Zone:
In this zone,the engine components are dried to remove any chemical
impurities present on the surface by passing components through a high
temperature zone.
20
Fig no. 3.1
21
Fig no. 3.2
5. Engine block is rotated and oil jets are attached to the block.The oil jets are
tight and torque up to a valve of 1.20-1.80 kgm.
22
3.2.1 Station E-2.0
Fig no.3.4
Fig no.3.5
6. Based on this coading and according to the table we are going to put the
crankshaft bearing.
23
7. Before putting the crankshaft in the crankcase the bearings are cleaned
properly and oil is put both on the bearings and crankshaft.After this,the
crankshaft is placed in the crankcase along with crank gear.
Fig no.3.6
8. Now key bearing caps are put one by one at their place.
9. To prevent the sideways movement of the crankshaft thrust bearings are
inserted in the central main bearing.
10. Now start tightening up the crankshaft main bearing caps up to a torque of
10-10.7 kgm.
11. All the bolts should have torque marks.
12. Check crankshaft for free movement and end play.
13. Piston assembly is placed according to crank pin depth.
1. Attachment of a connecting rod to the piston with the help of gudgeon pin.
2. Putting up circlips on both sides of gudgeon pin.
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3. Cleaning of connecting rod caps.
4. Placing of connecting rod bearings in connecting rod and cleaning.
5. Check for any dent marks.
6. The pistons for E-1,E-2,E-3 and CNG engines differ in the design of crown
of the pistons.
Fig no.3.7
25
4. Piston assembly is attached to the crankshaft.
26
Fig no.3.10
9. Place the dial gauge on the other piston and the note the reading shown by
the dial gauge.
10. Now rotate the crankshaft and clean the surface of other two pistons.
11. Place the dial gauge on the piston and take the reading in the similar way
as discussed earlier.
12. Compare the values with the table.
13. The gasket is choose according to these readings.Gasket may be green or
white.
14. Place the time case assembly on the trolley and move the trolley ahead.
27
4. Cleaning and oiling of spindle gear is done.
5. FIP gasket and setting and adjustment.
6. Timing gears are fixed with timing matched.For matching the timing point
A,B and C are matched properly.
Fig no.3.11
28
2. Timing cover fitment and tightening up of bolt up to a torque of 2.5 kgm.
3. Assembly of water pump gasket and torquing up to 2.5 kgm.
4. Assembly of rear oil seal and torquing up to 2.5 kgm.
5. Fitting of oil pump and tightening of bolt up to a torque of 2.5-3.8 kgm.
6. Fitting of oil pipe with “O” ring.
7. Fitting of bracket of strainer pipe and torquing up to 2.5 kgm.
8. Tightening and torquing of oil pipe up to 2.5 kgm.
29
3.2.6 Station E-6
Fig no.3.14
30
Fig no.3.15
3. Fix indicator pin on the end plate.Indicator pin is used to indicate the
markings provided on the flywheel.This help in dismantling the FIP or
adjusting the tappets.
4. Flywheel is bolted over the end plate.The torque of the flywheel is kept
between 21-23 kgm.
5. Attachment of disc clutch and cover clutch with guiding tool.
6. Tightening and torque checking of cover clutch bolt.
7. Matching of indicator pin with top dead center.
8. Piston topping and mark setting.
9. Gasket selection note gasket type,placing of cylinder head on block push
rod fitment.Placing of caps and rocking shaft.
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8. Attachment of thermostat.
Fig no.3.16
32
6. Oiling and fitment of crank pulley and torque.
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Fig no.3.19
4. Seal fitment.
5. Spring fitment and setting.
6. Cotter pins and locking.
7. Valve leakage check with soap solution.
34
Fig no.3.20
35
Fig no.3.21 Fig no.3.22
36
5. Cooling fan tightening torque 2.5 kgm.
6. Belt fitment and torque.
7. Assy of vaccum pipe with inlet manifold.
Fig no.3.23
37
Fig no.3.24
Fig no.3.25
Fig no.3.26
39
3.2.16 Station E-14
Fig no.3.27
40
3.2.17 Station E-15
Fig no.3.28
41
3.2.18 Station E-16
Fig no.3.29
42
4.0 HOT BED ENGINE TESTING LAB:
In this labn 100% engines which are assembled in the engine assembly shop
are tested in the hot bed testing lab.Engine is tested for 10-15 minutes.In this
lab engine is tested for various parameters which are as follows:
4. Checking for oil pressure at idle RPM which should be 1.8 bar at 650-720
RPM and at 80 degree.
Fig no.3.30
43
4.1 PERFORMANCE ENGINE TESTING LAB:
In this lab 10% engines which are tested in the hot bed testing lab.In the
performance testing lab engine is tested for 4 hours.First of all lapping is done
for 1.35 hours.In this lab engine is tested for various parameters which are as
follows:
1. Power
2. Torque
4. Smoke
6. Anyn leakage
In performance testing lab engines are tested at once time i.e 4 engines are
tested in one shift.The performance testing is done on the two beds namely.
1. Shanck Bed
2. SAJ Bed
These are made by the Indian manufactures.These are fully electronic.In this
various sensors are assembled.
44
Fig no.4.0 Fig no.4.1
45
TABLE OF CONTENT
S.NO CONTENT PAGE
N0.
1. ACKNOWLEDGMENT 5
1.0 OBJECTIVES OF TRAINING 6
1.2 TPM MANAGEMENT 8
1.3 COMPANY PROFILE 9
1.4 SHARE HOLDING PATTERN 11
1.2.1 VEHICLES PRODUCED AT SML 13
ISUZU LIMITED
2.0 ASSEMBLY LINE 15
2.1 ENGINES MADE AT SML ISUZU 16
LIMITED
2.2 TYPES OF ENGINE 16
2.3 ENGINE MODELS 17
2.4 ENGINE SPECIFICATIONS 18
3.0 ENGINE ASSEMBLY LINE 19
3.1 WASHING PROCESS 19
3.2 ENGINE ASSY PROCESS STATION 20
4.0 HOT BED ENGINE TESTING LAB 43
4.1 PERFORMANCE ENGINE TESTING 44
LAB
2
LIST OF TABLES
3
LIST OF FIGURES
S.NO CONTENT PAGE
NO.
1.2. VEHICLES PRODUCED AT SML 13
ISUZU LIMITED
1.3 VEHICLES PRODUCED AT SML 14
ISUZU LIMITED
3.1 WASHING PROCESS 19
3.2.0 STATION E-1 20
3.2.1 STATION E-2 23
3.2.2 STATION E-2.1 24
3.2.3 STATION E-3 25
3.2.4 STATION E-4 27
3.2.5 STATION E-5 28
3.2.6 STATION E-6 30
3.2.7 STATION E-7 30
3.2.8 STATION E-7.1 31
3.2.9 STATION E-8 32
3.2.10 STATION E-9 33
3.2.11 STATION E-9.1 34
3.2.12 STATION E-10 35
3.2.13 STATION E-11 36
3.2.14 STATION E-12 38
3.2.15 STATION E-13 39
3.2.16 STATION E-14 40
3.2.17 STATION E-15 41
3.2.18 STATION E-16 42
4.0 HOT BED ENGINE TESTING 43
4.1 PERFORMANCE ENGINE TESTING 44