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CHAPTER I

INTRODUCTION

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REPORT ON ORGANISATION STUDY AT

TAFE GEAR DIVISION

CHAPTER I - INTRODUCTION

ABOUT THE COMPANY

Tractors and Farm Equipment Limited (TAFE) is an Indian manufacturer

of tractors and other farm equipment with its corporate

headquarters in Chennai. The company was established in 1960and has reported annual revenue of $ 1 billion and a sales volume

of over 100,000 tractors annually. Tractors and Farm Equipment

Limited (TAFE) is a member of the $1.6 billion Amalgamations

Group. TAFE has collaboration with Massey Ferguson (now owned

by AGCO Corporation, USA). TAFE is a renowned manufacturer of

tractors and a variety of farm equipment under the TAFE Massey

Ferguson and Eicher brands. TAFE acquired Eicher tractors in

2005 through a special purpose vehicle, TAFE Motors and Tractors

Limited. It is a unit company of the Amalgamations Group, which

is a wholly owned subsidiary. It has major presence in a number

of Indian states like Rajasthan, Gujarat, Andhra Pradesh,

Karnataka, Madhya pradesh and Uttar pradesh. It is one of India's

largest Light Engineering Groups with diverse interests in Diesel

Engines , Automobile components , Tractors and related farm

machinery, lubricants, panel instruments, hydraulic pumps,

Engineering Tools, Storage Batteries, Paints , Engineering

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Plastics , Automobile franchises and Printing apart from interests

in Agribusiness , book selling and publishing. The group's

leadership technology, built on foreign know how has been

nurtured through indigenous efforts.

TAFE was established in 1961 in collaboration with

Massey Ferguson, UK to manufacture and market a range of

tractors and related farm equipment in India. One of the largest

tractor manufactures of tractors in India, TAFE's vision is to be the

first choice of customers in India and to also move towards a

growing presence in the international markets.

With a network of more than 500 dealers, branches,

service outlets as well as its own sales offices and depots

covering the entire width and breadth of India, TAFE is committed

to providing complete farming solutions to its customers and

empowering them to work towards increased farm productivity,

prosperity and profits.

TAFE started its production of the popular tractor

model, Massey Ferguson 1035 in 1961. Now they manufacture

tractors under three brand names, TAFE, Eicher and Massey

Ferguson. TAFE has a five decade old collaboration with MasseyFerguson (now a part of AGCO Corporation, USA), which is one of

the leading manufacturer of tractors in the world. The company is

currently investing in a Greenfield project at Manisa Industrial

Estate in Turkey with a capacity to manufacture about 15000

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tractors.TAFE has been a pioneer in the mechanization of theIndian farms. Beginning with the popularizing of tractors in

agriculture in the early 60s, TAFE has many firsts to its credit. TAFE

was the first company to market a total package of Tractors and

farm equipment to not only provides farm power but also

interfaces to transform the farm power to increased farm

productivity. TAFE was also the first to introduce the Direct Injection

technology in India, thereby intiating considerable fuel saving and

the resulting economies in tractor operations cost to its

customers. TAFE was also the first Indian manufacturer to launch a75 HP tractor to cater to the emerging needs of very large farms

and agri-businesses. With four manufacturing locations at

Chennai(Sembiam), Madurai (Kallidaipatti),

Bangalore(Doddaballapur), and Mandidheep (Bhopal), TAFE has a

large manufacturing base. Its Madurai plant, the latest and

possibly the largest such plant in the country is specially tailored

to take on short run production batches to the exacting standards

demanded by advanced countries. TAFE is also involved in

making diesel engines, gears, panel instruments, engineering

plastics, hydraulic pumps, plantations and passenger car

distribution through other divisions and wholly owned

subsidiaries. TAFE Motors and Tractors Limited has, apart from

the tractor manufacturing plant at Mandideep mentioned above, a

Diesel Engine plant at Alwar, Rajasthan producing a range of air

cooled and water cooled diesel engines upto 80 HP with plans are

on to increase the product range up to 125 KVA. The

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Transmissions Division located at Parwanoo in Himachal Pradesh

produces a range of transmission components both for captive

use as well as for sale to OE manufacture and marketing of farm

implements, trailers and accessories, distribution of passenger

cars, manufacture of hydraulic pumps and panel instruments to

discerning customers both in India and overseas. All its plants and

sales offices are linked by VSAT links providing fast and efficient

communications and data linkage another first of its kind in India.

Apart from its core business of manufacturing and

marketing tractors, TAFE is also involved in the following related

and unrelated areas.

As a natural sequel to producing tractors, TAFE has

developed a range of matching trailers, implements and

accessories. These are marketed through TAFE's dealer network by

a totally owned subsidiary, TAFE Access Limited (TAL). As a natural corollary,

TAFE, through TAL is also involved in the marketing and distribution

of lubricants and greases for tractors through its dealer network.

TAFE is also involved in the packaged power industry

through its Power Source Division. At its fully automated modern

plant at Maraimalai Nagar, near Chennai, it produces a range of

automobile batteries, under the AMCO brand name, which find wide

OE application in the new generation two and four wheelers

manufactured in India as well as in the replacement market. The

batteries are marketed through another unit of the

Amalgamations group viz., AMCO Batteries Limited. As well as for

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sale directly through a dedicated distribution channel under the

brand name of Speed.

The tractor's hydraulics is an important part in the

transformation of power into farm productivity and the hydraulic

pump is a critical component of any tractor. The transmission of

power developed in the tractor's engine to the ground is also a

major part of the total design of the tractor. TAFE therefore has in-

house facilities for the manufacture of hydraulic pumps and also

gears for tractors. A related facility for the manufacture of panel

instruments, not only for captive use but also for sale to the

growing automobile industry in India is an integral part of the

company.

TAFE has also diversified into Engineering plastics and

production of tools and dies for this industry. Its Doddaballpur

plant has clamp capacities ranging upto 1300 tons and is a major

supplier of the needs for precision plastic components of the

white goods, IT, automobile industries. Its commercial tool room

produces tools and dies to international specifications demanded

by discerning buyers.

TAFE's vision of being the customer's first choice on

offering to the customers quality products engineered to

perfection using technology that is contemporary and relevant to

the market it serves. This approach to quality as being inherent to

its existence has obtained for TAFE certification under ISO 9002,

the quality movement permeates throughout the organization

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and is apparent from the various laurels won by quality circles

from the company in national and international arenas.

TAFE's vision is not just wishful thinking but based on

recognized engineering, marketing and financial strengths, built

up over the past four decades. In all that it does, TAFE pursues

excellence. That this is not a cliche is reflected in the words of

TAFE'schairman, "To us in TAFE, excellence is not something that we

engineer, input or inspect into our products. It is an innate desire

that inspires our hearts at work and at home and ripples out into

the world around us.

TAFE Gears Division (TGD) was established in 1996

which is located in Pudupakkam 5 kms from Kelambakkam

district. Gears division is a supplier machine shop which

manufactures Crown wheel and Pinion used in transmission

system. Parts manufactured in this division are supplied to the

assembling units in Kallidaipatti (Madurai), Doddabalbur

(Bangalore) and for spare parts. TGD has total area of 2.83

hectares and the plant is built in 1500 sqmts. TGD functions for 3

shifts in 24 hours. Sunday is holiday.

COMPANY LOGO:

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PRODUCT PROFILE

Crown Wheel & Pinion (CWP)

Product Portfolio :

6T x 37T CWP

7T x 39T CWP

11T x 38T CWP

The above mentioned are the 3 versions of Crown

Wheel & Pinion (CWP) manufactured in this TAFE Gear

Division

INTRODUCTION TO CROWN WHEEL AND PINION

The final drive components, which reduce the rotational

speed of the gearbox output shaft to that supplied to the wheels

sometimes abbreviated as CWP. The reduction ratio (commonly

called the final drive ratio) lies in most common automobile

applications between 3:1 and 5:1. In all front engines, rear-wheel

drive cars with the engine mounted longitudinally, the crown

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wheel and the pinion rotates the drive through 90 deg i.e. from

fore aft to transverse.

A crown wheel is a wheel with cogs or teeth set at right

angles to its plane and the pinion is a small cogwheel that meshes

with the crown wheel. The pinion thread is specially made on the

thread gringer to ensure proper fitting. Tooth contact of a crown

pinion is insected on a Gleason machine at regular intervals of

time for uniform and adequate case depth. They are checked

thoroughly for high spots because this ensures premature failureand noise-free operation.

FEATURES

Crown wheel and pinion usually have the following features:

Excellent heat distortion control

High strength

Wear resistance property and

Noiseless and vibration free operation.

In a machine, when any torque is applied to the drive unit, the

tendency is for the crown wheel and pinion to be forced into or

out of mesh by the sliding contact.

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APPLICATION

Crown wheel and pinion are used widely in automotive

industries. They are one of the most stress prone parts of a

vehicle. They are used in automobiles to maintain forward motion.

To maintain forward motion both output drive shaft sides covers

are removed and the pinion and crown wheel are swapped

completely with differential.

ORGANISATION CHART

Tractors and Farm Equipment Limited

(TAFE)

Senior management Team

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MANAGING

DIRECTOR

&

CHAIRMAN

ED TAFE Motors and

Tractors Ltd.

ED - TAFE Power

Source DivisionED - TAFE Hydraulic

Pump Division

ED TAFE Gears

Division

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ED - TAFE Access Ltd -

Instrument Division

ED - TAL Precision

Parts

ED - TAFE Reach

Ltd.

ED - TAFE Engineering

Plastics Division

ED - AMCO Batteries

Ltd.

Chart of TAFE - Gear division (TGD)

ED TAFE Gear

Division (TGD)

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Directors

President

Vice President


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Sr. GeneralManager

GeneralManager

Divisional

Manager


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Manager Manager Manager ManagerManager

Asst. Manager Asst. Manager Asst. Manager Asst.

Manager Asst. Manager

Supervisors Supervisors Supervisors SupervisorsSupervisors

Labours Assistants LaboursLabours

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Productio HR StoresFinance Maintena


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CHAPTER II

PRODUCTION DEPARTMENT

PRODUCTION DEPARTMENT

PLANT LOCATION

REGISTERED OFFICE - HEAD OFFICE &

MANAGING

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861,Anna Salai

Chennai-600 002.

GEAR DIVISION

51/1, Vandalur-Kelambakkam Road,

Pudupakkam, Kelambakkam,

Kancheepuram district, 603 103.

Phone: 0411474647, 74847

TAFE GEAR DIVISION PLANT

The Gears Division of TAFE manufactures BEVEL gears

for tractors. The factory which is located at Pudupakkam, 40 kms

from Chennai is equipped with Gleasan machinery and highly

advanced in-house heat treatment facility to ensure that the gear

systems that roll out from here meet international standards.

PRODUCTION PROCESS CHART

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Raw material semi

finished Pinion

Raw material semi

finished CrownWheel

Hobbing Straight

stains

12 - Hole Drilling

Teeth cutting

Roughing Machine

Teeth cutting

Roughing Machine

Finishing Operation

Convex & Concave

cutting

Finishing Operation

Convex & Concave

cutting

Heat Treatment

plant CGCF (or) SQF

Heat Treatment

plant CGCF (or) SQF

Straightening,

Diameter & PilotGrinding

Inner Diameter

Grinding by BoringMachine


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Testing & Pairing

Operations

Lapping Operations

Threading Operation

for Pinion

Quality, Diameter &

Dimension Inspection

Storing

Packing


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PRODUCTION PROCESS

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Inspection

Dispatch


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Raw materials:

Raw Materials for Crown wheel is called as blanks and

for Pinion is Steel pillars. These raw materials are semi finished

raw material. These semi finished raw material are produced by

vendors by forging the iron blocks for Crown Wheel and forging

iron pillars. These raw materials are purchased by TGD. These

purchased raw materials are stored in Stores and distributed to

machine shop.

Machine Shop Soft cell:

These raw materials are delivered to Pinion cell and

Crown Wheel cell.

Note: - In the following stages the COOLANT OIL &

SOLUTIONS are used to reduce the friction heat of the Crown

Wheel & Pinion while drilling, cutting & grinding.

STAGES PINION CELL STAGESCROWN WHEEL

CELL

HOBBING The raw materials

will be processed

in Hob Cutter to

create straight

strains in the

Pinion. These

cuttings of straight

DRILLING The raw materials

will be processed

for drilling 12 holes

in the Crown

Wheel. This drilling

process is made by

Counter Boring

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strains are done

by Hob Cutter

Machine and

moved it to soft

grinding stage.

Machine and

moved to Teeth

cutting process.


CELL

SOFT

GRINDING

In this raw

material is grinded

to bring it to fixed

outer diameter.

There is chance of

irregular diameter

shape in raw

material. To make

a regular shape,

the raw material is

grinded with fixed

outer diameter

and passed to

rough cutting

stage.

ROUGHING

MACHINE

In this raw material

is processed for

cutting teeth. In

this process the

teeth for the Crown

Wheel is formed by

Rough Teeth

Cutting. This

process is done by

Rough Teeth

Cutting Machine

and passed to the

next stage for

finishing operation

ROUGHING

MACHINE

In this raw

material is

processed for

cutting teeth. In

this process the

FINISHING

OPERTION


is processed for

Convex & Concave

cutting of teeth to

reduce the

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teeth for the

Pinion is formed

by Rough Teeth

Cutting. This

process is done by

Roughing Machine

and passed to the

next stage of

finishing operation

for Convex &Concave teeth

cutting.

sharpness of the

teeth and for

finishing touch for

the teeth. In this

the Convex &

Concave teeth

cutting is made by

a single machine

Simultaneously and

passed it to HeatTreatment Cell.


CELL

FINSHING

OPERATION

In this raw

material is

processed for

Convex & Concave

cutting of teeth to

reduce the

sharpness of the

teeth and for

finishing touch forthe teeth. In this

the Convex &

Concave teeth

cutting is made by

--- ---

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2 different

machines

(separate machine

Convex & Concave

Teeth Cutting) and

passed it to Heat

Treatment Cell.

Heat Treatment Cell:

The Raw Materials of Crown Wheel and Pinion

processed in Machine Shop is brought to Heat Treatment Cell to

mold those Raw Materials for long life, increase the strength, to

withstand heavy load and avoid worning out. This Heat Treatment

Cell consists of 2 types of furnaces.

Continues Gas Carburizing Furnace (CGCF)

Sealed Quenching Furnace (SQF)

The Heat Treatment Cell will use any One or if needed use both

the above furnace.


This is big furnace for continuous operations includes

degreasing, carburizing operations, hardening operations,

heating, cooling, press quench operations, etc., This is a

continuous operation and takes 22 hours to complete its

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process. The Heat Treatment Cell mostly uses this furnace

for operation because of easy and less time consuming.


This is a collection of small furnaces and its not a

continuous process. Its operation are degreasing, carburizing

operation, hardening operation, washing, tempering, etc,. it

takes more than 23 hours to complete the process. It is time

consuming and more labour work compared to CGCF.

The process of both furnaces will be explained in detail in

machinery details of the furnaces. After processing the raw

materials in heat treatment it is passed to Shot Blasting.

Shot Blasting:

After tempering, the Pinion and Crown wheel are

subjected to Shot Blasting to give glossy appearance and to check

and impart strength of the Crown Wheel and Pinion. Shots are a

kind of small steel balls, having hardness of 30 to 35 HRC. This

process is for 10 to 15 minutes per batch. 1 batch contains 45 nos

of Crown Wheel or 90 nos of Pinion. After this process again the

processed raw materials are passed to Machine Shop Hard Cellfor further Finishing process.

Machine Shop Hard cell:

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STAGES PINION STAGES CROWN WHEEL

GRINDING

In this raw

material is

grinded by 3

grinding

machines to

bring it to

required

diameter. Those

3 grindingmachines are

used to process

the pinion for

grinding minor

diameter, major

diameter and

pilot grinding

and passed to

testing and

pairing process.

BORE

GRINDING


is processed for

bore grinding to

bring required &

fixed inner

diameter of the

Crown Wheel. Due

to Heat treatment

there is a chance ofchange in the

diameter. So to fix

the diameter this

bore grinding is

used and it is

passed to testing

and pairing

process.

TESTING &

PAIRING

In this the

processed Pinion

is tested toensure its

dense, required

dimensions and

finally Pinion will

TESTING

&

PAIRING

In this the

processed Crown

Wheel is tested toensure its dense,

required

dimensions and

finally Crown Wheel

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be Paired with

Crown Wheel

run together for

testing to match

each other and

passed it to

lapping process.

will be Paired with

Pinion run together

for testing to match

each other and

passed it to lapping

process.

STAGES PINION CROWN WHEEL

LAPPING

The Pinion is processed

in Lapping Machine for

the purpose of

polishing, clearing

carbon & grinding

particles, to improve

surface finish using

Coolant Oil and Lapping

powder by rubbing

action and final washing

in this process and

passed to threading

process.

The Crown Wheel is

processed in Lapping

Machine for the purpose

of polishing, clearing

carbon & grinding

particles, to improve

surface finish using

Coolant Oil and Lapping

powder by rubbing

action and final washing

in this process. This is

the last process for

Crown Wheel and it will

be moved to Quality

Inspection of Finishedgoods.

THREADING The Pinion is processed

in threading machine for

threading operation for

---

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required dimensions on

the middle of the Pinion.

This threading operation

will be a fixed for

required diameter. This

is the last process for

Pinion and it will be

moved to Quality

Inspection of Finished

goods.

Final Quality Inspection Finished Goods:

The finished goods Crown Wheel and Pinion will be

passed on to Final Quality Inspection. Here final inspection on the

quality of the Crown Wheel and Pinion will be inspected by

checking all dimensions and diameters of the Crown Wheel and

Pinion should be as per the requirements. The critical parameters

of the Crown Wheel and Pinion should be 100%. Then the

approved and qualified Crown Wheel and Pinion will be moved to

Stores for other process.

MACHINERY DETAILS

The general layout of the TAFE Gear division factory

consists of two main divisions viz:

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MACHINE SHOP

HEAT TREATMENT CELL

MACHINE SHOP:

The operation in machine shop includes both soft cell

and hard cell.

SOFT CELL

PINION CELL:

1) HOBBING MACHINE:

MACHINE MAKE : COOPER 010

OPERATION PERFORMED : SPLINE CUTTING

MACHINE PROCESS TIME : 332 sec

HANDLING TIME : 10 sec

TOTAL TIME : 342 sec

2) SOFT GRINDING MACHINE:

MACHINE MAKE : PARISHUDH

OPERATION PERFORMED : MAJOR DIAMETER

GRINDING


HANDLING TIME : 15 secTOTAL TIME : 125 sec

3) ROUGHING MACHINE:

MACHINE MAKE : GLEASON

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OPERATION PERFORMED : ROUGH CUTTING




FINISHING OPERATIONS:

4) CONCAVE MACHINING MACHINE:


OPERATION PERFORMED : CONCAVE CUTTING

METHOD USED : COMPARATIVEMETHOD




5) CONVEX MACHINING MACHINE:


OPERATION PERFORMED : CONVEX CUTTING

METHOD USED : COMPARATIVE

METHOD




CROWN WHELL CELL:

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1. VMC CNC MACHINE:

MACHINE MAKE : AMS

OPERATION PERFORMED : COUNTER BORING




2. ROUGHING MACHINE:

MACHINE MAKE : GLEASON 608

OPERATION PERFORMED : ROUGH CUTTINGMACHINE PROCESS TIME : 337 sec



3. FINISHING MACHINE:

MACHINE MAKE : GLEASON 610

OPERATION PERFORMED : FINE CUTTING




** The job from soft cell undergoes heattreatment before

it enters hard cell. **

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HARD CELL

1. STRAIGHTENING MACHINE:

MACHINE MAKE : BEMCO

OPERATION PERFORMED : STRAIGHTENING

TIME TAKEN : 61 sec

2. GRINDING MACHINE - I:


OPERATION PERFORMED : MAJOR DIAMETER

GRINDING

TIME TAKEN : 298 sec

3. GRINDING MACHINE - II:


OPERATION PERFORMED : MINOR DIAMETER

GRINDING


4. GRINDING MACHINE - III:

MACHINE MAKE : KAIZON

OPERATION PERFORMED : PILOT GRINDING


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5. BORING MACHINE :

MACHINE MAKE : GCI 300 CNC

OPERATION PERFORMED : INTERNAL DIA

GRINDING

(CROWN)


6. TESTING AND PAIRING MACHINE:


OPERATION PERFORMED : PAIRING OF PINION

AND

CROWN WHEEL


7. LAPPING MACHINE:


OPERATION PERFORMED : LAPPING


8. THREAD CUTTING MACHINE:

MACHINE MAKE : SIEMENS

OPERATION PERFORMED : THREAD CUTTING

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HEAT TREATMENT CELL:

In heat treatment cell the mechanical properties of the

job is improved by the application of heat. This is done in two

types of furnaces viz;


(Or)


Shot Blasting

CONTINUES GAS CARBURISING FURNACE :

a) Low carbon alloy steel is used in Heat treatment.

b) Sulphur based cutting oil is used in machine shop.

c) Endothermic gas is used as a carrier gas in the Heat

treatment process.

PHASES:

1)Degreasing furnace is operated at 250 Deg C (1

tray)

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Degreasing is used to restrict sulphur oil by

being combining with CO & CO2.

Duration for waiting degreasing is

approximately 8 mins.

Duration for Degreasing is approximately 40

mins.

Operating pushing cycle time is approximately

48 mins for every tray.

2)Main furnace has 18 separate trays at various

zones.

ZONENO.OF

TRAYS

TEMPERATU

RE Deg C

CARBON

POTENTIA

LPre heat

zone 2 930 0.92 %

Carburizi

ng zone

1

4 930 0.92 %

Carburizi

ng zone

2

4 930 0.92 %

Diffusion

zone 14 930 0.90 %

Diffusin

zone 24 930 0.90 %

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The main furnace and reheating zone are operated

with a carrier gas (Endothermic gas) and LPG for

enrichment of C potential.

3)Air cooling chamber - 1 tray (no heating)

Duration for cooling is approximately 7 mins to

refine the core grains.

4)Reheating - 4 trays. Reheating is operated at 820 to 800 Deg C & Cp-

0.70%

5)Quenching

Quenching makes the steel to reach from

(Austenite)FCC to BCT structure (Martensite)

BCT - Body Centered Tetrahedron.

Quenching process is carried out with Quenching

oil

(Savsol 001). Quenching process is carried out with Press

Quench machine to minimize Gear teeth distortion

and accurate flatness.

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After quenching process, the components are sent

for washing through alkali bath and water bath.

At Alkali washing bath, oil from the work piece will

be removed.

At Water washing both, alkali from the work piece

will be removed.

Finally it is sent through Tempering furnace to

relive the stress.

6)Tempering

It can accommodate three separate trays (150

celsius for 90 mins).

7)Endothermic gas generator

LPG and Air are mixed in the ratio of 1:9.5 to 10.5

and pass through a stainless steel retort at 1070Deg C. The gas will pass through a Nickel coated

Ceramic catalyst in a Stainless steel retort to

produce Endothermic gas. The carrier gas

(Endothermic gas) will have approximately 23% of

CO and 0.3% of CO2.

SEALED QUENCHING FURNACE :

PHASES:

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1)Degreasing furnace is operated at 150 Deg C. It is

operated to remove Sulphur based cutting oil, which is

used in machine shop.

Duration for Degreasing is approximately 120

mins.

2)Main furnace is a single chamber and the process is

divided into 4 segments.

SEGMEN

T

TEMPERATU

RE Deg C

CARBONPOTENTIA

L

TIME

TAKEN

FUEL

USED

Segment

1930 1.20% 5 min

LPG +

CO2Segment

2930 1.20% 450 min

LPG +

CO2Segment

3930 1.10% 360 min LPG

Segment

4820 0.92% 20 min LPG

After the process, the load is pushed from the

furnace into the elevator (above quenching tank)

and the load is quenched in oil below the elevator.

3)Hardening

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Quenching process is carried out with Quenching

oil (savsol 001).

For Pinion, the load is quenched along with the

fixture.

4)Washing:

After quenching process, the components (pinion)

are sent for washing through water bath along

with the fixture.

At Water washing bath, oil and other

contaminations from the Pinions will be removed

along with the fixture.

5)Tempering

Pinions are sent through tempering furnace along

with the fixture to relive the stress at (150 Deg C

for 120 min).

SHOT BLASTING :

After tempering, the Pinion and Crown wheel are

subjected to Shot Blasting to give glossy

appearance and to impart strength. Shots are a

kind of small steel balls, having hardness of 30 to

35 HRC.

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CHAPTER III

STORES DEPARTMENT

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STORES DEPARTMENT

PROCESS OF PURCHASING & STORING

Purchasing of Raw Materials, spares, equipments,

accessories, etc., Is a process of Stores department. The following

flow chart will explain the process of purchasing.

Flow Chart of Purchasing, Storing & Issuing

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Requirements

Purchase Requisition

QuotationPurchase Order (P.O)


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Approval

Material Receiving

Checking &

Inspection

Material Tagging


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Racking

Storing

Coding the Material

through SAP

Stock (Material)

Issue

Entering (Posting)

Issues in SAP


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ACTIVITIES

Raw Materials:

Raw Materials for Production purpose will be

stored by Store Department in Stores. The Stores will be

having 3 months Stock of Raw Materials for Reserves. The

Stores will place order on Raw Materials once in 3 months as

a cycle.

Materials Rejection:

Some Raw Materials may be rejected after

Checking & Inspection due to damage or low quality. Those

rejected materials will be returned to vendors who supplied

and payment will not be paid for the rejected materials.

Goods Receipt Note (GRN):

GRN is prepared by Stores department for the

materials received after Checking & Inspection. This GRN will

be forwarded to Finance Department for payment process.

Material Tagging:

The received material will tagged according to theusage and will be placed according to the respective bin by

Racking the material tagged in the racks of the stores. This

tagging helps to issue the materials easily and can find the

shortages easily.

System Analysis and Program Development (SAP):

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The Stores department will enter the coding of the

materials received in SAP. It also updates the issue of

materials in SAP. Stores department will also maintain the

entries of delivered finished goods in SAP. The delivered

finished goods will be given a code by SAP. SAP is softwareinterlinked with all departments.

Storing:

The materials received by the Stores department

from Vendors will be stored in Stores and issued for

production at the time of need. The Finished Goods will also

be packed stored in Stores. The Stores department also

stores materials like spares, accessories, new machinery,etc,.

Packing & Delivering:

After Checking & Inspection of Crown Wheel and

Pinion (CWP), the Stores department will pack the CWP in a

pair as matched by production Department. If CWP is for

dispatch for Tractor manufacturing units, 2 pairs of CWP is

packed in a plastic box and if CWP is dispatch for Spare

Parts, 1 pair of CWP is packed in a Card board. These packed

boxes will be delivered to necessary place by chartered

carrier Tractor manufacturing units or Spare Parts.

Delivery Note:

Delivery Note will be prepared by the Stores

department as per the delivery of Crown Wheel & Pinion

(CWP) to the Tractor manufacturing units or to Spare Parts.

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The prepared Delivery Note will be forwarded to the Finance

department for accounting.

Chart of Packing & delivery of CWP

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Receiving of CWP

(Finished Goods) from

Production

Packing & Storing

Delivering to Tractor

manufacturing units

or Spare Parts


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CHAPTER IV

MAINTANENCE DEPARTMENT

MAINTANENCE DEPARTMENT

Maintenance department is an essential department in

this unit which follows the 4 major activities. They are,

Preventive Maintenance

Actual Maintenance

Planned Maintenance

Special Projects & Developments

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ACTIVITIES

Preventive Maintenance:

Preventive maintenance can be described as

maintenance of equipment or systems before fault occurs. It

is also called as Planned maintenance. This Preventive

maintenance activity helps the manufacturing unit to

function without any disturbances or problems. By predicting

the future problems for production and taking necessary

steps to overcome and being ready to act on the problemimmediately and solve the problem. For example: - Taking

necessary steps to overcome the Electricity problems during

summer season.

Actual Maintenance:

Actual Maintenance is another major activity of theMaintenance department. In this the Maintenance

department will be always ready any time to solve the

unexpected problems while running of machines while

production. Solving of the unexpected problems on the day

to day process of production is called Actual Maintenance.

For example: - Solving the failures of machinery while

production.

Planned Maintenance:

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Planned Maintenance is the major activity of the

Maintenance department. The Maintenance department will

prepare plan and follow the plan to maintain and develop the

production process. Planned Maintenance is a regular

activity followed by the Maintenance department. For

example:- Regular service for machineries, Changing

machinery oil periodically, etc,.

Special Projects & Developments:

Special Projects & Developments is the major activity ofMaintenance department to support the production process

and develop the manufacturing unit. Special Projects &

Developments are the activities like installing new machinery,

upgrading the existing machinery, making add-ons for the

machinery to make the production process easy and fast.

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CHAPTER - V

FINANCE DEPARTMENT

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FINANCE DEPARTMENT

ACTIVITIES

Powers:

Finance department of TAFE Gear Division (TGD) is under

control of Finance department of TAFE Head Office in Anna

Salai, Chennai. Finance department of TGD will be reporting to

TAFE Head Office. Finance department of TGD is restricted

limited powers.

Impressed amount:

TAFE Gear Division (TGD) is allocated with an Impressed

amount (Reserves) minimum of Rs. 30,000 for operations of

Finance department for production purpose. Finance

department of TGD will maintain this Impressed amount. If the

Impressed amount decreases to Rs. 10,000, the Manager of

Finance department will make requisition to Head Office for

shortage of Impressed amount, immediately Head Office will

issue a cheque for the requested amount to Finance

department of TGD.

Funding Operations:

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Finance department of TGD is operated with Current A/C

in Central Bank of India in Kelambakkam. For withdrawal of

Impressed amount or other Sanctioned amount from Head

Office for Production purposes and deposits of cash by Finance

department of TGD by the Scrap sales is transacted through

this bank.

Petty Cash Accounting:

Finance department of TGD follows the Petty Cash

Accounting. It follows Petty Cash Accounting because it

transacts with only small value of money. Large transactions

for TGD production process are made by TAFE Head Office.

Petty Cash Accounting is recorded and filed through System

Analysis and Program Development (SAP) by verifying and

approving Petty Cash Receipt. This process is called as RealTime Accounting. Real Time Accounting is financial reporting

provides financial information on a daily basis.

Credit:

Finance department of TGD avails credit from the

government for Excise duty for purchasing Raw Materials and

will be adjusted with the Dispatch of Finished Goods to the

TAFE Manufacturing unit and to Spare Parts.

Salary & Wages:

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Salary for the Management Staff is paid directly by TAFE

Head Office by crediting the salary to the individuals bank A/C.

The Wages for the Contract Labours are paid by the Finance

department of TGD which will be sanctioned and given by TAFE

Head Office.

Tax:

Finance department of TGD will be paying certain taxes

like TDS (Tax Deducted at Source) 2% of Contract Labour

Wages, Scrap Sales tax 1%. These taxes are unavoidable andFinance department of TGD is liable to pay the taxes.

Focus Cost:

Focus Cost means Budget. Focus Cost is prepared by the

Finance department for future Production process. Focus Costwill be estimated by Divisional Manager of TGD unit and

Manager of Finance department of TGD. This Focus Cost will be

sent for approval to TAFE Head Office by Finance department

of TGD. TAFE Head Office will discuss with Divisional Manager

of TGD make some adjustments in Focus Cost if necessary and

approve for sanction.

CHART PROCESS OF PURCHASE & PAYMENTS

54 | P a g eRequisition &

QuotationApproval


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Delivery of purchase

Requisition

Purchase Order (P.O)

Goods Receipt Note(GRN) from Stores

Invoice Verification


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CHAPTER VI

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Payment


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HUMAN RESOURCE DEPARTMENT

HUMAN RESOURCE DEPARTMENT (HRD)

ACTIVITIES

Recruitment and Selection:

The candidate will be sent from TAFE Head Office to

Production unit for Selection & Recruitment process. The

candidate will be first screened by Personnel officer and Head

of the Department, and then screened by Divisional Manager.

After Divisional Managers screening, the candidate will be

interviewed by Senior General Manager in TAFE Head Office

and a final interview by Divisional Manager of HRD in TAFE

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Head Office. If the candidate passes the above process, the

candidate will selected and employment offer will be given.

CHART PROCESS OF RECRUITMENT & SELECTION

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Candidate

Screening byPersonnel officer &

Head of the

Department in TGD

Screening by

Divisional Manager -

TGD

Interview by Sen.Gen. Manager of TAFE

Head Office

Final Interview by

Divisional Manager of

HRD TAFE Head

Office


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Wages & Salary Administration:

Wage Administration for Contract Labour for

Production Operations will be under the control of

Human Resource Department of TGD.

Salary Administration for Management staffs of

TGD will be under the control of Centralized Payroll

Department of TAFE Head Office.

Performance Appraisal:

Performance Appraisal is the major activity of the Human

Resource Department. The following is Performance Appraisal

Process followed by HRD of TGD.

Performance Appraisal is the activity of HRD of TGD for

every Six months.

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Candidate is

Selected & offered

Employment


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Performance Appraisal is made by rating every

employee of TAFE Gear Division (TGD)

Performance Appraisal is processed by Performance

Appraisal Team which consists of Personnel Officer,

Superior of Appraisee & Divisional Manager TGD.

Attendance of employee is also taken for consideration

for Performance Appraisal.

Based on the Performance Appraisal employees &

labours, Salaries and wages will be increased andpromotion is given if necessary.

Employee Welfare:

Many welfare activities are undertaken and followed by

Human Resource department of TGD like,

Canteen facility is availed for Management staffs &

Contract Labour, where free healthy lunch is

provided for them.

Uniform & Shoes are provided to Management Staffs

at free of cost.

Safety equipments are provided to Contract Labours

for their safety.

Transportation facility is availed for Employees of

TGD.

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Medical facilities & Allowances are provided for the

employees of TGD.

Training & Development:

Training on new machinery or to new production

process is provided for existing employees

Training for new employees is provided.

Training calendar is scheduled by Human

Resource Department (HRD) of TAFE Head Office

and followed by HRD of TGD.

Divisional Manager of TGD will give suggestions in

framing the training calendar.

Induction & On the Job trainings are 2 types of

training provided for new employees of TGD.

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CHAPTER VII

CONCLUSION

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CONCLUSION

FINDINGS & INTERPRETATION:

TAFE Gear Division (TGD) is a sister concern of

Tractors Farms &Equipments (TAFE).TGD is under

control of TAFE.

TGD does not have separate department for

Marketing activities, because it supplies is

produced CWP to TAFE Tractor Manufacturing

units in Madurai (Kallidaipatti), Bangalore

(Doddaballapur) and to TAFE Spare Parts.

TAFE is operating separate divisions like TGD, TAL,

etc., to avoid the labour unions, strikes, etc,.

In TGD many innovative production process are

made as proto type, tested and implemented.

TGD is fully interlinked with System Analysis and

Program Development (SAP).

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Labours were employed through Contract Labour

Agencies for contract in production unit.

TGD concentrates more on Production Department

compared to other department.

TGD strictly follows 5- S principle.

SUGESSTIONS:

TGD can sell the CWP to third party also by setting

up Marketing Department to increase the revenue.

TGD can increase Production by extending the

Production Plant. TGD has all facilities to extend its

Production Plant.

Separate Packing Cell can be setup for the

purpose of Packing Finished Goods.

REFERENCES

http://www.tafe.com/

http://www.tafechannel.com/

http://www.frontpoint.com/tafe/green/htm/areaoffice.

htm

http://en.wikipedia.org/wiki/TAFE_Tractors

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http://www.tafe.com/http://www.tafechannel.com/http://www.frontpoint.com/tafe/green/htm/areaoffice.htmhttp://www.frontpoint.com/tafe/green/htm/areaoffice.htmhttp://www.tafe.com/http://www.tafechannel.com/http://www.frontpoint.com/tafe/green/htm/areaoffice.htmhttp://www.frontpoint.com/tafe/green/htm/areaoffice.htm


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