ORGANIZATION ATLAS HONDA LIMITED SHEIKHPURA

SUBMITED BY. ABDUL RAUF

REGISTRATION NO. 11013372-009

SESSION. 2011-2015

SUBMISSION DATE. 26-05-2015

1.1 Dedications

Our work is dedicated to our beloved parents, teachers, brothers, sisters and all of our well wishers.

1.2 ACKNOWLEDGEMENT

“To Him belongs the dimension of the Heavens and the earth, it is He who gives Life and death and He has power over all things.”

(Al-Quran)

With the deep sense of gratitude, bow my head before God for enabling us to complete this internship. ”Thanks” is too small a word to describe what we feel for our venerable parents and worthy teachers and for their valuable suggestions, through provoking guidance during our internship

We are also thankful to Mr. Waqar and Mr. Rana Shahzad who helped us a lot for our internship & provided his encouragement & support.

We are also thankful to my internship mentor Mr. Mahfooz Butt & Mr. Wasif Butt whose guidance helped us throughout the internship.

We are thankful to whole Millat staff because during our two week internship, we got a lot support & guidance from all of the MILLAT staff.

We are thankful and grateful to our friends who provide us required information which was necessary to complete this report.

1.3 EXECUTIVE SUMMARY:The management of the company was transferred to the employee’s group in 1992. After that, production and marketing activities were recognized to improve performance and profitability of company. Employee’s management accepted the challenge with new determination to lift the company to greater height of glory not only through efficient use of existing resources but also through product diversification and exploring new avenues of business expansion.

At present, the company has 7 different models of tractors ranging from 50 HP to 120 HP which meet all agro-climatic conditions, farms and buying capacities of various segments of farmers.

The company has spread its products throughout the length and breadth of the country. Today the population of MF tractors made by MTL exceeds 250,000 while the total number of tractors in the country is approximately 500,000. In other words, every second tractor in Pakistan is MF tractor.

Millat Tractors Limited today consists of a group of four companies and a market leader with its eyes set on becoming a global player in times to come, keeping in view the increasing demand of the group’s products within and outside the country.

The company’s pioneering efforts have developed vendor industry which now serves as a hub for the entire automobile and engineering sector of Pakistan. Sincere efforts of the company has produced substantial savings, self-reliance and controlled tractor prices over the year.

Agricultural mechanization has realized through introduction of modern implements and induction of skilled manpower trained the groomed by the efforts of the company. On the social front, the company has lent a helping hand to charitable, educational institutions and hospitals.

MILLAT HAS TRULY SERVED THE NATION IN ALL SPHERES.

This report is about the internship that we have undergone at MILLAT TRACTORS Limited, SKP from 1st June,2015 to 30 June, 2015. The main purpose of internship is to learn, by working in a practical scenario and to apply the knowledge acquired during studies, in a real world scenario to tackle the problems. The key learning & their activities from each department have been discussed in the report. The Production planning & control, vendor procurement and quality assurance were under study for the longer span. While the processes used in the shops are described only.

TABLE OF CONTENTS

Chapter No. 01

1.1 Introduction1.2 History

Chapter No. 022.1 Production Line up 2.2 Introduction to Internship Program

2.3 Overview of MTL Deptartments

Chapter No. 033.1 Machining Department3.2 Engine assembly plant3.3 Tractor assembly plant3.4 Quality Control

Chapter No. 044.1 IFS4.2 Suggestions4.3 Conclusion

2.1 Overview of the Organization

2.1 History:

Millat Tractors Limited was established in 1964 to introduce and market Massey Fergosun (MF) Tractors in Pakistan. An assembly plant was set up in 1967 to assemble tractors imported in semi knocked down (SKD) condition.In 1972, the company was nationalized under economic reforms order and renamed as “Millat Tractors Limited”.

In 1980, the government decided on indigenization of the tractor and entrusted this task to MTL. This was the turning point in the company’s history and it went about the task methodically and rapidly.

The company undertook this new role with enthusiasm and in the spirit of national development and proved its engineering capabilities by surpassing the deletion targets set by the government.

Pakistan Tractor Corporation transferred this role of indigenization in 1981 to Millat Tractors Limited. Just in one year's time, the company took a giant step towards self-reliance by setting up the first engine assembly plant in Pakistan.

In 1982, MTL took a giant step towards self-reliance by setting up the first engine assembly plant in Pakistan. This brought the manufacturing facilities in-house for which capabilities did not exist in the country and for parts which required high investment and precision.

Therefore, in 1984, sophisticated manufacturing facilities for the machining of intricate components were set up. These were previously not available in Pakistan. Currently, critical components like the engine block, sump, transmission case, axle housing, hydraulic lift cover, front axle support and Centre housing are all being machined most successfully in-house at Millat Tractors from local-sourced castings.

In 1992, the company was privatized and the employees joined hands and took over its management by winning an open bid.

The tractor Assembly plant started its production in 1992. The establishment of this modern plant not only increased production capacity to 16,000 tractors per year on a single shift basis, but also provided a quantum jump to the quality of the assembled tractors and pushed MTL into the ranks of the major tractor manufacturing companies of the world.

In 1993, MTL acquired the management control of Bolan Castings Limited in partnership with the employees of that company.

Mass production of Generating Sets was started in 1994, while a 3 ton forklift truck branded as Millat, based on TCM technology, was launched in the year 2002. Both of these products are made by using Perkins Engines and have been well accepted by the market.

In 2002, MTL established a wholly owned company named Millat Industrial Products (Pvt) Limited to manufacture quality automotive batteries. MTL believes in providing best value for money to its customers.

2.2 INTRODUCTION TO ORGANIZATION

MILLAT TRACTORS Ltd.

Millat Tractors Limited (MTL), an ISO 9002 certified company for its Assembly Plants and Material Testing and Gauge Control Laboratory, is Pakistan’s leading engineering concern in automobile sector.

It is manufacturing tractors under licensing agreement with Massey Ferguson, UK (owned by AGCO, USA), Diesel engines in technical collaboration with Perkins Engines UK, Diesel Generating Sets, utilizing alternators from Leroy Somer of France and Stanford New age of UK and the Forklift trucks under license from Heli Forklift Trucks China, and a range of Agricultural Implements.The company is also dedicated to customize its products as per customers’ requirements. Millat tractors is a perfect example of harmonious and successful business relations between a Pakistani company and its foreign partners, both from industrialized west and upcoming East China. These relations that span a period of well over quarter of a century and encompass a broad spectrum of investments and technology transfer agreements are a model for other companies venturing out to attract foreign investments.Millat tractors has played a vital role in transfer of technology and transformation of the fledlging local light engineering sector into a robust, vibrant, quality concious Auto Vending industry. There is a constant endeavor at all levels of the organization to better the company’s performance by offering upgraded range of its products and services. MTL’s cardinal principle has been to keep abreast with the latest technology.The company has been the regular recipient of the Corporate Excellence Awards of Management Association of Pakistan and the Top Companies Awards of Karachi Stock Exchange since early eighties. Millat Tractors Limited exports its various products like tractors, industrial equipment to different countries like Afghanistan, Bhutan, Bangladesh, Sri Lanka, Nepal etc.

2.3 Policy of the organization:

2.3.1 SAFETY POLICY:

1. All the employees have been provided safety equipment during performance of their duties.

2. An upgraded fire fighting system has been installed to cope with any mishap.3. All the machinery has been fenced properly to avoid any type of accident causing

injury to the employees as well as to the machinery.4. Special arrangements have been made for the availability of filtered drinking water

for the employees.5. All the employees are insured under Group Life Insurance Scheme.

2.3.2 HEALTH POLICY:

All the employees are got medically checked periodically through the Company’s panel Hospitals to diagnose diseases if any. In case someone is found suffering from some disease, the Company provides him medical treatment at its own expenses or through insurance company.

2.3.3 ENVIRONMENT POLICY:

The Company has a separate horticulture department to make the environment pleasant, green and full of flowers.

The Company also participates in various competitions on horticulture arranged by Government and other Institutions.

2.3.4 COMPITIORS:

Ghazi Ursus Farmatrac Ford Holand

2.4 2.4 BOARD OF DIRECTORS:

All decisions regarding:1 New investments.2 New borrowings.3 Approval of annual/ half yearly/ quarterly accounts/ dividend/ bonus etc.

4 All management and operational decisions.

CHIEF EXECUTIVE:

5 Overall controlling of the operations.

EXECUTIVE DIRECTOR:6 To manage all the business activities of the company.

COMPANY SECRETARY:7 To manage all secretarial jobs as required by the companies ordinance.

TECHNICAL DIRECTOR:

8 To manage the operational activities of the company.9 To improve the quality/standard of the products.10 To suggest the modernization/expansion plans.

DIRECTOR FINANCE:11 To manage the all-financial matters of the company.

12 To manage/improve the management information system.13 To manage the accounting, costing, taxation, auditing and all other related matters.

GENRAL MANAGERS PURCHASE:14 To manage the local purchases and imports of the company.

GENRAL MANAGERS / GENRAL MANAGERS ACCOUNTS15 To manage the monthly, quarterly, half quarterly and annual accounts of the

company.

MANAGERS TAXATION:16 To manage all the matters related to taxation.

GENRAL MANAGERS ADMINISTRATION17 To manage the personal and the administration matters of the company.

2.5 Organizational Structure

Chairman &Board of Directors

Chairman Board‘sCommittee

for Group Supervision

Director

Director

Director

Director

ChairmanAudit

Committee

ChiefExecutive

CompanySecretary

Director(Finance/CFO)

GM Finance

GM Marketin

GM Productio

GM (IT)GM Assembly

GM Quality

DGM Maintenanc

e

Head of Internal Audit

SM (IPD)

SIKANDAR MUSTAFA KHAN Chairman LATIF KHALID HASHMIDirector SOHAIL BASHIR RANADirector LAEEQ UDDIN ANSARI Director MIAN MUHAMMAD SALEEMDirector / Company SecretaryS M IRFAN AQUEELChief Executive OfficerJAVED MUNIR Director Finance / CFOMUHAMMAD AKRAMGM (Marketing)FAROGH IQBAL AHMEDGM (Engineering & Supply Chain)M. ATHAR ZUBAIR GM (Quality Assurance)MANSOOR A, ABBASIGM (Production) MUHAMMAD AYAZ KHURSHIDGM (IT)NASIM A. SANDHUGM (A&P)JAFFAR H. NAQVIDGM (Maintenance)M. SHAHID MUFTISM (IPD)SHOAIB USMAN BANDAYHead of Internal Audit

Number of Employees

1. Permanent 2502. Contract 25003. Daily wages 800

Main officesHead Office

Millat Tractors LimitedSheikhupura Road,Shahdara Lahore.

Millat Equipment office 10 KM, Raiwind Rd.

3.1 Introduction of All Departments

Production DepartmentThe responsibilities of production department are to produce different products of MTL with the specified standards of quality. The production department consists of four divisions. The assembly plants are ISO 9001:2000 certified for QMS. The functions of the department are being converted to Enterprise Software i.e.IFS.

Technical DepartmentThe Technical Department is responsible for development of new products. The BOM for different products is developed and updated here. The vendors are developed for different components by this department. The changes in prices for components are also negotiated with vendors by personnel of technical department.

Material Management Department.The Scheduling, Ordering, Storage and Issuance of material for Production are done in this department. Three month schedules are prepared according to the availability of material and production plan approved by Production and marketing in some divisions.

Maintenance Department

The Maintenance department is responsible for keeping the plant in running condition and undertaking improvement projects. The scope of maintenance work ranges from civil, Mechanical and Electrical.

Finance DepartmentCapital allocation, issuance and costing are some of the main functions of this department.

IT DepartmentThe installation and maintenance of computers, networks and software packages being used by the company are the main responsibilities of this department. An on-going special assignment for IT is related to coordination between other departments and foreign and local consultants for successful implementation of IFS.

Marketing DepartmentThe different divisions of marketing department are responsible for Pre delivery inspection, Delivery and Marketing of products of MTL.

Quality Control DepartmentThe effective implementation of QA procedures is the responsibility of this department. The Product Quality is the direct responsibility of this department at various stages of production. They functions with the help of quality inspectors on production Lines and a state-of-the-art QC Lab. This Lab is ISO certified by Moody’s international.

Administration DepartmentThe different divisions of Admin department are responsible for Human Recourse Development, Security, Purchase Ordering, Horticulture of the company. The other services like food availability for personnel are also a responsibility of this department.

Internal Audi DepartmentTo assure the transparency in functionality of different departments, the IA Department conducts periodic audit of these departments.

Manufacturing Departments

Production DepartmentThe Production Department of MTL is responsible for manufacture of MTL products which are complaint with the strict levels of quality. The products include tractors, fork lifters, generators sets.

Engine Assembly PlantThe EAP is responsible for production of Engines for Products of TAP and MPA like Tractors of all models, Gen-Sets etc. The Central Loop is fed by sub-assemblies around it. There are some stages of Quality inspection for building Quality in the products.

Tractor Assembly PlantThe TAP is responsible for assembly of different models of the Tractors. The plant consists of Rear Axle Build, Line 1, Line2, and Line3. Line 2 is managed by ICI Industrial Coatings Ltd. The production rate of Main Conveyor ranges from 8-15 Tractors/Hour according to need. The sub-assemblies are also synchronized with the speed of the main conveyor.

Multi- Products Assembly PlantThe MPA division is responsible for the production of products like Fork Lift Trucks and Gen-Sets.The primary customers for the Gen-Sets are PTCL and PAF.

4.1 PLAN OF INTERNSHIP PROGRAME

(a)I do internship in four department1- Manufacturing / Machining Department2- Engine Department3- Tractor Assembly Plat4- Quality Assurance Department

(b) Start and end date of internshipThe internship Program started on 14 t h June, 2010 & ended on 25t h June 2010.

( c ) Duration spend in departments:

During internship the departments under study were:

Tractor Manufacturing / Machining Dpt. from 1 to 6 t h June.

Tractor Engine Assembly Plant from 8 to 13 June.

Tractor Assembly Plant from 15 to 23rd June.

Quality Control Dpt. From 24 to 30th June.

5 Training Program

5.1.1 MACHINING DEPARTMENT

There are following seven machining lines in the Machining department of MTL.

The Machining Process like Drilling, Boring, Threading, Facing etc. are carried out on the parts of Engines and Tractors. There are different Lines for different products. It means that the Plant has Products-Type Layout. The material is issued form MM store to Machining Division with the help of ITN (Internal Transfer Note). It is then sent to MM store as finished products, which are then issued to either EAP or TAP.

5.1.2 MACHINING:

“Machining is the process of removing material from a work piece in the form of chips”.

The term metal cutting is used when the material is metallic. Most machining has very low set-up cost compared to forming, molding, and casting processes. However, machining is much more expensive for high volumes. Machining is necessary where tight tolerances on dimensions and finishes are required.

Machining Department is one of the major departments of MTL. Machining of major parts of tractor is done in this deptt. Almost all types of machining processes can be seen in this deptt .the major machining processes are

o Millingo Drillingo Tappingo Turningo Honing etc.

5.1.2 DRILLING:Drilling is the most common machining process. One

estimate is that 75% of all metal-cutting material removed comes from drilling operations. Drilling involves the creation of holes that are right circular cylinders. This is accomplished most typically by using a twist drill. The figure below illustrates a cross section of a hole being cut by a common twist drill:

The chips must exit through the flutes to the outside of the tool. As can be seen in the figure, the cutting front is embedded within the work piece, making cooling difficult. The cutting area can be flooded, coolant spray mist can be applied, or coolant can be deli-veered through the drill bit shaft.

CHARACTERISTICS OF DRILLING:

The characteristics of drilling that set it apart from other powered metal cutting operations are:

The chips must exit out of the hole created by the cutting. Chip exit can cause problems when chips are large and/or continuous. For deep holes in large work pieces, coolant may need to be delivered through the

drill shaft to the cutting front. Among the powered metal cutting processes, drilling on a drill press is the most likely

to be performed by someone who is not a machinist.

Thefigure below labels the important angles for a typical twist drill bit.

The figures below illustrate various drill bits and their cut hole configurations

5.1.3 BORING “Boring is used to accurately enlarge existing holes and make their diameters highly accurate”

Boring is used for holes that need to have diameter and total run out controlled to a high degree. Typically, a part has holes machined on regular equipment and then the part is transferred to a dedicated boring machine for final operations on the especially accurate holes. Boring can also maintain high accuracy between multiple holes or holes and surfaces. Tolerances can be held readily within ± .005 mm (±0.0002 inches). Dedicated boring machines are designed to machine holes with the tightest tolerances possible with a machine tool.

When designing a part with holes, it is important to determine what holes must be bored.

The reason for this is that jig boring requires extra time and attention, and the jig boring machine at the machine shop may have a back log of jobs. Jig boring can therefore have a big impact on the lead time of a part. A cross section of a hole being jig bored is shown below

5.1.4 REAMING

“Reaming is a process which slightly enlarges a pre-existing hole to a required diameter.”

A reamer is similar to a mill bit in that it has several cutting edges arranged around a central shaft, as shown below. Because of the delicate nature of the operation and since little material is removed, reaming can be done by hand. Reaming is most accurate for axially symmetric parts are produced.

5.1.5 HONING“Honing is a final finishing operation conducted on a

surface, typically of an inside cylinder, such as of an automotive engine block”.

Abrasive stones are used to remove minute amounts of material in order to attain the dimensions with in tolerance limits in cylindrical parts. Honing is a surface finish operation, not a gross geometry-modifying operation.

5.1.6 MACHINING LINES

“A machine line is a sequence of several machines that are arranged for the manufacturing of a specific part or a group of parts”

Cylinder Head Line Centre Housing Line Transmission Case Line Lube Oil Sump 240 Line Cylinder Block Line Axle Housing Line Sump 4.41 Line

5.2 ENGINE ASSEMBLY PLANT

THERMAL ADVANTAGES OF DIESEL:

Loss of coolant 31%Friction 11%Exhaust gases 24%Thermal efficiency 34%

In engine assembly plant, different engine parts are brought in and then assembled to form the basic and major part of the tractor “The engine”.

First of all, components are cleaned for the removal of any oil and degreasing purposes in machine by Trichlone at 50 degrees centigrade. Components contain crankshaft and some gears and the cylinder block.

The crankshaft is first assembled on the main cylinder block and then cylinder caps and bushings are placed and bolted.

Cylinder block is mounted on a movable turning fixture to pass through a line of different processes.

Pistons are graded as A, B, C so that the piston are should be fit accurately for required combustion

A 0-15

B 15-30

C 30-45

(Units are in Micron)

Pistons fitted with piston rings are injected in the cylinders in a particular arrangement of their rings. Compression and oil rings are adjusted such that their ring cuts do not align with each other to prevent the air or fuel leakage.

Idler gears and some other major components like fuel injection pump and oil pump are also bolted to mesh with the idler gear

Idler gear provides power from crankshaft to all the other components that are required to perform certain tasks to run an engine.

These PERKINS Diesel engine are designed to run at maximum RPM of 2470 but these are set for 2200RPM as standard for the using purpose.

5.2.1 TESTING SHOPWhen all of the components of the engine are attached and the assembly of engine is complete, then the engine is brought into a lab containing Engine Test Run Beds.Engines are operated for the very first time on these beds to check their performance at different speeds to meet the needs. Power and oil pressures are also checked in Test Run.

If any engine is found to undergo any problem in any part of the run, then it is sent to another section called Rectification Shop.

Professional technicians then locate the problem by their experience and fix it. Then engines are then sent to the main tractor assembly area

5.2.2 CRANK SHAFT

Crank shaft is fitted in the Cylinder Block. Its function is to convert the reciprocating motion into circular motion.

When placing in the cylinder block, some bushings are first placed on the sections to prevent wear and tear of this expensive part. Bearing caps also prevent the crankshaft as well as support it when running at high RPMs.

Side bearing surfaces are also added around the center Web of the shaft

5.2.3 PISTON

Piston moves in reciprocating manner. They move due to heat energy which comes from the burning of fuel, the fuel used is diesel. The pistons are connected to crank shaft through connecting rods which transfer the movement of pistons to crankshaft.

In Millat Tractor, the three cylinder engine of MF-240 and MF-260 uses the aluminum alloy piston with 1 compression and 2 scrapper rings and an oil ring, total of 4 rings.

5.2.4 FLY WHEEL

The flywheel is used to store the power as it has large moment of inertia. The power is coming in one stroke that is why we use flywheel to get power continuously.

During the assembly of engine, flywheel is added last.

5.2.5 TYPES OF PUMPS USED IN ENGINE

There are four types of pumps used in engine.

1. Lift Pump: It pumps the fuel from fuel tank to fuel injection pump through fuel filter.

2. Fuel Injection Pump: It pumps the fuel into the cylinder. It takes fuel from lift pump. It is called as the heart of the engine.

3. Lubricating Oil Pump: The function of this pump is to move the lubricating oil from sump to all working parts of the engine.

4. Water Pump: This pump moves water from radiator to water gallery of the cylinder block in order to prevent the heating of engine.

5.2.6 Engine Weights

Engine Type Engine Weight

MF-240 250 kgs

MF-260 (Turbo charger) 255 kgs

MF-375S 305 kgs

MF-285 355 kgs

5.2.7 Engine Oil Capacity

Engine Type Capacity

D 3.152/T3.1524 6.80 liter

4.41/4WD/4.41E 7.50 liter

5.2.8 Engine Power

MF-240 50 hp

MF-260 (Turbo charger) 60 hp

MF-375S 75 hp

MF-385 85 hp

MF-385 4WD 85 hp

5.3 TRACTOR ASSEMBLY PLANT

Assembling department is totally responsible of collecting parts which are gathered from more than 250 vendors and Perkins engines from England and assemble a structure which is widely used for making the land of Pakistan fertile and cultivable.Assembling department is using U-shaped assembly line for assembling tractors. These are the main activities involved in assembling.Engine basement is firstly put onto the assembly line

Make smaller additions of structures in a calculated time

Then this structure is sent for paint in painting department which is a part of that assembly line

Other body parts having Red color are also painted there When that basic structure is painted wheels are fitted with it Assembled engine is then fitted ion this structure Seats and other accessories like gears breaks accelerator etc is fitted Finally all the nuts and bolts are tighten for strengthening Testing department checks the quality of color and test drive After final approval tractor is ready for delivery and wait in the queue.

5.3.1 CROWN WHEEL AND PINIONA 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 grinder to ensure proper fitting. Tooth contact of a crown pinion is inspected on a Gleason machine at regular intervals of time for uniform hardness and adequate case depth. They are checked thoroughly for high spots because this ensures premature failure and noise-free operation. The crown wheel & pinion are paired and checked for centralized tooth bearing and desired proximity. An elliptoid contact pattern is ensured between the crown wheel and pinion. They are made of fine-grained steel billet.

5.3.2 BEVEL GEAR

Bevel gears are gears where the axes of the two shafts intersect and the tooth-bearing faces of the gears themselves are conically shaped. Bevel gears are most

often mounted on shafts that are 90 degrees apart, but can be designed to work at other angles as well. The pitch surface of bevel gears is a cone.

5.3.4 POWER TAKE-OFF SYSTEMS AND HYDRAULICS

In addition to towing an implement or supplying attractive power through the wheels, most tractors have a means to transfer power to another machine such as a baler, swathe, or mower. Unless it functions solely by pulling it through or over the ground, a towed implement needs its own power source or else a means of transmitting power from the tractor to the mechanical operations of the equipment.Early tractors used belts or cables wrapped around the flywheel or a separate belt pulley to power stationary equipment, such as a threshing machine, buzz saw, silage blower, or stationary baler. In most cases, it was not practical for the tractor and equipment to move with a flexible belt or cable between them, so this system necessitated that the tractor remain in one location with the work brought to the equipment, or that the tractor be relocated at each turn and the power set-up reapplied. Modern tractors use a power take-off (PTO) shaft to provide rotary power to machinery that may be stationary or pulled. The PTO shaft generally is at the rear of the tractor, and can be connected to an implement that is either towed by a drawbar or a three-point hitch. This eliminates the need for a separate implement-mounted power source, which is almost never seen in modern farm equipment.Virtually all modern tractors can also provide external hydraulic fluid and electrical power to the equipment they are towing, either by hoses or wires.

5.3.5 TRANSMISSION (MECHANICS)

A transmission or gearbox provides speed and torque conversions from a rotating power source to another device using gear ratios. In British English the term transmission refers to the whole drive train, including gearbox, clutch, prop shaft (for rear-wheel drive), differential and final drive shafts. The most common use is in motor vehicles, where the transmission adapts the output of the internal combustion engine to the drive wheels. Such engines need to operate at a relatively high rotational speed, which is inappropriate for starting, stopping, and slower travel. The

transmission reduces the higher engine speed to the slower wheel speed, increasing torque in the process. Transmissions are also used on pedal bicycles, fixed machines, and anywhere else rotational speed and torque needs to be adapted. There are two types of gearing systems, Manual and Automatic.

5.3.6 MANUAL TRANSMISSION:

Manual transmission comes in two basic types:

a simple but rugged sliding-mesh or unsynchronized / non-synchronous system, where straight-cut spur gear sets are spinning freely, and must be synchronized by the operator matching engine revs to road speed, to avoid noisy and damaging "gear clash",

and the now common constant-mesh gearboxes which can include non-synchronized, or synchronized / synchromesh systems, where diagonal cut helical (and sometimes double-helical) gear sets are constantly "meshed" together, and a dog clutch is used for changing gears. On synchromesh boxes, friction cones or "synchrony-rings" are used in addition to the dog clutch.

5.3.7 AUTOMATIC TRANSMISSION:

Epicyclical gearing or planetary gearing as used in an automatic transmission.They primarily use hydraulics to select gears, depending on pressure exerted by fluid within the transmission assembly. Rather than using a clutch to engage the transmission, a fluid flywheel, or torque converter is placed in between the engine and transmission. It is possible for the driver to control the number of gears in use or select reverse, though precise control of which gear is in use may or may not be possible. Automatic transmissions are easy to use.

5.3.8 DESCRIPTION OF TAP:

This are will define the different processes being held in different sections of TAP.

5.3.9 SEGREGATION AND DEGREASING:

The components from vendors are degreased here. and then components are supplied to all stages

5.3.10 REAR AXLE BUILD:At this stage, rear axle is assembled. this stage is subdivided in different units as,

o Crown wheel assemblyo Centre housing assembly

o Hydraulic pump assembly

o Axle shaft assembly

o Axle housing assembly

o Hydraulic lift cover assembly

These all sub stages provide different components and assembly of rear axles along with centre housing is done. Hydraulic pump and lift cover is also installed.

5.3.11 HUDRAULIC SYSTEM TEST RIG:Hydraulic lift cover is then checked at this section to ensure that all the lifting components are working correctly.

5.3.12 CHASIS BUILD:This stage is also subdivided in different sections.

Link and Yoke assembly Transmission assembly Engine assembly Front support assembly Foot Board and steering assembly Brake paddle assembly Fuel tank bracket assembly

Links and yokes along with other gears are assembled in the transmission case to make it work for the power and speed conversion. Pressure plate and clutch plate are bolted in the flywheel of the engine. Transmission case and engine are attached to the centre housing on

the moving DOCK. Then front support, footboard, stearing, brake paddles and brackets for fuel tank are attached.

5.3.13 CHASIS PAINT SHOPChassis paint shop contains three sub sections.

o Grey paint on chassiso Red/green colour coatingo Heating oven

The chassis is first painted manually after sealing the necessary holes and screws. In other sections, Red/Green colour is painted after degreasing the sheet metal from the inventory. Degreasing and primer coating is done automatically. Then both, chassis and sheet metal parts are brought into heating oven to let them dry.

5.3.14 FINAL BUILDIn final build stage, there are certain other sub stages too

o Radiator o Fuel tanko Wiringo Seat assemblyo Link chaino Bulk heado Dash boardo Acceleratoro Batteryo Wrappero Hood topo Fendero Front grillo Fuel/grease/oilo Front tireo Rear tireo Lower Links

All the listed components are attached one by one to the recently painted and baked portion of the tractor. Meanwhile wrapping section attaches the MTL monogrammed sticker to the Hoods.Big tractors MF-375 is filled with 37litres of Mobil oil while small unit i.e. MF-240 are filled with 32litres. 9 liters of diesel is also pump into their tanks.

5.3.14 RACTIFICATION

This section checks the recently manufactured tractors for the very first time. Technicians test drives each one of the tractor to ensure the proper working of each component. If any minor trouble is found, skillful workers take it into notice right on the place. For major problems tractor is sent to another section.After maintenance, tractors are also sent to road tests.

5.3.15 TOUCH UP PAINT BOOTHIf paint is missing on any of the components, it is repainted in touch up paint section.

5.3.16 PREDELIVERY INSPECTIONAfter minor and major rectification and also after passing the paint n retouching section, pre delivery inspection is done on the tractor in a PDI deptt. If tractor has passed all the sections then a PDI sticker is applied on it to ensure that marketing section can now hand it over to its owner.

PDI and segregation are not considered the part of TAP but they are former and later stages of TAP.

5.4 QUALITY CONTROL DEPARTMENT

There are three main sections of quality control department.

1. QC-Assembly2. QC-BOF3. QC-Machining4. QC- Lab and Gauge Control

5.4.1 QC-ASSEMBLY:

In this section, the quality of assembling of different parts is checked. In MTL, we have three assembling units.

1. EAP (Engine Assembly Plant)2. TAP (Tractor Assembly Plant)3. MPA (Multi Products Assembly)

GAUGE STORE:Different types of gauges and fixture are available in gauge room for inspection of incoming supplies and in house machining components.

Gauges are used where production is involved

Plug and Pneumatic Plug gauges Snap gauges Thread gauges Thread ring gauges

MECHANICAL TESTING LAB:

Mechanical Testing lab is concerned about measurement of different mechanical properties of parts like hardness, ultimate tensile strength, compression test, bend test, pull test, elongation, impact testing, yield strength etc.

To meet above tasks this lab is provided with following machines.

o Brinell Hardness Testing Machineo Rockwell Hardness Testing Machineo Chirpy Impact Testing Machineo Universal Testing Machine (UTS)

Rockwell Hardness Testing Machine is used to measure hardness of harden and tempered materials and Brunel Hardness Testing Machine is used to measure hardness of forged and casting materials.

VPN and BHN are the hardness numbers that provide the mechanical properties information about the material being test

Pull test: Test the threads of studs

Impact test: Tests the fatigue of material

Vickers hardness test: for CASE hardness of material

Rockwell harness test: for surface hardness of material

METALLURGICAL LAB:This lab is concerned about study of castings, forgings and heat treated materials.

In this lab

Microstructure of castings is observed. Grain size of forgings is observed. Various types of case depths, surface hardness and core hardness of heat treated

materials is observed.This lab is divided into two sections.

Sample preparation. Microscopic Analysis. In Microscopic analysis sample is observed under microscope and hardness is measured with Vicker Hardness Machine and then reports is prepared.

CHEMICAL TESTING LAB:This lab is concerned about study of chemical composition of material, rubber testing, paint testing, and corrosion resistance testing of components.

This lab consists of following apparatus

o Carbon strolling apparatuso Spectrophotometer (for Phosphorus)o Titration unito Muffle unito Viscosity batho Flash point testero Ovenso Salt spray machineo Purometer hardness test (for rubber)

The operations performed on these machines are ,

Chemical composition of ferrous and non ferrous alloys is checked. Different properties related to rubber are checked here like Hardness (DHN), Heat

aging, volumetric expansion, Oil resistance etc. Different properties of paints are checked here like Adhesiveness, gloss, flexibility

etc.

Sault Spray Test is conducted to check out corrosion resistance of components. In this test corrosion atmosphere is produced in chamber in accordance with ASTNB117 (5% NaCl solution, 1.5bar pressure, 35°C temperature) and samples are tested in this chamber for given time.

OIL TESTING LAB:In this lab diesel, lubrication oil and grease are checked.

Flash point of diesel and lubrication oils is checked. Two types of Flash point apparatus are used here.

o Close Cup Apparatus is used to check flash point of diesel.o Open Cup Apparatus is used to check flash point of lubrication oil.

Total Base Number of diesel and lubrication oil is checked on TBN Tester. Viscosity of diesel and lubrication oil is checked on viscometer. Dropping point of grease is checked.

TEST RIGS SECTION:Test rigs section is provided with different rigs for function and performance test of different components.

Test rigs available in this section are given below.

Oil bath performance test rig. Hydraulic linkage performance test rig. Air pressure leakage test for oil bath and fuel tank. Starter motor performance test rig. Power steering performance test rig. Alternator performance test rig. Wire harness performance test bench. Test bench for

o Temperature gauge.o Fuel gauge.o Battery gauge.

Test bench for Tractor meter. Load test rig for

o Cable hand throttle pump.o Cable foot throttle.o Cable hand brake.

6.0 Analysis

SUPPORT ACTIVTIESSUPPORT ACTIVTIES

IINFRASTRUCTURENFRASTRUCTURE:: The Company has its own infrastructure to manufacture its products and

to launch them in market.

HR MHR MANAGEMENTANAGEMENT:: The Company has a strong HR network as up-to date training,

motivating and rewarding the workforce on efficient work is the part of organization.

TTECHNOLOGICALECHNOLOGICAL D DEVELOPMENTEVELOPMENT:: MTL is known for its advancement in technological sector

throughout the country yet the company is aiming to be better in that sector.

PROCUREMENTPROCUREMENT:: All the Purchasing material required to assemble a tractor is bought at the

most reasonable price the organization can have.

PRIMARY ACTIVITIESPRIMARY ACTIVITIES

IINBOUNDNBOUND-L-LOGISTICSOGISTICS: : The Company uses different parts to make a tractor in a special unit

area.

OOPERATIONSPERATIONS: : All the operations are carried out within the organizations from gear fitting to

assembling engine and from small nuts to 5 feet tires.

OUTBOUNDOUTBOUND-L-LOGISTICSOGISTICS:: After completing the process of manufacturing a tractor, it is sent to

the go-down along with other fully finished tractors

MMARKETINGARKETING ANDAND S SALESALES:: The Market and sales is done through the dealers and local

correspondents of the company along with the formal methods of Advertisement.

SSERVICESERVICES:: The Company have a wide network of after sale services

6.1 SWOT ANYLSIS

S STRENGTHSTRENGTHS

Good employee safety and health system A better system of communication Unbiased or non-discriminatory actions Concentration on training and development Involvement of departmental heads in recruitment process lets hire the best

applicants.

W WEAKNESSESEAKNESSES

Methods used for forecasting personnel needs

Some of the policies require to be updated

Outdated training system

Less space in office for employees

O OPPORTUNITIESPPORTUNITIES

Use of motivational tools

Use of more sources to attract labour force

Use of new methods for forecasting

T THREATSHREATS

Infusion of incompetent labour in work force

Government policies

6.3 Conclusion:Millat tractor limited as a leading and pioneer organization is doing very well. Their plans are very well organized, managed, according to circumstances and they avail the opportunities very effectively. I am pretty sure that company has ability to achieve its

goals as stated in vision statement. After my internship in Millat Tractors Limited and doing financial analysis I reach at the same conclusion that they are "LEADERS ALL THE WAY". The management is very effective and their plans are mostly about their future. Therefore I conclude that Millat Tractor has going on concern and it will progress further and they have ability to overcome risks and prosper.

6.4 Recommendations

Having gone through the HR process and policies of the company, We have reached the

following conclusions:

All the policies need to be up dated.

For forecasting the future needs of manpower planning, the company may use the

advanced techniques e.g. computer software, etc.

Although the company is emphasising the training and development; yet there is a dire

need to update the training programs to something like On-job training. Moreover, for

technical jobs simulation may also be used.

Although the system of communication of the company includes Internet; yet there is a

need to train the employees to use this system aptly.

In order to attract a more diverse work force, the company may use other advanced

techniques like Internet, etc.

Employee confirmation depends upon the assessment report of departmental head. This

may be replaced with some better assessment procedure.

In order to win over the employee loyalty, the company may improve the salary

administration system.

The company should implant a private intranet in its existing systems of

communications.

The system of communication may be made transparent so that the employees may have the information about what is happening around them. Moreover, it will also inspire a sense.