TRAINING REPORT

SUBMITTED IN REQUIREMENT FOR SIX WEEKS INDUSTRIAL TRAINING

AT

INTERNATIONAL TRACTORS LTD. (SONALIKA),

HOSHIARPUR.

SUBMITTED BY:
ASHUTOSH GUPTA REG. NO. : GME/SL/15/4619
VIRENDRA KR. CHAURASIYA REG. NO. : GME/SL/15/4601
RAM SHANKAR SINGH REG. NO. : GME/SL/15/4613

B.E. (MECHANICAL ENGINEERING)

Sant Longowal Institute of Engineering and Technology

Preface

If you know the laws of buoyancy it doesn’t mean that you know how to
swim. It is only through jumping in the water that you get the feel of the
depth. This is applicable to every aspect of life. Therefore, practical
training is of utmost importance. The object of undergoing this training
was to get familiar with the weary waters of the industry and to learn how
to put theory into practice. I have been greatly privileged to have
undergone training at ITL (Sonalika). This report contains the extract of
things I learned during my training period
Acknowledgement
Any endeavour cannot lead to success unless and until a proper platform is provided
for the International Tractors Limited. The persons of my department and all other
departments have extended 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 it feels to be in a company where discipline, quality and hard work are the
motto. This training helped me a lot in bridging the gap between the
theoretical and the practical aspects of my knowledge. First of all I would
like to thank Mr Sandeep Meena for his valuable guidance & encouragement
as a teacher and a friend throughout my training period. I am also thankful
to Mr Sunny Kaushal for giving me an opportunity to undergo training in
such a renowned company. I am sure that the knowledge & information that I have
gained during this period would be of immense value for my growth in the
field of Mechanical Engineering.
Contents

1. The Indian Tractor Industry

2. Introduction to the Company
3. Background of the company
4. Timeline of the company
5. Company Organization chart
6. Manufacturing facilities at plant
i. Gear Division
ii. Light Machine & Cylinder Block Shop
iii. Heavy Machine Shop
iv. Engine Assembly Line
v. Sheet Metal & Fabrication Shop
vi. Assembly and Paint Shop
7. Heavy Machines Shop
8. Project
The Indian Tractor Industry
India is mainly an agricultural country. Agriculture accounts for
approximately 25 percent of India’s GDP. Agriculture in India is the
means of livelihood of almost two thirds of the workforce in the country
and employs nearly 62 percent of the population. It accounts for 13
percent of India’s exports. About 42 percent of India’s geographical area
is used for agricultural activities. It is therefore considered a vital sector of
the Indian economy.

The Indian tractor industry is the largest in the world, accounting for one
third of global production. The other major tractor markets in the world
are China and the USA. The global spotlight on tractor manufacture in
terms of unit volume seems to be swinging away from the USA, UK and
Western and Eastern Europe towards India and China, where growth in
the number of producers and the total volume of production in recent
years has been impressive.

Until 1960, the demand for tractors was met entirely through imports.
Indigenous manufacture of tractors began in 1961, but India continued to
import tractors to bridge the total volume needs up to the late 1970s. The
Indian Tractor Industry has come a long way since then. Volume growth
in the past four decades show a compound annual growth rate of 10
percent, despite seasonal variations that cause natural fluctuations in the
demand for tractors, subsequently impacting the industry volumes.

The Indian tractor market is traditionally a medium-horsepower market

consisting of mostly 31-40hp, which constitutes almost 51 percent to
growth in this category. Growth of the Industry is closely related to
growth in this category. In other-size categories, 41-50 hp category
achieved the second highest growth of 34 percent and constitutes 24
percent of the total market share. The rest of the market share is largely
with the 21-30 hp category followed by the category of tractors having
more than 50 hp.
The Indian Tractor Industry has numerous challenges, some of them
being:-
1. Reducing the average age of tractor buyers from the age group of
above 40 to younger people
2. Development of new products using latest technology and
advancements in the field of electronics and mechatronics and
making the tractors more comfortable, stylish and yet keeping them
in range of a farmer.
3. Reduction of emissions in accordance with the new international
emission standards
Introduction to the Company

Industry Automobile
Founded 1969
Founder Lakshman Das Mittal
Hoshiarpur, Punjab,
Headquarters
India
Area served Worldwide
Tractors, multi-utility
vehicles, engines, farm
machinery attachments,
Products
diesel gensets, auto
components and pick &
carry cranes
Number of
5000
employees

Sonalika group is one of the top tractor and agriculture machinery

manufacturers in India. Apart from tractors its product line includes
engines and various farm equipments and implements. Established in
1969, Sonalika group, since its inception, has tried to understand customer
need to be facilitating them with its value for money products. The
Company has a state-of-art manufacturing facilities, spread in almost 60
acres, located in the outskirts Hoshiarpur, Punjab. Sonalika is the one of
the top 3 tractor manufacturing companies in India. Today the group
stands tall with an approximate turnover of 5000 crore INR. A growth
rate of 22% y-o-y makes it one of the fastest growing corporate in India.
It is also one of the few debt free companies. Group has strength of about
5000 employee technocrats. The company works on the maxims of
low production cost and clean and safe environment. Such efforts have
fetched the company the accreditation like ISO 9001 and ISO 14001.
International Tractors Ltd. Was incorporated on October 17, 1995 for the
manufacture of tractors and has since then built a distinct position for
itself in the tractor industry. ITL is manufacturing various tractors of
Sonalika brand between 30 – 90 hp and Solis brand between 20 – 120 hp.
ITL reached the milestone of selling 1 lac tractors in fiscal year 2017-18.
Sonalika International Tractors Ltd. has established World's No.1
integrated tractor manufacturing plant in Hoshiarpur, Punjab with a
production capacity of 3 lakh tractor annually.
The global recognition of ITL’s growth has been highlighted by strategic
investment into the Group by leading international brands like Yanmar of
Japan.
Since its inception in 1996, Sonalika ITL has come across a long way and
has today become No.1 tractor brand in 4 countries (Nepal, Bangladesh,
Algeria, Myanmar) & is the 3rd largest tractor manufacturer in India.
Sonalika group’s products exist in various international markets.
Company exports its products to over 100 countries including Algeria,
Australia, Bangladesh, Brazil, Iran, Ivory Coast, Malaysia, Mauritius,
Mongolia, Nepal, Oman, Japan, Senegal, South Africa, South Korea,
Switzerland, Sudan, Canada, US, Ukraine, and Zimbabwe.
Owing to its customer centric approach, Sonalika has registered its
success globally through sheer dedication towards serving farmers and
making their lives easier. Sonalika understands the needs of the farmers
and provides them tailor made farm mechanized solutions.

Competitors
Competitors of ITL include Mahindra-Swaraj, TAFE (Massey), John
Deere, Escorts, New Holland etc.
Timeline of Sonalika

1969 Modest Beginning as Farm Equipments Manufacturer,

formed Sonalika Agro Industries

1996 Entered into Tractor Manufacturing by Selling its First

Handmade Tractor

Collaborated with Renault Agriculture of France & Claas

2000
Tractors of Germany

2001 Stared In-House Manufacturing of Tractor Engines

Ranked 4th Largest Tractor Manufacturing Company in

2005 India. First compact tractor Baagban Launched. Tied up
with Yanmar of Japan

2008 Modern Looking RX Series Launched

Developed Diesel Saver Unit & Technologically

2009 Advanced Worldtrac Series

Orchard Special Tractor Range- GardenTrac and High

2011
End Tractor Rx 60 MM Super Launched
2012 Increased Global Footprints Entered into 60 Countries

Ultra- Modern Plant for Manufacturing Combined

2013 Engine and Rotavators Inaugurated. Launched AC Cabin
Tractors

Ranked 3rd Largest Tractor Manufacturing Company in

2014 India, Launched First 110HP Tractor in India. Joint
Hands with L&T and PNB for Financial Agreement.

Launch of HDM (Heavy Duty Mileage) series of tractors.

2015 Global presence increased to 80 countries.

Inaugurated World's Number 1 integrated tractor

2017 manufacturing plant in Hoshiarpur by Hon'ble Chief
Minister of Punjab, Captain Amarinder Singh.

Achieved Milestone of 1 Lakh Tractor sales in one year

2018 2017-18
Company Organisational Chart

Chairman
|
Vice-Chairman
|
Managing Director
|
Chief Operating Officer
|
Joint Chief Operating Officer
|
HOD of Every Dept.
|
Managerial Staff
|
Executives
|
Support Staff
|
Workers
Manufacturing Facilities
A number of manufacturing facilities are available at the International Tractors
Ltd. (Sonalika), Hoshiarpur. The whole manufacturing system is divided into a
number of departments.
i. Gear Division
ii. Light Machine Shop & Cylinder Block Line
iii. Heavy Machine Shop
iv. Engine Assembly Line
v. Sheet Metal & Fabrication Shop
vi. Paint Shop
vii. Assembly Shop

(i) Gear Division

The Facility delivers all types of gears & shafts like Main Shafts, Lay shafts,
Input Shafts, Synchromesh Gears, Gears with Dog Teeth, Shifter Sleeves,
Synchro Hubs & Cones.
(ii) Light Machine Shop

In L.M.S. the light parts are produced and proper machining is given to
them.Light Machine Shop is where we manufacture sophisticated Control
Valves for high pressure (200 Bar) Tractor applications with Hardened
(60HRC) Bush and Spools for prolonged service life. This infrastructure have
capabilities to Design, Develop and Manufacture complete Hydraulic
Assemblies for Tractor applications of Lift Capacity upto 3000 Kgs and Flow
rates upto 45 LPM.

Components Manufactures in Light Machine Shop

 Control Valve
 Composite Valve
 Feathering Valve
 Relief Valve
 Release Valve
 Hardened Alloy Steel Bush & Spool Assemblies.
(iii) Heavy Machine Shop

In Heavy Machine Shop all major components of Tractors are machined. These are

 Crank Case
 Differential Housing
 Gear Box Housing
 Clutch Housing
 Trumpet Housing

This infrastructure is equipped with the advanced CNC Machining Centers, Special
Purpose and General Purpose Machines. All the components are thoroughly
checked and inspected for its geometrical accuracy on the imported 3D Coordinate
Measuring Machine.

(iv) Engine Assembly Shop

The assembly line for Engines is one of the best lines fitted with high quality
automated slat conveyor system having various safeties and DC Multi Nut Runner
systems on the different stages which ensures consistent and zero defect production.

(v) Sheet Metal & Fabrication Shop

Stamping facility is equipped with Ultra modern presses from internationally

renowned suppliers. This facility delivers all type of sheet metal components i.e. Skin
Panels, Inner panels, Floor Panels, Pillars, Reinforcements, Cross Members, Oil
Pans, Fuel tanks etc.

(vi) Assembly & Paint Shop

In assembly line various parts are being assembled into a single unit termed as
“tractor”. During assembly the various parts are being fitted according to the stage.
This would include the assembly of important parts such as rear cover, cover, gear
box, differential housing and trumpet housing. Firstly the various sub-parts of the
rear cover are being fitted into the gear box. After that both the rear cover and the
gear box are taken to the line where the various things such as brakes, P.T.O. shaft,
cage assembly, trumpet housing etc. are fitted to the differential housing. Then this
whole assembly is fitted with the engine against the gear box. After whole assembly is
fitted with the engine, this assembly is taken to the Chassis paint area, where it is
washed and dry followed by paint on the chassis. Then the tractor reaches to the
final stage where certain electrical and other accessories such as battery cover,
steering wheel, radiator etc. are fitted. Proper level of engine oil is also filled into the
differential and gear box. Greasing of various parts is also performed with grease
gun. After that the tractor is taken out of the line after taken it out from the hooks.
This stage is termed as dismounting stage. Then the testing of the tractor is
performed which include the checking for vibrations, noise, brakes, oil level and
other factors that affect the performance of tractor.

To achieve the rollout of 1 tractor every 2 minutes, Sonalika ITL has installed a
modern robotic paint facility with six robots working on an automated line, using
the finest corrosion-resistant industrial paint.

CED Dip tank capacity of 70000 litres assures uniform paint film thickness and
creates Eco- friendly Paint ( Low VOC & Lead Free) with higher degree of paint
Utilization.

International Tractors Ltd. has tractor assembly line equipped with capacity of 3 lac
tractors per year with a roll out time of around 2 minutes.
Flow Chart of Chassis Assembly
Heavy Machines Shop
The Heavy Machine Shop is one of the most important shops of the industry.
It plays a very important role in the production of the tractor. As the name
suggests all the heavy components namely, the differential housing, the gear box
housing, the crank case housing, the cage and trumpet are machine here. The shop
is called the backbone of the industry.

The Heavy Machine Shop divided into five sections.

1. Differential housing line
2. Gear box housing line
3. Cage & trumpet line
4. Crankcase housing line
5. Tool room

All the sections are highly equipped with modern machinery and
equipment. Each section has a process layout i.e. the raw material is
received at o n e e n d a n d t h e f i n i s h e d c o m p o n e n t i s
dispatched from the other. The material received is in
f o r m o f casting. The m achining process is carried out
und er strict quality norms. There is in process inspection at
each workstation. The component is made to
g o through final inspection before it is dispatched
f o r assembly. The Material handling System in the H.M.S shop consists
of hydraulic lift trucks, power hoists, roller conveyors, overhead crane,
fork lift trucks, bins etc. the shop has well designed network of roller
conveyors. The castings from the truck are loaded onto these conveyors
and the material travels to reach the respective section. At the end of each
conveyor a section for inspection has been made so as to make the component
through the inspection process. Each workstation is provided with a
power hoist of 500Kg (load carrying capacity). These are used to pick casting from
conveyor and load them onto the machine and vice versa. There is also
a provision of a 2-ton carrying capacity overhead crane in each section.
VERTICAL MILLING CENTER : -

The machine is called vertical milling centre because in this the tool is
perpendicular to the axis of the job. VMC is a fully automatic and
high precision machine. The machine is controlled by computer, which
regulates the feed and rpm of the tool and also the movement of the job.
In this machine the tool is stationary and the job moves horizontally
(x-axis and y-axis). The movement of tool is restricted to z-axis
only.

The various operations that are

performed on VMC are:
 Face Milling
 Chamfering
 Rough Milling
 Reaming
 Fine Milling
 Boring
 Drilling
DUPLEX MILLING MACHINE : -

It is a hyd raulically controlled milling machine. On this machine

the milling of both the faces of the differential housing is done
simultaneously. The machine is fitted with two circular cutters having
64inserts and one wiper each. The 64 inserts are for rough
milling and one wiper is for finishing. The job is
f e d between these two cutters. Movement of job is in x-axis only and
movement of cutters is restricted to y-axis only. The machine is a high
precision machine and produces components with high degree of surface
finish.

ROUGH BORING MACHINE : -

It is a hydraulically controlled boring machine. In this machine we can
bore the hole for brake housing of dia. 109mm left & right on the
differential housing & also bore the hole for trumpet housing of dia.
129mm left & right on differential housing. In this machine we can
also bore T.P. Carrier hole of dia. 114mm.

TWO WAY BORING MACHINE : -

It is hydraulically controlled boring machine. In this machine tool is

m ove parallel to the job and from both s id e. This m achine
is us ed for boring the hole for P.T.O. shaft of dia. 71 mm.

FINE BORING MACHINE :-

It is also a hydraulically controlled boring machine. This machine bores

the hole of dia. 130 mm for trumpet mounting and brake housing
mounting of dia. 110 mm simultaneously by fixing the fixture with
this machine.
RADIAL DRILL MACHINE : -

This machine is move in a radial direction of job. The operation done

in this machine to drill the hole for drain plug of dia. 10.2 mm×24 mm
and then tapping is done of dim. 24×1.5 mm.

MULTI SPINDLE DRILL MACHINE : -

In this machine, 20
holes are drilled on
left and right side of
differential housing
simultaneously.
Drilling is done for
mounting the trumpet
and brake housing.
FLEXI ARM (TAPPING MACHINE) :-

This machine is used for tapping holes on the differential housing.

Project
 CYCLE TIME ANALYSIS OF DIFFERENTIAL HSG. (VMC- 279)
(FOR TWO WHEEL DRIVE- 2 WD)

Sr. TOOL RPM FEED CYCLE START CYCLE END CYCLE

no. DISCRIPTION (mm/min.) TIME(min.) TIME(min.) TIME/OPERATION
1 Tool Change & 0:00:00 0:00:30 0:00:30
Pallet Change
2 Rough Milling 650 1700 0:00:30 0:04:24 0:03:54
Cutter Dia. 80 mm
3 Tool Change 0:04:24 0:04:36 0:00:12

Drill 2000 700 0:04:36 0:05:58 0:01:22

4 Dia. 10.2 mm
5 Tool Change 0:05:58 0:06:08 0:00:10
6 Chamfer 200 500 0:06:08 0:06:23 0:00:15
Angle 15®
7 Tool Change 0:06:23 0:06:33 0:00:10
8 Fine Milling 800 2500 0:06:33 0:07:56 0:01:23
(finishing)Dia. 80 mm
9 Tool Change 0:07:56 0:08:09 0:00:13
10 Drill 1500 500 0:08:09 0:08:26 0:00:26
Dia. 15.5 mm
11 Tool Change 0:08:26 0:08:39 0:00:13
12 Hole Miller 1660 150 0:08:39 0:08:56 0:00:17
Dia. 11.5 mm
13 Tool change 0:08:56 0:09:16 0:00:16
14 Reamer 450 400 0:09:16 0:09:43 0:00:27
Dia. 12 mm
15 Tool Change 0:09:43 0:09:55 0:00:12
16 Reamer 597 400 0:09:55 0:10:14 0:00:19
Dia. 16 mm
17 Pallet out 0:10:14 0:11:06 0:00:52
18 Rough Milling 650 1500 0:11:06 0:12:50 0:01:44
Cutter Dia. 80 mm
19 Tool Change 0:12:50 0:12:58 0:00:08
20 Drill 2800 500 0:12:58 0:13:11 0:00:13
Dia. 6.8 mm
21 Toll Change 0:13:11 0:13:16 0:00:05
22 Drill 2046 500 0:13:16 0:13:41 0:00:25
Dia. 12 mm
23 Tool Change 0:13:41 0:13:51 0:00:10
24 Drill 1600 240 0:13:51 0:14:11 0:00:20
Dia. 22.5 mm
25 Tool Change 0:14:11 0:14:19 0:00:08
26 Chamfering 2000 500 0:14:19 0:14:51 0:00:32
Angle 15®
27 Tool Change 0:14:51 0:15:06 0:00:15
28 Fine Milling 800 2500 0:15:06 0:15:43 0:00:42
Finishing Dia. 80 mm
 CAPACITY STUDY FOR THE DIFFERENTIAL HOUSING (2-WD)

Sr. M/c. Operation Loading Machining Unloading Total Capacity No. of

no. Description Description Time Time Time time shift/M/C Machine
1 Duplex Milling Side Rough 0:01:00 0:04:46 0:00:41 0:06:27 74 1
DMH-198 Milling
2 Duplex Milling Front & Rear 0:01:00 0:05:22 0:00:30 0:06:52 69 1
DMH-262 Rough Milling
3 Duplex Milling Front & Rear 0:00:27 0:05:11 0:00:18 0:05:56 80 1
DMH-272 Fine Milling
4 Window Milling Side 0:00:29 0:05:14 0:00:29 0:06:12 77 1
WMH-136 Fine Milling
5 Window Milling Window 0:01:11 0:03:57 0:00:45 0:05:53 81 1
WMH-180 Milling
6 Rough Boring 0:00:20 0:02:19 0:00:18 0:02:57 162 1
7 Rough Boring 0:00:25 0:02:50 0:00:15 0:03:30 137 1
RBH-241
8 Rough Boring 0:00:53 0:02:05 0:00:44 0:03:42 129 1
RBH-110
9 Fine Boring Left & Right 0:00:44 0:05:04 0:00:27 0:06:15 76 1
FBH-109 Bore
10 Fine Boring TP Carrier 0:00:30 0:01:47 0:00:31 0:02:48 171 1
RBH-61 Bore & Face
11 Fine Drilling 0:00:38 0:01:07 0:00:43 0:02:28 195 1
MDH-114
12 Drilling M/C Front & Rear 0:00:23 0:01:05 0:00:32 0:02:00 240 1
MDH-111 Face Milling
13 Drilling M/C Drain Plug 0:00:20 0:02:25 0:00:16 0:03:01 159 1
RH-120, 80 Tap & Dowel
on gear box
side face
14 Tapping M/C Tapping All 0:00:54 0:15:00 0:00:17 0:16:11 29 1
TH-65,116,170 Holes
 CAPACITY STUDY FOR THE DIFFERENTIAL HOUSING (CRD)

Sr. M/c. Operation Loading Machining Unloading Total Capacity No. of

no. Description Description Time Time Time time shift/M/C Machine
1 Duplex Milling 0:01:10 0:03:06 0:00:28 0:04:44 101 1
DMH-323
2 Duplex Milling Front & Rear 0:00:35 0:05:55 0:00:21 0:06:51 70 1
DMH-58 Milling
3 Duplex Milling Side 0:00:29 0:04:51 0:00:24 0:05:44 83 1
DMH-59 Milling
4 Window Milling Window 0:00:55 0:05:32 0:00:23 0:06:50 70 1
WMH-180 Milling
5 Rough Boring 0:00:24 0:02:29 0:00:18 0:03:11 150 1
RBH-333/332
6 Rough Boring 0:00:18 0:02:33 0:00:19 0:03:10 151 1
RBH-246
7 Rough Boring Rough Bore 1
RBH-135 Left & right
8 Fine Boring 0:00:56 0:02:47 0:00:29 0:04:12 114 1
FBH-60
9 Fine Boring PTO 0:00:24 0:01:48 0:00:21 0:02:33 188 1
FBH-108 Bore
10 Drilling M/C Drilling Left & 0:00:28 0:01:33 0:00:30 0:02:31 191 1
MDH-141 Right Face