Internship Report @ Millat Tractors Limited (MTL) 2013
Upcoming SlideShare
Loading in...5
×
 

Internship Report @ Millat Tractors Limited (MTL) 2013

on

  • 2,855 views

6 week Internship Report @ Millat Tractors Limited (MTL), Lahore, Pakistan.

6 week Internship Report @ Millat Tractors Limited (MTL), Lahore, Pakistan.

Statistics

Views

Total Views
2,855
Views on SlideShare
2,855
Embed Views
0

Actions

Likes
1
Downloads
168
Comments
1

0 Embeds 0

No embeds

Accessibility

Categories

Upload Details

Uploaded via as Microsoft Word

Usage Rights

© All Rights Reserved

Report content

Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
  • Full Name Full Name Comment goes here.
    Are you sure you want to
    Your message goes here
    Processing…
Post Comment
Edit your comment

Internship Report @ Millat Tractors Limited (MTL) 2013 Internship Report @ Millat Tractors Limited (MTL) 2013 Document Transcript

  • Millat Tractors Limited 2013 INTERNSHIP REPORT Azlan Zahid Millat Tractors Limited 4/1/2013 to 5/16/2013 University of Agriculture Faisalabad Page 1
  • Millat Tractors Limited Acknowledgements We are pleased to acknowledge Mr. Naseem A. SandhuGM(Admin) and Mr. Azhar Noor Dy.GM (Mktg.) Millat tractors limited who helped us to work here as internee. We have learned a lot during my period of internship in MTL. We have observed our theoretical knowledge being converted to practical processes. We also acknowledge Mr. Khawaja Ali Hassan AM (Mfg.) from manufacturing department, Mr. Hafiz Faheemand Abdul MannanfromEngine Assembly Plant (EAP), Mr. Athar GM (QA) and especially Mr. Muhammad AkmalDy. Manager (Production) from Tractor Assembly plant (TAP), and all others for their help and support in instructing and giving us sound knowledge about their respective plants. University of Agriculture Faisalabad Page 2
  • Millat Tractors Limited Executive Summary Millat Group is Pakistan’s leading engineering concern in automobile sector & has a history that spans almost half a century. MillatTractors Limited MTL is market leading industry of agricultural tractors & holds above 50% market share. We carried our work according to the given schedule. The activities assigned to us were very precise and intellectually challenging. The activities include are; complete visit to market and dealership network to know about the market policy of MTL, the current demand of tractors & market position of MTL, after sales services provided to the customers, visit dealer’s workshop to know about the quality of the Product. Viewing of machining of different parts, Engine assembly, Tractor assembly and different operations after which the real product comes out. The course of action adopted to complete these activities was to first understand the Assembly machines and then the assembly of the parts .These activities were done in the supervision of the assigned engineers. Our activity also includes to keep an eye on how QA dept. is working and how this dept. make it possible the best quality product. The response we got from market dealers about the quality of the product is fairly satisfactory. We also conducted many survey in different departments during our internship at MTL regarding material flow, health and safety conditions and mishandling of tools and parts. According to our observation and analysis the reason behind the poor quality of the product is due to the poor materials supplied by the vendors and inefficiency of QA dept. We found that customer’s perception about MASSEY FERGUSON is good and irrespective of the quality customer is always willing to purchase MASSEY FERGUSON. Currently, high price is the major factor for decrease in the tractors demand. As Pakistan is an agriculture country, Govt. should implement such policies in agriculture sector that favors farmer. Govt. should right off the tax on tractor on immediate basis in order to provide support to this falling sector. University of Agriculture Faisalabad Page 3
  • Millat Tractors Limited Report on Internship at Millat Tractors Limited (MTL) We, thegroup of 07 students of B.Sc. Agricultural Engineering form University of Agriculture Faisalabad (UAF) got an opportunity to do internship in a professional engineering environment at Millat Tractors Limited (MTL). Our aim was to get training and experience about the processes happening in this industry. Name 1. 2. 3. 4. 5. 6. 7. Uni. Reg. #. 2009-ag-3108 2009-ag-3109 2009-ag-3084 2009-ag-3100 2009-ag-3092 2009-ag-3150 2009-ag-3204 AzlanZahid Muhammad Ali Usman Hassan Tanzeel-ur-Rehman NadeemAkram Haseeb Bilal Muhammad Aamir Our training schedule was as under Sr. #. 1 DATE DURATION DEPTT: REPORT TO 27-03-2013 to 09-04-2013 02 Week Marketing Division GM (Marketing) 2 15-04-2013 to21-04-2013 01 Week Manufacturing Dept. GM (Production) 3 22-04-2013 to29-04-2013 01 Week Engine Assembly Plant GM (Production) 4 02-05-2013to 09-05-2013 01 Week GM (Production) 5 10-05-2013to 16-05-2013 01 Week Tractor Assembly Plant (TAP) Quality Assurance (QA) GM (QA) Supervisor University of Agriculture Faisalabad Page 4
  • Millat Tractors Limited Internship Program Date 01-04-2013 Period Full Day Department Engine Assembly Plant 02-04-2013 Full Day Tractor Assembly Plant 03-04-2013 Full Day Dealership & workshop visit Sheikhupura and Ferozewala SajjadHussain& Imran Ayub 04-04-2013 1st Half 2nd Half Field Marketing Services Role of dealership network After sales Service network Physical inspection of specs of tractor Khalid Sandhu (SM-FM) Ali Akhtar (SM-Svc) 05-04-2013 Full Day Lahore market & customer Survey Current tractor demand & factors Azhar Noor (DGM-Mktg) Marketing 09-04-2013 Activity Responsibility Abdul Mannan KhurramA.Warraich (SM-P) Report completion from 06-04-2013 to 08-04-2013 Report Submission M. Akram (GM-Mktg.) 15-04-2013 Full Day Manufacturing Cylinder Block Line Khawaja Ali Hassan 16-04-2013 Full Day Manufacturing Cylinder Block Line (Ext) Khawaja Ali Hassan 17-04-2013 1st Half 2nd Half Full Day Manufacturing Transmission Line CNC Cylinder Head Line (Ext) Khawaja Ali Hassan 19-04-2013 1st Half 2nd Half Manufacturing Central Housing Line Lub Oil line Khawaja Ali Hassan 22-04-2013 Full Day Engine Assembly Segregation & Washing Section Engr. Hafiz Faheem 23-04-2013 Full Day Engine Assembly Engine Assembly Section Engr. Hafiz Faheem 24-04-2013 Full Day Engine Assembly Engine Test Section Engr. Hafiz Faheem 25-04-2013 Full Day Engine Assembly Rectification Section Engr. Hafiz Faheem 18-04-2013 Report completion from 26-04-2013 to 28-04-2013 HR Dept. Report Submission 29-04-2013 02-05-2013 Manufacturing Full Day Tractor Assembly Plant (TAP) Visit of Assembly Lines University of Agriculture Faisalabad Khawaja Ali Hassan SaeedIkram Muhammad Akmal Dy. Manager (Production) Page 5
  • Millat Tractors Limited 03-05-2013 Full Day Tractor Assembly Plant (TAP) Mishandling Survey 06-05-2013 Full Day Tractor Assembly Plant (TAP) Material Flow Analysis 07-05-2013 Full Day Tractor Assembly Plant (TAP) Paint section survey Muhammad Akmal Dy. Manager (Production) 08-05-2013 Full Day Tractor Assembly Plant (TAP) Rear AxleBuild Line Muhammad Akmal Dy. Manager (Production) 09-05-2013 Full Day Tractor Assembly Plant (TAP) Chassis Build Line Muhammad Akmal Dy. Manager (Production) 13-05-2013 Full Day Quality Assurance (QA) Introduction to QA dept. and its different sections Mr. Athar GM (QA) 14-05-2013 Full Day Quality Assurance (QA) Testing Labs visit Mr. Mansoor 15-05-2013 1st Half Quality Assurance (QA) CMM and UMM Said Noor 16-05-2013 2ndHalf HR Dept. Report completion from 15-05-2013 to 16-05-2013 Report Submission Muhammad Akmal Dy. Manager (Production) Muhammad Akmal Dy. Manager (Production) SaeedIkram (HR Manager) Office Stamp University of Agriculture Faisalabad Page 6
  • Millat Tractors Limited Contents Page Section Page Number Acknowledgements Executive Summary Organization Structure 02 03 11 1. Introduction 1.1. Millat Tractor Ltd 1.2. Bolan Castings Ltd 1.3. MillatEquipment Ltd 1.4. Millat Industrial Products Ltd 2. About The Company 2.1. Hierarchy Of Strategic Intent 2.1.1. Company’s Vision 2.1.2. Company’s Mission 3. History 4. Products of Millat Tractors Limited 4.1. Tractors 4.1.1. Tractor Types and Comparison 4.2. Agriculture implements 4.3. Multi-Products 5. Marketing Division MTL 5.1. Different Sections of Marketing Division 5.2. Internship Activities 1st and 2nd week 5.2.1. Day 1 Activity 5.2.2. Day 2 Activity 5.2.3. Day 3 Activity 5.2.4. Day 4Activity 5.2.4.1. Free Services details 5.2.5. Day 5Activity 6. Machining Division of MTL 6.1. Lines in Machining Division 6.2. Major Vendors 6.3. General Operations in Machining 6.4. Details of Machining Lines 7. Internship Activities 3rd Week (Machining) 7.1. Day 01 Activity 7.1.1. Cylinder Block Machining Operations 7.2. Day 02 Activity 10 10 10 10 10 12 12 12 12 14 15 15 15 17 21 23 24 31 31 31 31 32 32 32 35 35 36 37 38 46 47 47 51 University of Agriculture Faisalabad Page 7
  • Millat Tractors Limited 7.3. Day 03 Activity 7.4. Day 04 Activity 7.5. Day 05 Activity 8. Engine Assembly Plant 8.1. Segregation Section 8.2. Engine Assembly Line 8.2.1. Sub‐Assembly or Pre‐Assembly 8.3. Engine Test Section 8.4. Rectification Section 8.5. Finished Engine store 9. Internship Activities 4th Week (EAP) 9.1. Engine Build Operations 10. Tractor Assembly Plant (TAP) 10.1. Tractor Assembly Shop 10.2. Tractor Assembly Shop seven stages 10.3. Sections of TAP 11. Internship Activities 5th Week (TAP) 11.1. Task 01 11.1.1. Introduction 11.1.2. Detail Data of Mishandling Survey 11.1.3. Reasons of Mishandling 11.2. Task 02 11.2.1. Introduction 11.2.2. 1st Group Questionnaire (Segregation Section) 11.2.3. 2nd Group Questionnaire (Assembly Lines) 11.3. Task 03 11.3.1. Introduction 11.3.2. Questionnaire (Painting Section) 12. Internship Activities 6th Week (QA) 12.1.Introduction 12.2.Different types of gauges 12.3.Inspection and Testing Facilities in Labs 12.3.1. Oil and Grease Testing 12.3.2. Paint and Coating Testing Lab 12.3.3. Rubber Testing 12.3.4. Material Testing 12.3.5. Mechanical Testing 12.3.6. Metallographic and Microstructure 12.3.7. Metrology 12.4.Coordinate Measuring Machine 13. Target Setting At Millat Tractor University of Agriculture Faisalabad 51 51 51 53 54 55 58 58 61 63 63 66 71 71 72 74 81 81 81 81 82 83 83 84 85 88 88 88 91 91 91 91 91 91 91 92 92 92 92 92 93 Page 8
  • Millat Tractors Limited 14. Internal Problems Analyzed At Millat Tractors Limited 14.1.Product Development (Operational Level Problem) 14.2.Weak in Aggressive Marketing 14.3.Unsatisfied Delivery Procedure 14.4.Lack of Proper Survey 14.5.Delay Tractor Delivery 14.6.No Team Work 14.7.Centralized Decision Making 14.8.Time Consuming Procedure 14.9.No Customer Dealing Department in Real Meaning 15. Market Analysis 15.1.Problems regarding the quality 16. Reasons for Market Downfall 17. Suggestions 18. Conclusions 19. References 94 94 95 95 95 96 96 96 96 96 96 96 97 97 101 101 List of Tables & Graphs Table.1. Internship Schedule Table.2. Internship Program Table.3. Marketing Network Table.4. Customer Survey details Table.5. Production and Sales Table.6. Production against Workers Table.7. Different Ranges for Engine testing Table.8. Production and Sales (engine) Table.9. Data of Mishandling Survey 04 05 22 33 33 52 59 65 82 Graphical Representation of Production and Sales Volume Graphical Representation of Market Share across Pakistan Graphical RepresentationProduction against Workers Graphical Representation of Daily Engine Assembling Graphical Representation of Production and Sales volume (engine) Graphical Representation of Weekly Production in TAP Graphical Representation production and Sales Volume 34 34 52 64 65 90 90 Line Diagram of Material Flow Line Diagram of Engine Assembly Plant 46 64 University of Agriculture Faisalabad Page 9
  • Millat Tractors Limited 1. Introduction Millat Group is Pakistan’s leading engineering concern in automobile sector & has a history that spans almost half a century. Millat Group encompasses four major companies MILLAT TRACTOR LIMITED, MILLAT EQUIPMENT LIMITED, MILLAT INDUSTRIAL PRODUCT LIMITED and BOLAN CASTINGS LIMITED. Today the group manufacturers: Tractor under licensing agreement with Massey Ferguson, UK (owned by AGCO, USA), Diesel Engine, Diesel Generating Sets and Prime Movers, Forklift Trucks under license from M/s Anhui Heli Co. LTD. China, a range of Agriculture Implements, Gears, Batteries and Automotive castings. The company is also dedicated to customize its products as per customer’s requirements Millat Group has played a pivotal role in transfer of technology & transformation of the fledging local light engineering sector into a robust, vibrant, quality conscious Auto Vending Industry. The fact that Millat Tractor has a market share of more than 50% and indigenization level of 90% is a testament to the efforts of Millat Group over that last 47 years. 1.1. Millat Tractors Ltd Millat tractors Ltd MTL- an ISO 9001 :2008 certified company for its assembly & material testing & gauge control laboratory-is Pakistan’s leading engineering concern in automobile sector. It manufactures MF-240, MF-350, MF-260, MF-375, MF-385, MF-385 4WD, Implements, Prime movers, Forklift Truck & Power Generation Sets www.millat.com.pk 1.2. Bolan Casting Ltd In 1993, the Company in collaboration with the employees of Bolan Casting Limited (BCL) acquired the management control of Bolan Casting Limited by purchasing 51% of the Company shares offered by the government as part of the process of privatization. BCL provides major casting for Automobile Industries and also 50% of the Company requirements are met from it. Since acquisition of the control by MTL, BCL has also performed very well and has been on a growth pattern. www.bolancastings.com 1.3. Millat Equipment Ltd Millat Equipment Limited is an associated Company and was incorporated in 1993 as a private limited Company under the Companies Ordinance, 1984, and was converted in to unquoted Public Limited Company on April 20, 2004. The Company is engaged in the business of manufacturing of automotive, agricultural and industrial vehicles, parts and components thereof. www.millatgears.com 1.4. Millat Industrial Product Ltd Millat Industrial Products is a subsidiary of the Millat Tractors Limited. The Company is engaged in the business of manufacturing and sales of vehicular, industrial and domestic batteries. www.millatbatteries.com University of Agriculture Faisalabad Page 10
  • Millat Tractors Limited University of Agriculture Faisalabad Page 11
  • Millat Tractors Limited 2. About The Company Millat Tractors Limited is a Pakistan‐based company engaged in the assembly and manufacturer of agricultural tractors, implements and multi‐application products. Millat Tractors Limited (MTL) is an ISO 9002 certified company for its Assembly Plants (Tractor Assembly, Engine Assembly, and Industrial/Agricultural Products), Material Testing and Gauge Control Laboratory. It is Pakistan’s leading engineering concern in the automobile sector, that manufactures; Tractors, under licensing agreement with Massey Ferguson, UK (AGCO, USA) Diesel Engines Diesel Generating Sets and Prime Movers Forklift Trucks, under license from Anhui Heli Forklift Trucks China and A range of Agricultural Implements. The company is also dedicated to customize its Diesel Generating Sets and Prime Movers asper requirement of its Customers. The company has spread its products throughout the length and breadth of the country. Today the number of MF tractors made by MTL exceeds 250,000 while the total number of tractors in the country is approximately 500,000, giving it a market share of above 50%. In other words every second tractor in Pakistan is MF. This achievement has been made possible only through the Company’s commitment to Quality, After Sale Service, and competitive Prices. During the fiscal year ended June 30, 2010, the Company delivered 40,140 tractors. In fiscal 2010, it produced 40,178 tractors. And in this year 2013, their target is to achieve production of about 32,000 tractors. 2.1. Hierarchy Of Strategic Intent 2.1.1. Company’s Vision “Millat to be global group of companies, recognized for a range of quality products with innovative design capabilities”. 2.1.2. Company’s Mission “Millat to be market leader in agricultural tractors and machinery, building companies image through innovation and competitiveness, grow by expanding market and investing into group companies, ensuring satisfaction to customers and stakeholders and to fulfill social obligations.” University of Agriculture Faisalabad Page 12
  • Millat Tractors Limited Proposed Company’sVision: vision of Millat Tractors should be: 1. “To improve and maintain the leadership position” 2. “Millat Tractors Limited is dedicated to provide quality innovative products with the best package of guaranty and warranty for its customers whenever they are” 3. “To make Millat Tractors as leaders all the way” Proposed Company’s Mission:Mission Statement of Millat tractor should be: “ To retain and improve Millat Tractor good will, profit ability and market leadership by manufacturing the quality Tractors and machinery and making human capital more committed, productive and efficient.” 3. History Millat Tractors Limited (MTL) was established in 1964 to introduce and market Massey Ferguson (MF) Tractors in Pakistan. An assembly plant was set up in 1967 to assemble tractors imported in semi-knocked down (SKD) condition. The company was nationalized under Economic Reforms Order in 1972 and started assembling and marketing tractors on behalf of Pakistan Tractor Corporation (PTC) which was formed by the Government for import of tractors in SKD condition. In 1980 the Government decided on indigenization of the tractors and entrusted this task to PTC (Pakistan Tractor Corporation). PTC transferred this role of indigenization in 1981 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 surprising the deletion targets set by the Government. 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 1992, the company was privatized. The employees joined hands and took over the management by winning an open bid. To maintain its leadership role in tractor manufacturing in the country, MTL continues to look toward future, to identify and exploit new opportunities and to consolidate existing ones. The Tractor Assembly Plant is part of this philosophy. This plant started its production in 1992. The establishment of this modern plant not only increased production capacity to 16000 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 ranks of the major tractor manufacturing companies of the World. The Company made a strategic decision right in the beginning to bring those manufacturing facilities in-house for which capabilities did not exist in the country and for parts which required high precision and investment. 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 Engine Blocks, Sump, Transmission Case, Axle Housing, University of Agriculture Faisalabad Page 13
  • Millat Tractors Limited Hydraulic Lift Cover, Front Axle Support and Centre Housing are all being machined most successfully in-house at MTL from locally sourced castings. At MTL, we firmly believe that producing to International quality standards is the key to our continued success and growth, and our quality control department converts this belief into reality. In 1992, the company was privatized. The employees joined hands and took over the management by winning an open bid. To maintain its leadership role in tractor manufacturing in the country, MTL continues to look toward future, to identify and exploit new opportunities and to consolidate existing ones. The Tractor Assembly Plant is part of this philosophy. This plant started its production in 1992. The establishment of this modern plant not only increased production capacity to 16000 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 ranks of the major tractor manufacturing companies of the World. After successful takeover, MTL also acquired the management control of Bolan Castings Limited (a Public Limited Company specializing in intricate automotive castings) in partnership with employees of the company, in 1993. In 1992, the production of Millat Tractors was just 8,000 units per annum with variety of only 2 main products, now the annual production is reached from 8,000 units to 45,000 units with variety of 8-different main models. Moreover, the company looks to the future with optimism and plans to broaden its customer base. Consequently the opportunities are being explored in multi-application of engines and tractors in areas other than farming sectors. Mass Production of Generating Sets was started in 1994, while a 3-Ton Fork Lift Truck branded as Millat, based on TCM technology was launched in the year 2002. In addition, Millat Tractors Limited has been the regular recipient of the Corporate Excellence Award of Management Association of Pakistan and the Top Companies Award of Karachi Stock Exchange, since early eighties. MTL’s Annual Report has been acknowledged as the Best Annual Report by the Institute of Chartered Secretaries and Admin Association of Pakistan for several years. A wide range of Massey Ferguson Tractors from 50 HP to 85 HP is available to cater to the needs of farmers. These Tractors can be procured against Cash, as well as through Bank Financing. Brief Specifications of each of the Tractors are available under Tractors In Industrial Products, a wide range of Generating Sets 15 KVA to 40 KVA, Forklift Trucks (3 ton) and Prime Movers (Power packs) from 50 HP to 85 HP. Also deals in range of Generating Sets from 27 kVA to 2000 kVA. A wide range of Agricultural Implements is also available like Chisel, Disc &Mould Board Plough, Tine Tillers, Offset Disc Harrow, Ridger, Front Blade, Multi‐purpose Rear Blade, Agricultural Loader, Farm Trailer, Hydraulic Tipping Trailer, Jib Crane, Post Hole Digger, Lawn Mover, and Pneumatic Pruning Set etc. University of Agriculture Faisalabad Page 14
  • Millat Tractors Limited The biggest Spares Network ensures the availability of Genuine Parts, for the complete range of products throughout the country. Now HOLOGRAM SEAL backed by oneyear warranty ensures its genuineness. Millat also ensures to provide prompt after‐sales service to its valued customers through spread network of main and rural workshops throughout the Country. Products of Millat Tractors Limited 4. Millat Tractors Limited is manufacturing a large variety of agriculture equipment. The major share of its product is of tractors.Some of the major products of Millat Tractors Limited are as follow: 4.1. Tractors       MF-240 MF-260 MF-350 MF-350+ MF-375 MF-385  MF-385 (4WD) 4.1.1. Tractor Types and Comparison University of Agriculture Faisalabad Page 15
  • Millat Tractors Limited University of Agriculture Faisalabad Page 16
  • Millat Tractors Limited University of Agriculture Faisalabad Page 17
  • Millat Tractors Limited University of Agriculture Faisalabad Page 18
  • Millat Tractors Limited University of Agriculture Faisalabad Page 19
  • Millat Tractors Limited University of Agriculture Faisalabad Page 20
  • Millat Tractors Limited University of Agriculture Faisalabad Page 21
  • Millat Tractors Limited University of Agriculture Faisalabad Page 22
  • Millat Tractors Limited Marketing Network of MTL University of Agriculture Faisalabad Page 23
  • Millat Tractors Limited University of Agriculture Faisalabad Page 24
  • Millat Tractors Limited University of Agriculture Faisalabad Page 25
  • Millat Tractors Limited University of Agriculture Faisalabad Page 26
  • Millat Tractors Limited University of Agriculture Faisalabad Page 27
  • Millat Tractors Limited University of Agriculture Faisalabad Page 28
  • Millat Tractors Limited University of Agriculture Faisalabad Page 29
  • Millat Tractors Limited University of Agriculture Faisalabad Page 30
  • Millat Tractors Limited 5.2. Internship Activities of 1st and 2nd week 5.2.1. Day 1Activity On day 1 (01-04-2013)as per schedule we had avisit to Engine Assembly Plant where we reported to Mr. Abdul Mannan. He briefed us all the engine assembling stages & engine testing system. We spent full day over there & observed things closely. Firstly we went to segregation section where all parts are received. After that these parts go through the process of De-greasing (Trichloroethylene) & Washing (Redline). Then we moved to main assembly line where all the parts are assembled on its turn as given in Engine Build/Test Card. The workers were doing necessary quality checks where required. When the engine was completely assembled it was ready for test run. In engine testing section the engine was attached to the testing machine for a duration of 40min. The engine was tested against the different rpm & loads. The pressure in the oil galleries was tested by a software operated testing machine. If the engine passes the test it is ready to go to the Tractor Assembly Plant. 5.2.2. Day 2 Activity On day 2 (02-04-2013) as per schedule we had a visit to Tractor Assembly Plant where we reported to Mr. Khurram A Warraich. He brieflydescribes all the operations happening in Tractor Assembly Plant&also told us that the Plant is ISO certified. During this brief introduction we came to know the production capacity of the plant which is normally 58 tractors per shift. There are 2 shifts per day & one shift can produce max of 97 tractors. Around 112 persons work there in 1 shift. There are 3 assembly lines (Rear Axle Build line, Chassis Paint Line, Final Build Line).We closely observed all the assembling stations turn by turn.Whenever we found it difficult we consulted with the station supervisor. When the tractor is fully assembled it is passed to QA. Then the QA issues the fitness certificate to that tractor & if it does not match the standards it is sent back to remove the fault. If it clears all the required tests it is further passed to marketing department. 5.2.3. Day 3 Activity On third day (03-04-2013) we visited the Sheikhupura and Ferozewala dealers and their workshops. Our major concern was to know about the market share of MTL and its competitors, quality of the brand, dealership network and commissions. In these regions MTL occupied the maximum market and the share is about 100%. The dealership network is very extensive to facilitate the farmer at his doorstep and workshops are available at every 10 km distance. From today’s visit we concluded some points that are listed below. According to the dealers, the overall quality of the tractors is not satisfactory because of the reasons like the performance of Fuel Injection Pump is not good as it consumes more fuel due to University of Agriculture Faisalabad Page 31
  • Millat Tractors Limited the greater rotor clearance. The major problem is of Differential System (Crown Wheel).There is also a problem of Rear Rim distortion in shape and early rusting of the rims.Pressure is not maintained in the Hydraulic System under loaded conditions due to the manufacturing fault.The chassis is not properly painted due to which sometimes it rusts. We collected this information by visiting the dealer’s workshop by interviewing the fore-man there on duty. 5.2.4. Day 4 Activity On 4th day (04-04-2013) we dealt with after sales services regarding warranty and its terms and conditions,claim details, IFS software, rejection section and material management department.Warranty of tractor is 1 year or 1200 hours from the date of delivery. Accidental case is not accommodated. Parts can be claimed from nearby dealer’s workshop. Within first 24 hours any problem in engine the whole tractor is replaced. Within 100 hours any problem in engine the whole engine is replaced.MTL does not debit any claimed part in its account until it is anassembling fault. Claim is not provided if it is driver’s fault the team assures either it is a driver fault, manufacturing fault or assembling fault. Claims are entered through IFS software (International finance solution) which is inter connected with MMD (Material Management department), MIR (Material Issuance Requisition) and Material Rejection Department. 5.2.4.1. Free Services The free service accommodates the tuning, labour, oil filters and primary diesel filters. MTL provides 138 Rupees per hour as repair time schedule to the labour. First free service at 30 hours Second free service at 200 hours Third free service at 600 hours 5.2.5. Day 5 Activity On day 5 (05-04-2013) we had a meeting with Sir Azhar Noor (DGM-Mktg) he briefed us about marketing tactics, need of marketing and customer survey. Then we went to the Lahore market and visited the customers to know their opinion about MTL, current tractors demand, customer satisfaction level, brand equity, company’s repute, and future demand of tractors. The production of MTL is 42000 in 2011-2012 and is now reduced to 32000. The details of the customer survey are given below. University of Agriculture Faisalabad Page 32
  • Millat Tractors Limited Name M.Hanif Location Noshehra Cont.# Model 0344-6084451 MF-240 MF-375 0333-7914614 MF-240 M. Raza Khan Ziarat Muzafar Rahim Shamkay 0307-4444274 MF-240 GT Road, Lahore Area 8 Acre 5 Acre 50 Acres Remarks Fiat Engine is better than Massey. Easy starting in cold weather, brand trust and after sales services are good. problem of hydraulic pump. 2nd gear fault, no quality of tractor, paint, seals and nut bolts are not of good quality. Suggestions Improve fuel consumption Sheet metal should be of good quality Improve overall quality rather than focusing on quantity. Customer Survey details Graphical representation of the total production and sale of last five years is given below Total production and Sale per Annum Year Units Produced Units Sold 2007 27081 27127 2008 27506 27260 2009 30244 30677 2010 40178 40140 2011 42188 42011 2012 32004 32006 Production and Sales University of Agriculture Faisalabad Page 33
  • Millat Tractors Limited 45000 40000 35000 30000 25000 Units Produced 20000 Units Sold 15000 10000 5000 0 2007 2008 2009 2010 2011 2012 Graphical Representation of Production and Sales volume 70 60 50 40 Millat tractors Al-Ghazi Tractors 30 Others 20 10 0 2010 2011 2012 Graphical Representation of Market Share across Pakistan University of Agriculture Faisalabad Page 34
  • Millat Tractors Limited Machining Division 6.1. Lines in Machining Division There are nine lines in the machining division listed below 1. Axel Housing Line (Right and Left) 2. Cylinder Block Line (old) 3. Cylinder Block Line (Ext) 4. Cylinder Head Line (Ext) 5. Center Housing Line 6. CNC Line 7. Lub Oil Sump Line (240) 8. Lub Oil Sump Line (385) 9. Transmission Case Line We visited each of these machining lines in 5 days and studied the process of machining ofcasted components. In all the components the first operation was usually a milling operation to provide University of Agriculture Faisalabad Page 35
  • Millat Tractors Limited a flat surface to locate component. And then all the fixtures throughout the machining line used inside diameter for locating part also known as dowel holes. 6.2. General Operations in Machining 1. Drilling 2. Rimming 3. Boring 4. Counter Boring 5. Spot Facing 6. Counter Sinking 7. Milling 8. Tapping 9. Facing 10. Turning 11. Honing University of Agriculture Faisalabad Page 36
  • Millat Tractors Limited 6.3. Major Vendors 1. 2. 3. 4. 5. 6. 7. Bolan Casting Millat Equipment Ltd. KSB Pumps Chenab Castings Sino Diesel Sturlings Millat Electric Ltd. University of Agriculture Faisalabad Page 37
  • Millat Tractors Limited Cylinder block It is foundation of the engine. All other engine parts are assembled in or attached to cylinder block. There are two cylinder block machining lines. Old Manual machining line New Automatic machining line Old Machining line Capacity of old line is 48 parts per shift. It uses casted cylinder blocks from Karachi and machines them through a number of operations. These include Drilling, boring and reaming holes for attaching various parts such as crank and cam bores, water jacket holes etc Cylinder bores are machined and then provided surface through process of honing. Since overhead camshafts are used in the engines manufactured here, camshaft bearings holes are bored. Surfaces to which parts are attached are milled, machined and surface finished. Oil passages are drilled. Coolant passages are cleaned out. Then all seal plugs are fixed and then the cylinder block is tested for any leakages through pressure test. There is an automatic hooter attached with the test bench. If the pressure drops inside the submerged cylinder block, it indicates a leakage and automatically buzzer starts sounding. Engine cylinder liners are then fitted inside the cylinder. They save the cylinder walls from getting damaged due to continuous reciprocating motion of piston against cylinder wall. Cylinder liners are again bored and honed for smooth and accurate surface finish. New Automatic Machining line It has got a capacity of 72 parts per shift which is quite faster than the old machining line as it uses different transfer systems that perform different machining operations in a single plant thus decreasing the cycle time and increasing productivity. Cast iron blocks used here are casted in china. All the 22 operations performed are same as old line but in different sequence. Different plants and machines used in this process are i. Plant 6269 University of Agriculture Faisalabad Page 38
  • Millat Tractors Limited ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. xvi. xvii. xviii. xix. Plant 1554, a PLC operated plant and it can take 10 components at a time for machining Machine 1676 Machine 730 Machine 5307 Plant 1623 Machine 762, rear and front face finish operation Plant 5939, can have 5 cylinder blocks machined at a time. Plant 1617 oil bearings supply and bearing notches, it divides different operations thus increasing work efficiency Machine 3940, milling machine Plant 1647 this plant does 6 different operations Machine 763, plug stage M/C 6270 boring and finishing of liner bores M/C 6400 cylinder bores and honing process M/C 5202, pressure test, water gasket test M/C 1779 liner fitting M/C 747 liner boring M/C 4676 liner honing Final stage, here machined cylinder block is given a final inspection Transmission Case Machining Line Transmission case is a very important component of a tractor and it has got one semi‐automatic line. That line had been shut down for some maintenance work so the 3 CNC i.e. computerized numerical control machines were being used for its production. CNC machines were being operated by specialized operators who would enter a part program into the machine and then close the door for CNC to work. At a time, 3 components could be loaded into the CNC machine which would be machined one after the other.After machining the total weight is 77.8 Kg with grade 14 and hardness of 179‐203 BHN. University of Agriculture Faisalabad Page 39
  • Millat Tractors Limited Operations  Triplex Milling Machine This is the first operation on transmission case. Cast transmission case is fitted in machine fixture and mills the three side’s top, rear and end face of transmission case by the help of triplex milling machine.  Radial Drilling Machine In this operation top face of the transmission case is drilled by the help of radial drill machine and in this operation two dowel holes are also making for other machining purposes.  Front Face Drilling In this operation 17 drills are used to make holes on the front face of transmission case by the help of front face drilling machine.  Horizontal Milling Machine In this operation horizontal milling machine are used to finish the surface where the fly wheel rotates.  Vertical Gangue Drill Machine In this operation 18 holes are made at the rare end of transmission case by the help of vertical gangue drill machine.  Horizontal Milling Machine In this operation bottom face of the transmission case is faced by the help of horizontal milling machine.  Radial Drilling Machine It is also used to make the hole at the rear end of transmission case. These holes are made for some other purpose.  Vertical Boring Machine This operation is used to make rough bore in the transmission case holes where the different types of shafts are passed for power transmission.  Rimming Machine In this operation all the holes of transmission case are rimmed or finished by the help of rimming machine.  Horizontal Milling Machine In this operation both right and left side of the transmission case are finished by milling machine. University of Agriculture Faisalabad Page 40
  • Millat Tractors Limited  Radial Drilling Operation Machine In this operation holes are made on the both faces of transmission case by the help of radial drilling machine and drilling, boring and taping operation can be performed. After these operations final product is ready Design Office The main purpose of design office is to design the different parts of machine which is broken .It also make the different types of Jigs and Fixtures which are used on different machine to hold the work piece and guide the cutting tool. Bushes are also used on jig plates to guide the cutting tools. If any jig, fixture and machine part is broken at operation time it send to the design office where it’s designing is performed. After designing it forwarded to the tool room. Jig Jig is used to guide the cutting tool and it may or may not be used to hold the work piece. Fixture Fixture is only used to hold the work piece on machine table. Lubrication Oil Sump Line Sump is a part of a tractor engine in which Lubrication oil is present. It is filled with the bottom face of block where the Crankshaft is present. It is also called Lubrication oil pan. Material for cutting tools Carbide Operations Different types of operations performed on sump by the help of different machines according to our desire. Operation No 1 In this operation the upper face of Sump is finished by single spindle vertical Milling machine. We use any milling operation is only for level the surface to prevent leakage of oil. University of Agriculture Faisalabad Page 41
  • Millat Tractors Limited Operation No 2 In this operation side face of the sump is leveling or finishing and rear and of the sump is also milling by single spindle horizontal milling machine. Operation No 3 In this operation front face of sump is milled by the help of double spindle horizontal milling machine. Operation No 4 In this operation the other side of sump is milled by 6the help of single spindle horizontal Milling machine. Operation No 5 In this operation 5 holes are made at the front end of sump and 8 holes are made at rear end of sump by the help of double sided multispindle drilling machine. Operation No 6 In this operation holes are made at the upper face of sump by the help of vertical gangue drill machine. Operation No7 In this operation the surface where the bearing shell is placed is first bore and then finish by the help of horizontal boring & facing machine. Operation No 8 In this operation the front face holes of sump is tapped and also make ream dip hole where the quantity of lubrication oil checked by the help of two stages tapping and drilling machine. After these operations final shape of the sump is ready. Center Housing Line Centre housing is a part of a tractor which is attached to the rare end of transmission case. It is also called gear box. With the center housing right and left axle are also fitted. The casting of the center housing is made Bolan casting limited Karachi. Operations Different operations are performed on center housing to get desired shape .These operations are divided in to four sections. University of Agriculture Faisalabad Page 42
  • Millat Tractors Limited Section 1 Sr. # M/c Name Op. No Op. Description 1 2 3 4 Milling Vertical Milling Double head milling Multi spindle Drilling 20A&B 30 40 50&60 Lug facing and drain hole Mill the joint face Bolton and strainer milling Dowel hole drilling and rimming 5 Multi spindle Drilling 70,80&90 Drilling bottom and strainer faces Drilling joint face Section 2 Sr. # M/c Name Opine Op. Description 1 2 3 4 Duplex Milling Horizontal Milling Face milling Radial Drilling 140 150 160 185 Mill side cover face Mill the crown wheel clearance Mill pinion side and end face Tapping joint, Drain hole and bottom hole Section 3 Sr. # M/c Name 1 2 Face Milling Drilling Four Way Boring 3 4 Two way Boring Four Way Boring Op. No and 200,210 220&230 240 290&320 Op Description Facing front end.PTO, Drilling side cover faces and Pump pin Drill front end dowel roughing Axle bore axle faces main sleeve Bore lay shaft and PTO bore. Facing sleeve bore and pump pin Finish Axle bore. Axle bore sleeve Bore ream facing for Dowel Lay shaft and PTO bore Section 4 Sr. # M/c Name Multi spindle 1 head Multi spindle 2 head Op. No index 330&350 index 360 Op. Description Drilling Axle face Pump pin stud for holes Drilling the faces University of Agriculture Faisalabad Page 43
  • Millat Tractors Limited 3 4 Face Milling Milling 380 400 Lug sided faces Lug cutting 5 Radial drilling 410 Taping Axle and sleeve faces Axle Housing An axle is a central shaft for a rotating wheel or gear. In some cases the axle may be fixed in position with a bearing or bushing sitting inside the hole in the wheel or gear to allow the wheel or gear to rotate around the axle. In other cases the wheel or gear may be fixed to the axle, with bearings or bushings provided at the mounting points where the axle is supported. The box wing type housing is used to place the axle is called axle housing. Operations Caste axle housings take from Bolan Casting Limited after these different types of operations perform on axle housing to get its desired shape by the help of different types of machines which is shown in table given below. Sr.No 1 M/c Name Double End horizontal Boring Machine. Op.No 10 2 20 3 Double End Horizontal Boring Machine. Lathe Machine. 4 Lathe Machine 40 5 Lathe Machines. 50.Lh/Rh 6 Lathe Machines 60,Lh/Rh 30,Lh/Rh OP.Description Rough Bearing Bore Large End Rough Oil Seal Bore Small End Rough Retainer Bore Small End Finish Bearing Bore Large End Finish Oil Seal Bore Small End Finish outer Dias Of Large End, Small End Finish End Back Side Finish Small End Face Rough Large End Back Side Finish Large End Finish Spigot dia rough Small End Face Finish End Flange University of Agriculture Faisalabad Page 44
  • Millat Tractors Limited 7 Duplex Milling Machines 70 Fender Boss Mills 8 Multi Drilling Machine 80 Make Hole On Large End And Small End 9 Vertical Drilling Machine. 90 Make Hoes On Fender Face. 10 Horizontal Milling Machine. 100 Thrust Face Mills 11 Radial Machine. 110.L/H 12 Radial Machine 110.R/H 13 Radial Machine 120 Brake Shaft Holes Counter hole Shaft Lower Link Brake Shaft Hole Counter Hole Shaft Lower Link Hole And Finish Finish Of shaft Lower End Holes LH/RH. Cylinder head Cylinder heads machined here are first casted out of Cast Iron for 3 cylinder engines. They are machined to take various parts that are attached or installed in the head such as valves. Cylinder head forms the top of the combustion chamber while piston and ring form the bottom. Then they are bought in this plant to be accurately machined to be used in the engine assembly. There is one machining line for cylinder heads and its capacity is 90 components per day shift. After machining, the final weight of cylinder head is 25kg and it’s a grade 17 with hardness of179‐235 BHN. There are 2 transfer systems in cylinder head machining line. Cooling jackets, intake & exhaust manifolds are casted inside the cylinder head. Exhaust Manifold It is a set of tubes. It carries exhaust gas from cylinder head to the exhaust system. The manifold attaches to the head so the exhaust ports in head align with the tube openings. An in‐line engine has 1 exhaust manifold. Inlet manifold It is set of tubes that carry air or air‐fuel mixture from throttle valves to the intake ports in the cylinder head. On in‐line engines, the intake manifold attaches to the side of cylinder head. At the start of the machining operations casted parts are fed into a PLC operated transfer system where milling, drilling and taping of cover plate occurs. Then it is fed into 2nd plant which is also PLC operated where cover plate is drilled and reamed. Also, inlet and exhaustmanifold milling occurs here and it takes 3 min times approximately. The parts are then fed into an RLC University of Agriculture Faisalabad Page 45
  • Millat Tractors Limited based transfer system where operations like drilling, counter boring, taping, reaming and sub‐drilling occurs. Then valve seats are accurately machined so that valves accurately fit in them. Inlet hole is larger than exhaust hole to make more air come into the cylinder for combustion. 7.Internship Activities 3rd Week(Machining) Machining Division (15-04-2013 to 21-04-2013) Quality starts with machining. It is the backbone of an industry. In MTL there are two machining sections Old and Extension. In old, all components are machined expect head. In Extension Cylinder Head and Block aremachined.Machining Extension was made in order to enhance the production capacity of the plant. In old section, the operations are done manually and in Extension, all the operations are done automatically. We visited all Assembly lines and observed all operations happening on these lines. CMM Quality MM store Casting Feed on line Line inspection Gauges Quality inspector Machining Not Ok Lot Ok Engine Assembling Plant Washing Pallet Tractor Assembling Plant Line Diagram of Material Flow University of Agriculture Faisalabad Page 46
  • Millat Tractors Limited 7.1 Day 01 Activity On day 01 (15-04-2013), we went to Machining division and reported to Khawaja Ali Hassan. He gave us the general overview of machining division i.e. what is happening here, what kind of machinery we are using, what operations being carried out here and how it is happening and told us the infrastructure of the machining division. He also introduced us to the supervisor of Cylinder Block Line. Supervisor guided us and gave us all the information regarding the machines and operations being carried out at the given Machine Line. He said to us if you have any questions regarding any operation or machined part, don’t hesitate to ask me. We took a complete round of the Machine line and observed each and every operation very carefully. At the end of the day, we reported to Mr. Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined.Our objective was to understand the assembling procedure and all the operations performed. We keenly observed all the operations in the cylinder block line.The list of the operations is given below. 7.1.1. Cylinder Block Machining Operations OP 10 Machine type: Radial Drill Machine. Tools: Core Drill, Rimier, Spot face and Counter Sink OP 20 Machine Type: Milling machine Function: Head face and sump face milling OP 30 Machine Type: Radial Drill machine Function: Dowel hole (Reference hole) and sump face. University of Agriculture Faisalabad Page 47
  • Millat Tractors Limited OP 40 Function: Drilling at Sump face OP 50 Function: Chamfering at the sump face. OP 60 Function: Threading at sump face. OP 70 Function: Bearing cheeks (finishes the bearing sides of block). OP 80 Function: Rough boring of the Liner. OP 90 Function: Milling at opposite cam side. OP 100 Function: Rough milling at front and rear end. OP 110 Function: Drilling Head face, rear end and front end. OP 120 Function: Drilling and tapping at head face and sump face. OP 130 Function: Drilling and reaming head face and opposite cam side(Plug fitting). OP 150 Function: Bearing cap fitting with torque 110lb. OP 160 Function: Final milling rear and front end. University of Agriculture Faisalabad Page 48
  • Millat Tractors Limited OP 170 Function: Rough boring cam and crank bore. OP 180 Function: Finishing of crank and cam bore with tolerance 25 micron. OP 190 Function: Drilling and reaming of front end. OP 200 Function: Drilling and reaming at rear end. OP 220 Function: Milling at cam side. OP 230 Function: Notch making in crank bore for shell bearing fitting. OP 240 Function: Drilling at cam side. OP 250 Function: Drilling at opposite cam side. OP 270 Function: Drilling in crank bore and filter face. OP 280 Function: Tapping at rear end, front end, cam side and opposite cam side. OP 290 Function: Plug fitting in reference holes (Dowel Holes). OP 300 Function: Final milling at Head face . University of Agriculture Faisalabad Page 49
  • Millat Tractors Limited OP 310 Function: Final boring in Liner bore. OP 320 Function: Honing to give cross hatching. OP 340 Function: Pressure test machine to test oil leakage. OP 350 Function: Liner press machine. University of Agriculture Faisalabad Page 50
  • Millat Tractors Limited 7.2. Day 02 Activity On day 02 (16-04-2013)as per schedule we went to Cylinder Block Line (Ext). We reported to supervisor there. He gave us a brief introduction about the part being machined and told us about the production and man power at his line. We visited the Line with him and he gave us the general overview about the operations being performed there. He told us that the plant is automatic, finishing is better and production is higher than old Cylinder Block Line. We observe each and every operation there and took help from the workers. Line consists of Plant rather than OP. We observed less man power is required there as the plant is automatic. At the end of the day, we reported to Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined. 7.3. Day 03 Activity On day 03 (17-04-2013) as per schedule we went to Transmission Line, where we reported to supervisor there. He gave us the complete info about the part being machined and brief us about the operation being performed at his Machine line. He gave us info about the machines and man power of the Line. We visited each and every OP with him and observed the things carefully. In 2nd half we went to CNC line. We visited the whole section. On that day only 1/3 CNC was operated. We had a good observation of the operation of CNC. At the end of the day, we reported to Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined. 7.4. Day 04 Activity On day 04 (18-04-2013) as per schedule we went to Cylinder Head Line (Ext) and there we reported to supervisor there. He gave us a brief introduction about the part, he told us about the daily production which was 90parts/day. He told us that the plant is automatic, man power requirement is less and finishing is much better. Then we took a complete round of the Cylinder head line with him. He briefed us about all the operations being performed at the Line. We spent whole day there and observed all the operations. At the end of the day, we reported to Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined. 7.5. Day 05 Activity On day five (18-04-2013), as per schedule we went to Center Housing Line. We reported to supervisor of the line. He guides us about his line and then he took a complete round of the line with us and gave us all the information regarding the part and operations being performed at the Line. We visited the Line and observe all the operations closely and got all the reqd. information by interviewing the supervisor. In 2nd half we went to Lub Oil Sump Line. Supervisor there gave us a general overview of the part and Machine line. We visited each and every station of the Line and observed the things closely. At the end of the day, we reported to Khawaja Ali Hassan and asked him some questions about the Machine Line and the part being machined. University of Agriculture Faisalabad Page 51
  • Millat Tractors Limited Components Production/Shift Workers Transmission case Cylinder Head Axel housing Block(old) Block(Ext) Central Housing Sump(240) Sump(385) 48 90 56 48 75 55 59 19 33 15 21 38 15 33 12 12 Production against Workers Production against Workers 100 90 80 70 60 50 Production/Shift 40 Workers 30 20 10 0 Transmission case Cylinder Head Axel housing Block(old) Block(Ext) Central Housing Graphical Representation of Production against Workers University of Agriculture Faisalabad Page 52
  • Millat Tractors Limited Receiving of Engine components from the vendors Material management dept. Quality check Engine Assembly line Both 3 and 4 in‐line cylinders are assembled here. In 3 cylinder type there are engines MF240, MF260, MF350, MF350+ which are used in tractors as well as fork lifters, generator sets and prime movers. 4 cylinder Engines of MF375, MF385, MF385‐4WD are assembled which are used in big tractors. Engine build card is followed in the engine assembly plant. Each type of engine has its own colored card.All the operations listed on the build card are duly followed and each worker signs in the build card corresponding to each job that he performs. So any fault could be traced back to that worker. There are total 10 operations on the main assembly line for building up an engine. Production Capacity of EAP plant is 59 engines of 3 cylinder type and 36 engines of 4 cylinder type per shift and there is double shift for the engine assembly plant. Production is increased on demand. Engine assembly plant (EAP) has been divided into 4 sections which are as follow 1. Segregation 2. Engine Assembly Line 3. Engine testing or Test shop 4. Rectification Section University of Agriculture Faisalabad Page 53
  • Millat Tractors Limited Vapor degreasing is a surface finishing process. It involves solvents in vapor form to cleanse the workpiece in preparation for further finishing operations. The acting principle behind the vapor degreaser process is that the solvents will dissolve the contaminants on the workpiece and remove them by dripping off the part. A basin of solvent is set up with a heating coil to bring the solvent to boil. As the solvent evaporates it rises to the fill‐line in the chamber, above this is air with a much lower density than the solvent. This contains the vaporized solvent in a closed space where the workpiece is placed. The solvent condenses on the more frigid workpiece and the now liquid solvent dissolves the greases on the part. With the impurities contained in the liquid beads, the solvent runs off the part. Some systems are designed to capture and reclaim this solvent, making the process much more economical. University of Agriculture Faisalabad Page 54
  • Millat Tractors Limited 8.2. Engine Assembly line Engine Assembly line is a line in which all the parts of engine is fitted with Engine block. This line starts with block and complete on full engine. The assembly line is divided in to different operations which are given below. The operation line starts from operation 10 and completes on operation 100. Operation No 10 Operation No 10 is divided in to three main steps. 1. In this step Head Studs, Shells, Crankshaft, Bearing caps and Thrust washers are build on engine block . 2. In this step Main Bearing caps is fitted with bolts and give torque, Tightening the Head Studs and Sump Studs, Bearing Shells, Drain plug and Water Plug build in the block. 3. In this step Oil Gallery Plug, Main Oil Seals Dowels and Water Plug fits, Tightens the bolts of Main Bearing caps and after this block is fitted on trolley. Operation No 20 Operation No 20 is divided in to two main steps 1. In this step Punch the Engine No,Tight and fits the Oil Pump and fits the Timing Case with the help of bolts. University of Agriculture Faisalabad Page 55
  • Millat Tractors Limited 2. In this step Hub Dowel, Idler Gear Hub, Timing case Gasket, Oil Pump Gear and lock is fitted. After this align the Timing Case and tight the all bolts and give torque Operation No 30 Operation No 30 is divided in to two main steps. 1. In this step fit the Main Oil Seal with Gasket, fit and tight the Water Connection,fit the connecting rod shells and fit the Piston in the Block. 2. In this step tight the Connecting Rod and give torque, fit and tight a stress pipe and fits the Main Oil Seal bolts. Operation No 40 Operation No 40 is divided in to two main steps. 1. Fit the idler gear, Came Shaft with gear and Elbow, fit the Fuel Injection Pump,lock the Idler gear and “D” mark align the came and gear. 2. Fit and align the Timing mark, tightening the Fuel Pump and Came bolts and give torque and check the Back Lash of gears. Operation No 60 Operation No 60 is divided in to three main steps. 1. Fit and tight the Cylinder Head, alignment of Sump, joint the Front over Rear Half moan and fit and tight the drain Plug 2. Torque the Cylinder Head bolts, compounding the Sump and tighter the bolts of Sump. 3. Fit the Sump and torque the bolts of sump. Operation No 70: Operation No 70 is divided in to two main steps. 1. fit the Rocker Shaft assembly and torque and adjust the tappet, fit the Dip Stick and Dip Stick Tube and oiling the Rockers Levers. 2. Fit the Induction many fold and Lift Pump and tight the bolts and give torque, fit the Oil Pressure Pipe. Operation No 80: Operation No 80 is divided in to two main steps. 1. Joint the Timing Case, fit the Screws, fit the Bracket and Levers and tight the all Screws. 2. Fit the Injector, Pressure Pipes and Hose Pipe with clamps, tightthe Timing Case Screws and give torque. University of Agriculture Faisalabad Page 56
  • Millat Tractors Limited Operation No 90: Operation No 90 is divided in to two main steps. 1. Fit the Oil Filter Assembly, Exhaust Many Fold and Returning Pipe , tight the Injectors Nuts and fit the Front Lifting Hook. And also fit the Thermo state Valve. 2. Fit the Crank Pipe and Breather Pipe, tighten the Hose Pipe Clamps, Fit and tight the Tappet Cover and tighten the oil filter. Operation No 100: Operation No 100 is divided in to three main steps. 1. Open the Engine Fit the Water Outlet Plugs and Fit the Transmission Studs. 2. Fit and tight the Adopter Plates bolts, Fit the Fly Wheel Bolts and torque and also tight the Crank Pulley bolts. 3. Fit the Adopter Plates bolts and torque and also fit and torque the Fly Wheel bolts. University of Agriculture Faisalabad Page 57
  • Millat Tractors Limited Sub‐Assembly or Pre‐Assembly On one side of the main assembly line there is a sub‐assembly section that assemblesdifferent key components together and then these assembled components are installed inthe engine on main assembly line. This speeds up the process, reduces cycle time andincreases efficiency of the process. After these operations the Engine is ready.Now after these operations Engine is forwarded to the Test Shop. Engine Test Section: University of Agriculture Faisalabad Page 58
  • Millat Tractors Limited There is a complete testing setup for every engine that comes out of the main assembly line.Here engine is thoroughly checked for its working and any possible faults such as enginenoise, rpm, loading, leakages, exhaust smoke etc. Different ranges are given below . Tester 1st Time 2ndTime Time R.P.M Brake Power (minutes) (NM) (K.W) Low Idling R.PM 750 750 5 1000 50-55 5.8 Low Idling Oil Pressure 5 1500 60-65 9.4 High Idling Oil Pressure 2470 2470 5 1500 90-95 14.9 Tappet setting .010” .010” 20 2250 146-160 35-37 Different Ranges for Engine testing In the Test Shop there are different types testing beds which are used for testing the Engine R.P.M, Oil leakage and tappet setting University of Agriculture Faisalabad Page 59
  • Millat Tractors Limited In engine build card different performance factors of every engine are entered after testingand if there is an error found then engine is referred to the rectification section.This table shows the ranges of testing values. If the engine below this values then the engine is passed but if the values greater than the engine is rejected and forwarded to the Rectification. University of Agriculture Faisalabad Page 60
  • Millat Tractors Limited Rectification Section In this section the fault in any tested engine is removed using standard procedures. If thereis any part that needs to be replaced or any adjustment in existing component is neededthen it is carried out here and then again sent to engine testing shop for final inspection. Fuel Leakage: Check Fuel injection pump, Fuel injection pressure and Fuel lift pump. University of Agriculture Faisalabad Page 61
  • Millat Tractors Limited Water Leakage: Check Cylinder Head rear plate. water pump, Head Gasket, Water Plug, Drain Plug and Oil Leakage: Check Tappet Cover , Cylinder Head Gasket , Front rear half moan joint , Sump joint , Timing Case cover , Rear end oil seal , Oil filter , Drain plug , PTO plate , Pressure pipe and elbow pipe and Timing case cover seal. Any type of sound: Check Timing gears and Knocking. Appearance: Check Missing and Vibration. Or any types of disturbance which create in engine are rectifying in the Department and forwarded to the Test Shop. University of Agriculture Faisalabad Rectification Page 62
  • Millat Tractors Limited Finished Engine Store All the engine that passes inspection test are sent to Finished engine Store and further moved to Tractor Assembly Plant according to production requirement 9.Internship Activities 4th Week (EAP) Engine Assembly Plant (22-04-2013 to 29-04-2013) Engine is the prime mover for power generation. And during its assembling it has to undergo 5 sections namely Segregation, washing and cleaning, assembly line, test shop and rectification sections. Several quality checks are performed during assembling by line inspection gauges to ensure the quality.In 4th week of our training, according to our schedule we went to Engine Assembly Plant, where we reported to Hafiz Faheem. He gave the general overview of Engine Assembly Plant. We visited each section on Engine Assembly Plant with him. He gave us the brief introduction about Segregation, Washing and Cleaning, Engine Assembling Line, Test Shop and Rectification Sections. Our objective was to study and examine all the operations keenly. We completed our objective that was assigned to us. University of Agriculture Faisalabad Page 63
  • Millat Tractors Limited Not Ok Washing and Degreasing Segregation OP.10 OP.20 components OP.30 OP.40 OP.50 OP.60 OP.70 Tractor Assembling Plant Ok EngineTest section Fed to Line OP.80 OP.90 Line Diagram of Engine Assembly Plant Weekly Production in Engine Assembly Plant 57 60 54 53 51 50 46 40 30 21 17 20 10 9 11 11 13 9 9 6 3 0 23-04-2013 24-04-2013 25-04-2013 MF 240 MF 375 26-04-2013 29-04-2013 Gen Set Graphical Representation of Daily Engine Assembling University of Agriculture Faisalabad Page 64 OP.100
  • Millat Tractors Limited Graphical representation of the total production and sale of last six years is given below Total production and Sale per Annum Year Units Produced Units Sold 2007 27081 27127 2008 27506 27260 2009 30244 30677 2010 40178 40140 2011 42188 42011 2012 32004 32006 Production and Sales (Engine) 45000 40178 40140 42188 42011 40000 35000 32004 32006 30244 30677 30000 27081 27127 27506 27260 2007 2008 25000 20000 15000 10000 5000 0 2009 Units Produced 2010 2011 2012 Units Sold Graphical Representation of Production and Sales volume (Engine) University of Agriculture Faisalabad Page 65
  • Millat Tractors Limited Our main objective was to understand the assembling procedure and all the operations performed. We keenly observed all the operations in the assembly plant the list of the operations is given below. 9.1. Engine Build Operations 1. OP 10 The major functions performed in this are Build card Crank shaft Bearings Caps and thrust washers installation. Punching of block number Main bearing caps Bearing shells Trolley support University of Agriculture Faisalabad Page 66
  • Millat Tractors Limited 2. OP 20 The major functions performed in this are Bench the engine number Fit the idol and cam shaft gears and torque them Tighten the Timing Case and bolts along with alignment Build the Water-Let and Hub Build the FIP and Burge Piece Timing Case and bolt them 3. OP 30 The major functions performed in this are Build the Main Oil Seal and Bearing Shells Insertion of piston in cylinder hole Tighten the Cone Rod and torque it Bolt the Main Oil Seal 4. OP 40 The major functions performed in this are Build the pipe of Balancer section Alignment of Balancer Fit the Balancer and Balancer Section Pipe Build the Fuel Pump Stud the Sump Build the Fuel Pump Gear Make a timing mark on gear and torque it Tighten the balancer and torque it Check the Back-Lash 5. OP 60 The major functions performed in this are Build the Cylinder Head and tighten it Sump alignment Build the Sump Tighten the pump and torque it Build the Drain Plug and tighten it University of Agriculture Faisalabad Page 67
  • Millat Tractors Limited Bolt the sump Build the House pipe Torque the Cylinder head 6. OP 70 The major functions performed in this are Build the Dip Stick Tube and Dip Stick Insert the Rocker Shaft Assembly and build the Breath pipe Tappet adjustment Build the Lift pump and Push rod Build the Tappet cover, Exhaust cover and Plate and tighten them 7. OP 80 The major functions performed in this are Build and align the Timing case Cover and torque it Build and tighten the Injectors and tighten them Fit the Pressure pipe and tighten it 8. OP 90 The major functions performed in this are Build and tighten the Crank pulley Build and tighten the Induction manifold Build and tighten the House pipe Build and tighten the Side Plate and torque them Build the Cooler and Oil Filter along with head Build the Return pipe and Water Out-let Build the Thermostat and tighten it 9. OP 100 The major functions performed in this are Pull down the engine on trolley Build the Bracket and Fan pulley and tighten them Tighten the Pulley an torque it Build and Tighten the Flywheel and torque it Open the supports of engine Bolts the Flywheel University of Agriculture Faisalabad Page 68
  • Millat Tractors Limited Whenever we faced any problem regarding any part or operation, we asked supervisor there, he guide us properly and is always willing to help us. We observed the things and collected helpful information by interviewing the staff at Engine Assembly Plant. Each engine when assembled is tested for set duration of time in Engine Test Section on Test Bed. There are 12 Test Beds in Engine Test Shop. Engine is attached on the Test Bed and different load is applied for different interval. University of Agriculture Faisalabad Page 69
  • Millat Tractors Limited If the engine fulfills the quality standards, it is ready to go to Tractor Assembly Plant but if it fails it is sent to Rectification Section. QA dept. in Engine Assembly Plant is working efficiently to maintain the quality of the product in order not to letdown the MTL. There is a complete testing setup for every engine that comes out of the main assembly line.Here engine is thoroughly checked for its working and any possible faults such as enginenoise, rpm, loading, leakages, exhaust smoke etc.In engine build card different performance factors of every engine are entered after testingand if there is an error found then engine is referred to the rectification section. University of Agriculture Faisalabad Page 70
  • Millat Tractors Limited Tractor Assembly Plant(TAP) This is the main plant of Millat Tractors. All the components of tractor carried from different locations are assembled here.In this plant all the parts of thetractor are assembled in assembly lines. We worked as interns here for five days. Productioncapacity of 3 cylindersis 59 tractors per shift and for 4 cylindersit is 36 tractors per shift.They work in double shift. 10.1. Tractor Assembly Shop Start from axle assembly on one side and receive a computer tractor from the other side. The whole assembly process is manual. The process can be categorized in seven stages narrated below 1. Axle assembly 2. Plough assembly 3. Plough testing plant University of Agriculture Faisalabad Page 71
  • Millat Tractors Limited 4. 5. 6. 7. Gear box assembly Engine attachment Washing and drying assembly Final stage 1) Axle Assembly This is the first stage in tractor assembly. There are two axle assembly lines, one for right axle and other for left axle. Axle is fitted in axle tube which is followed by brake assembly. On week end of the axle roller bearing is placed. The further operation on axle assembly line is the fixing of left and right axels with center housing. Centre housing is one of the main components of the tractor. Mainly it comprises of crown wheel and pinion mechanism, six different gears, hydraulic pump and power transmission shaft. 2) Plough Assembly It contains hydraulic cylinder, piston and plunger assembly. Cylinder contains hole in its bottom, through which the pressurized oil from the hydraulic pump enters which operates the plunger assembly which governs the rise and fall of plough. The pressure of the hydraulic pump is variable and its control is provided with two levers through which the rising and falling speed of plough is controlled. 3) Plough testing plant Perfection of plough assembly is must. As plough is one of the main functions of the tractor. So its correctness is checked immediately after its fitting. The known weight which, is decided by considering factor of safety, is being lifted by this. The oil leakage and the correct rotation of PTO shaft is also checked here. If it is working well then it is sent for further operations otherwise rectif8cation is done on finding a fault. 4) Gear box Assembly The gearing of the tractor is controlled through gear box, it is a bit complicated and contains many gear trains placed in the gear box housing. After gear attachment, levers for the gear alteration are fixed on the position provided at the top of the gear housing. 5) Attachment of Engine The most important part “the engine” of the tractor is attached here. Engine is attached and the contacts are provided to the gear box 6) Washing and Painting Plant More than fifty percent completion of the task is done up till now. Here the main body of the tractor is washed for the removal of any dust particles or other contaminants attached during University of Agriculture Faisalabad Page 72
  • Millat Tractors Limited previous stages. This is followed by drawing of this assembly, which is followed by the coating of this assembly with paint. 7) Final Stage Now the final touch is given to the tractor assembly which comprises of the wiring, attachment of head light, seat, safety covers, fuel tank, radiator, battery etc 8) Pre-delivery Testing Now the tractor is ready for trial run, after having trial run, any fault e.g. leakage of oil, missing of any nut or bolt, tightening of nut or bolt etc is identified and rectified. NOW THE TRACTOR IS READY TO SEND TO THE MARKETING DIVISION 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. Power Take-Off Systems and Hydraulics In addition to towing an implement or supplying tractive 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. University of Agriculture Faisalabad Page 73
  • Millat Tractors Limited 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. Manual Transmission Manual transmission comes in two basic types: 1. 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", 2. and the now common constant-mesh gearboxes which can include non-synchronized, or synchronized / synchromesh systems, where diagonal cut helical (and sometimes doublehelical) gear sets are constantly "meshed" together, and a dog clutch is used for changing gears. On synchromesh boxes, friction cones or "synch-rings" are used in addition to the dog clutch. Automatic Transmission Epicyclical gears or Planetary gears 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. 10.2. Sections of TAP This will define the different processes being held in different sections of TAP.This is the most important plant of the tractor industry. There are four important sections of tractor production. These are as follows: Segregation and Degreasing Assembly line Sheet Metal Washing and Paint Shop Test shop/Rectification area University of Agriculture Faisalabad Page 74
  • Millat Tractors Limited 1) Segregation and Degreasing In this section, components of tractor are counted and supplied to all stages of productionin racks through trolleys and folk lifters etc. Components are vapor degreased here by 80 degree University of Agriculture Faisalabad Page 75
  • Millat Tractors Limited centigrade of water and by blowing of air. Cleaning, packing and opening ofwrappers of components are done here. 2) Assembly line After segregation and degreasing of components, they are distributed to the assembly line. There are 10 stages in assembly line as op 10‐100. But we will discuss only the major three stages ofassembling and paint of our concern product i.e. Tractor. a) Rear axle build b) Chassis build c) Final build a) Rear axle build In rear Axle building of a tractor there are five main assembling are being done. Theseinclude crown wheel assembly, center housing assembly; axle housing assembly; axle shaft assembly and hydraulic lift cover assembly. • In crown wheel assy. Crown wheel and pinion both are assembled and torque by workers and are passed to the center housing section by roller conveyors. Preloading test of pinion is done here in this section. Two presses are used here for press fitting. • In center housing assy. Pinion and crown wheel are assembled by hammering and nut bolt. PTO shaft is assembled and fitted in center housing. Two plates named cover plate and response plate are attached to the left and right of center housing. And then hydraulic pump and coupler gears for running PTO shaft are assembled in it. • In axle housing assy. Both left and right housing are assembled. Left and right differ from each other in a sense that right one has differential paddle attached to it. And left one is simpler in assembling than right axle housing. Here brake shoes are assembled and attached. Lather brake is for MF240, manual disc brake is for MF260 and MF350. While hydraulic disc brakes are for MF375, MF385 and MF385 4WD. In hydraulic brakes, reduction units are used. And then complete housing is passed to the conveyor. • Axle shaft is assembled then to attach both axle housings. • In hydraulic lift cover assy. It is assembled to the top of axle housing. Hydraulic System Test Rig Hydraulic lift cover is then checked at this section to ensure that all the lifting components are working correctly. b) Chassis build After the rear assembly is mounted on trolley, chassis building is started. It includes assembling and testing of many important components of tractor. Its stages include Gear box assembly, Steering assembly, Transmission assembly, Engine assembly, Foot board assembly, Brake University of Agriculture Faisalabad Page 76
  • Millat Tractors Limited paddle assembly, Front support assembly, Fuel tank bracket assembly and Link and York assembly. These all are done on moving conveyor which have 10 tractors per hour. In Steering assembly, first of all steering is assembled. Manual steering is for MF240 and MF260 and Hydraulic steering is for MF350, MF375 and MF385 model. In Link and York assembly, links and York’s are attached to the chassis. In Gear box assembly, 8 gears including forward and 2 reverse gears are assembled. In tractors crush gearbox is used. Gear box is also tested here. In Transmission assembly, assembled gear box is fixed inside it. Both PTO shaft and lay shaft are attached on front and back sides of transmission case. In Engine assembly, first of all engine is prepared in sub‐assembly where PTO plate, clutch plate and input plate are attached to the engine. And then engine is fixed to the chassis. In Foot board assembly, assembled brake paddle and foot board are attached. University of Agriculture Faisalabad Page 77
  • Millat Tractors Limited In Front support assembly, complete and assembled front support from sub assembly is brought and is attached to the front portion of the chassis. After chassis assembly is done, whole chassis is sent to the gray paint shop, where at high temperature of water chassis body is rinsed and degreased in booth # 1 and then is warm air dried, and then is gray painted. And it is then sent to the oven for further drying and phosphating. Pressure plate and clutch plate are bolted in the flywheel of the engine. Transmission case and engine are attached to the center housing on the moving DOCK. Then front support,footboard, steering,brake paddles and brackets for fuel tank are attached. c) Final build The complete chassis is now ready for the final build assembly in line 3. Here many important components are assembled and then the complete tractor is ready for further testing and rectification if necessary.The final major components of tractors include radiator, fuel tank, wiring, seat assembly, lower link chain, bulk head, dash board, accelerator, battery, wrapper, hood top, steering, fender, front grill, front tire and rear tire . Radiatorfor 240, 260 and 385 are all different and is assembled by nut and bolt in the first stage of assembling in line 3. Fuel tankfor 240, 260 and 350 are same and made up of steel with a capacity of 48‐ 50 liters. And the fuel tank for 375, 385 and 385 4WD is made up of plastic or ABS material with a capacity of about 75‐85 liters. Wiringis completed here. It is of three types that are main harness, back to front and front to back. Seat assemblyis completed is sub assembly and is ready to be fixed. Seat is same for all models. Lower link chain is assembled then. It is of golden color, is used to prevent unnecessary movement and maintains level. Bulk head is that where dash board is attached. Brakes, clutches, master cylinder, steering pump and orbital unit are all placed inside it. It is for big tractors. Dash board is assembled then. It is different for 240,260 and 350. Tachometer, hour meter, rpm meter indicator lights and neutral lights are all attached to it. It shows no mileage as in cars. Both hand and foot accelerators are attached in this stage. Battery is same for all tractors. Vaseline is used for assembling. In low power engines battery is attached in the front of the tractors. And for high power it is mounted below the foot board. Wrapper is of silver color. It is same for 240 and 260, but different for other models. Hood top is different for all models Then steering is assembled. University of Agriculture Faisalabad Page 78
  • Millat Tractors Limited Fender from paint shop is fixed. Bracket is different for all models. Front grill is attached. It is for air intake. Rear tire has got treads. Tire size is different for different models. Front tire has got grooves on it . 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. 3) Sheet Metal Washing and Paint Shop Chassis paint shop contains three sub sections. 1. Grey paint on chassis 2. Red/green color coating 3. Heating oven The chassis is first painted manually after sealing the necessary holes and screws. In other sections, Red/Green color 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. During its assembling in line 3, there is a sub assembly for painting metal body of tractor. It is called red oxide metal paint shop. Here the metal sheets are moved on conveyors by hangers. First they are washed, dried at high temperature and then is manually gray painted, then is sent to the oven for phosphating and drying, then it is painted red oxide from one side, and then again dried in oven and this process goes on till we receive clear red oxide color of sheet from both sides. 4) Test Shop/ Rectification Area 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.In this area tractor is thoroughly checked and tested. The entire nuts, bolts, gauges, meters, oil and fuel lines are checked. Roller machine test is done for 10 minutes to check the tractor on high RPM and to check any leakage and brakes are adjusted. After maintenance,tractors are also sent to road tests. Touch Up Paint Booth If paint is missing on any of the components, it is repainted in touch up paint section. University of Agriculture Faisalabad Page 79
  • Millat Tractors Limited Pre-Delivery Inspection(PDI) PDI and segregation are not considered the part of TAP but they are former and later stages of TAP.This is basically the job of marketing department. Before handing over the tractor to its owner, it is assured that it is functioning properly and having no problem. This department again performs total checkup of tractor and if there is any fault then it is sent to major rectification department. After minor and major rectification and also after passing the paint n retouching section, pre delivery inspection is done on the tractor in a PDI dept. 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. University of Agriculture Faisalabad Page 80
  • Millat Tractors Limited 11. Internship Activities 5thWeek (TAP) 11.1. Task 1 To know about the mishandling in different sections of TAP and to analyze the reason behind that 11.1.1.Introduction Mishandling is a very big issue in any industry and its cost is always beard by the industry thus the profitability is decreased. Mishandling can be narrated as the miss use of the tool or the miss use of the component to be assembled both are under the issue of mishandling. Millat lost 2.5 million as mishandling expenses in Tractor Assembly Plant only which is a big loss. We the internees were asked to conduct the survey in Tractor Assembly Plant on Mishandling. Our main concern was to know about three main questions and to help understand the reasons and to give suggestions to limit the mishandling losses. Q.No.1. Do the worker know about what is mishandling? Q.No.2. Why mishandling occurs? Q.No.3. Suggestions by the workers i.e. how we can minimize this mishandling. On our first day, we went to Tractor Assembly Plant where we were asked to conduct a survey on mishandling. We were advised by Mr. Akmal i.e. how we can conduct a survey and what questions we should ask to the workers. We went to the workers and asked them the questions. As a matter of fact 40% of the workers even don’t know about the concept of mishandling, as our moral duty we told them that what is mishandling in actual. 11.1.2.Detailed Data of Mishandling The below given data will help in understanding the current status of the workers on mishandling. This will show that either the worker understands mishandling or not and some of the major reasons of mishandlings like the roll of expert or newly appointed worker in mishandling, either the correct way of rejection is adopted or not, inspector sincere to MTL or not i.e. the part that should go to the vendor due to manufacturing mistake is debited to vendor or MTL by showing mishandling case, mishandling due to press machine malfunctioning and either the inspector is available on the line all the time or not. So this all data is tabulated below. University of Agriculture Faisalabad Page 81
  • Millat Tractors Limited Survey Questionnaire Sr. #. Worker familiar with the concept of mishandling 01 02 Yes Yes Reasons why mishandling occurs Lack of way of Inspector Press Timely Rejection of Expertise Rejection bias to machine the component of the of the vendor or malfunct Worker Inspector laborers compone sincere in ioning nt rejection Yes Improper Sincere No Yes Yes Yes Improper Sincere Yes Yes Yes 03 Yes Yes Proper Sincere No No Yes Yes 04 No Yes Improper Sincere Yes Yes Yes Yes 05 Yes Yes Proper Sincere Yes No Yes Yes 06 Yes Yes Proper Sincere No Yes No No 07 Yes Yes Proper Sincere Yes Yes Yes Yes 08 Yes Yes Proper Sincere Yes Yes Yes Yes 09 No Yes Proper Sincere Yes Yes Yes Yes 10 No Yes Proper Sincere Yes Yes Yes Yes 11 No Yes Proper Sincere Yes Yes Yes Yes 12 No Yes Proper Sincere No Yes Yes Yes 13 No Yes Proper Sincere Yes No Yes No 14 Yes Yes Improper Sincere Yes Yes Yes Yes 15 Yes Yes Improper Sincere No Yes Yes Yes Inspector Availability Yes Yes Data of Mishandling Survey 11.1.3.Reasons of Mishandling The following are the main reasons of mishandling. 1. Above all the reasons one thing in common was that newly appointed worker always do losses as he is unfamiliar with the system, so less expertise of the laborer is the main reason in mishandling. We also came to know that some appointments of workers on reference are not right some of those workers are not fit for the job hence they greatly mishandle tools and components as they are not eligible. 2. QA should not allow the bad quality piece fed to assembly line, once it is assembled it becomes mishandled willingly or unwillingly. 3. Due to over burden of production mishandling occurs. University of Agriculture Faisalabad Page 82
  • Millat Tractors Limited 4. Duties changing again and again cause mishandling as every worker best knows his work. 5. While making fun at working time, sometime tools become the part of their fun. 6. It occurs due to low quality of tools used. 7. By the worker i.e. use of improper tool for specific function. 8. By the negligence of the worker like sometimes the threads of the nut and bolt mismatch and it is tightened so both the parts become waste. 9. Millat Tractors Limited purchases low quality parts which breaks during working so it also becomes the case of mishandling. 11.2. Task 2: To know about the material flow through different sections of TAP and analyze problems regarding material flow 11.2.1.Introduction: On day 2 (07/05/2013), we reported to Muhammad Akmal Dy. Manager (TAP). He gave us a brief description about the productivity of the plant. The overall productivity of the plant depends on both input resources and output of the plant. The productivity can be increased either by increasing the output or decreasing the input resources. Input resources includes Man Material Machine Tools & Equipment Method We have already completed our task related to MAN input on day 1. On 2nd day, we were given a task on material input. As per given instructions we prepared 2 questionnaire. 1 for segregation section and the other 1 was for plant. We made two groups consisting 3 members each.1st group went to segregation dept. and 2nd was on Assembly lines. We interviewed some of the workers and supervisors there. They responded to our questionnaire to the level of their knowledge. The questionnaires are given below. University of Agriculture Faisalabad Page 83
  • Millat Tractors Limited 1st Group Questionnaire (Segregation Section) Q.1. What is the purpose of Segregation section? The purpose is to receive the part from MM according to the production requirement and then deliver it to its work station. Q.2. Which is the 1st station for vendor’s part? Quality Assurance (Q.A) .If the parts satisfy the standards then it is moved to Material Management (MM) Q.3. Why washing is done of vendor’s parts? To remove oil and grease on the parts Q.4. Which chemical is being used for washing the parts? Tri-clone. The chemical in the tank is replaced after every 15 days. Q.5. Washing is done of all components? If not, then of which components? No, washing is done on some specific components; the parts involve in motion (Gears, Lift covers, Central housing parts) Q.6. What is the washing process used in segregation section? Tri-clone is heated at a temperature of 82-85◦C .Fumes are produced and removes oil and grease. Q.7. What will be the effects if the washing is not done? If washing is not done then, the chips remain on the parts, get mixed with oil and reduces the part’s life. Q.8. Is segregation section facing any problem regarding stillage and rack lifters? No,there is no such problem. Everything is fine. Q.9. Are the parts placed properly in the bins and racks or not? Yes, parts are placed properly and there is no piling of parts. Segregation section is performing the duties at its best. Q.10. Are the parts delivered to stations on time? If not, then what are the reasons? Normally this doesn’t happen but sometime it happens because of on non-availability of the fork lifter or Stillage University of Agriculture Faisalabad Page 84
  • Millat Tractors Limited 2nd Group Questionnaire (Assembly Lines) Q.1. Storage Bins are enough in number? Worker 1 2 3 4 Remarks No Yes Yes No Remarks: Storage Bins are not enough in every section. Some line facing severe shortage of bins. Due to this, parts are placed on the floor that results in Mishandling of parts For higher productivity, the number of bins should be increased. This will reduce Mishandling and time of production. Q.2. Is segregation section doingMishandling of the parts? Worker 1 2 3 4 Remarks Yes Yes Yes No Remarks: Workers from Segregation section just throw the parts in the bins that might results in damage of some parts. This results in poor production cost. Authorities should consider this factor seriously and proper training should be given to worker to avoid mishandling University of Agriculture Faisalabad Page 85
  • Millat Tractors Limited Q.3. Are Rejection Bins are enough in number? Worker 1 2 3 4 Remarks No Yes Yes No Remarks: Rejections bin are placed apart. It took some extra time to take the rejected parts to the rejection bin that effect production badly. It should be provided in easy reach of each station Q.4. Different colored bins for different model’s part should be introduced or not? Worker 1 2 3 4 Remarks No No No No Remarks: It would be great if this happens but it could never be happened in this scenario because presently the space available is not enough to accumulate many bins at each station. Q.5. Are the parts placed properly in the bins and racks or not by Segregation section? Worker 1 2 3 4 Remarks No No No Yes University of Agriculture Faisalabad Page 86
  • Millat Tractors Limited Remarks: Workers from segregation section don’t drop or deliver the parts to each station. They just throw in into the Storage bins. Shortage of fork lifters or stillage forces the workers to do their work quickly in order to keep the production running. In addition, training should also be given to the workers to avoid mishandling of the parts. Q.6. Are the parts delivered to stations on time? If not, then what are the reasons for delay? Worker 1 2 3 4 Remarks: Remarks Yes Yes Yes Yes Usually it doesn’t happen but sometimes it does happen. The main reason for this is Shortage of Fork lifter and Stillage. The production rate is very fast, for this material flow should also be fast but the quantity of fork lifters and stillage doesn’t respond to the number of work stations. Shortage of racks is also another factor for the delay of parts. Station having only one rack of each part suffers the most. When the rack is emptied, then parts will be delivered by taking the rack to the segregation section. A lot of time is consumed in moving the racks that slows down production. University of Agriculture Faisalabad Page 87
  • Millat Tractors Limited 11.3. Task 3: To know about the painting section and analyze problems regarding workers and painting quality. 11.3.1.Introduction: On day 3 (08/05/2013), we reported to Muhammad Akmal Dy. Manager (TAP). He gave us task to get familiar with the painting section and to know about the current painting quality, instruments used, processes carried out, problems regarding theworker’s health and safety and to find out the weaknesses and reasons behind poor worker health in that section. He told us that painting section is very critical section regarding the worker’s health. Two of the workers are already suffering from Lungs infection. Our task was to find out the reasons behind that. We prepared a questionnaire regarding the painting processes, equipment used and prevailing health and safety conditions. The questionnaire is given below Questionnaire (Painting Section) Q.1. What are the components painted in this section? Red Gray Fender, Fender Plate, Shroud Fender Support Dash board, Dash board Tank clamp path Top hood, Side hood Channel Strip Side panel Q.2. Silver Wrapper Either spray paintguns are available or not in this section? Yes, guns are available in this section. Infact are surplus in number. Q.3. Either spray paint guns are of good quality or not in this section? Yes, guns are of good quality made by Bashir Sons. Q.4. Either safety nasal mask are available or not? Yes, the masks are provided by MTL keeping in view the safety of the workers. University of Agriculture Faisalabad Page 88
  • Millat Tractors Limited Q.5. Either worker wears safety nasal mask or not? No, Workers don’t wore. Masks in summer but in winter they often wore it. Q.6. What is the effect of paint on the health of worker if the safety measures are not taken into account? Workers have no sound knowledge about their safety. Recently two cases are reported in which the workers are suffering from lungs infection. Q.7. Either quality of the paint is good or not? MTL is using ICI Paints according to prescribed standards of Massey Ferguson and it is of good quality, Q.8. Either work load for worker is manageable or not? Yes, work load is very much manageable. After every 70 hangers the worker in the paint booth is replaced. Q.9. Either the worker are sufficient or not? Yes, man power in this section is enough in number. Total 24 workers are available in each shift including supervisor and housekeeping staff. Q.10. Either paint is available on time or not? Paint is available at paint booth and there is no delay Q.11. what are the major problems faced by workers regarding the painting? No problem at all. Workers consider themselves that they are highly skilled in their respective job and can dealt with the problem Q.12. Either proper temperature is there or not? ◦ Stove oven temperature ranges from 140-150 C. stove oven doesn’t start till the temperature ◦ reaches to 140 C. Dry oven temperature is 130◦C. University of Agriculture Faisalabad Page 89
  • Millat Tractors Limited Weekly Production in TAP Capita produced 90 80 70 60 50 40 30 20 10 0 MF 240 MF260 MF 375 Total 2/5/2013 42 25 10 77 3/5/2013 38 27 11 76 6/5/2013 31 24 14 69 7/5/2014 36 15 17 68 8/5/2015 19 0 24 35 Graphical Representation of Weekly Production In TAP 45000 40000 35000 30000 25000 Units Produced 20000 Units Sold 15000 10000 5000 0 2007 2008 2009 2010 2011 2012 Graphical Representation of Production and Sales volume University of Agriculture Faisalabad Page 90
  • Millat Tractors Limited 12. Internship Activities 6thWeek (QA) 12.1. Introduction In our 2nd week of internship as per our schedule we reported to GM (QA) Mr. Athar. He gave us a brief introduction about quality, its control and assurance. Product or service that fulfills or completes its task or work effectively for specified period of time is referred as quality. QA has three sections 1. Bought Out Finished (BOF) 2. In House Quality Manufacturing 3. Production Lines Quality He told us in order to ensure the quality of the components to be assembled we have different types of gauges, fixtures and jigs, micro gauges, dial gauges, height gauges, depth gauges and many others. 12.2. Different types of gauges Snap gauge : To determine the outer diameters Plug gauges : To determine internal diameter or bore Slip gauges : To determine the gaps between two components Ring gauge : To determine the thread outer diameters Dial gauges: To determine the multiple dimensions (ovality, tapperness, bore, length, clearances) in microns. 12.3. Inspection and Testing Facilities in Labs 12.3.1.Oil and Grease Testing Dropping point apparatus Flashing point apparatus Different viscometer and viscosity bath 12.3.2.Paint and Coating Testing Lab Salt spray testing machine Thickness meter Glossiness meter 12.3.3.Rubber Testing Durometer rubber hardness tester Ovens and weighing balance University of Agriculture Faisalabad Page 91
  • Millat Tractors Limited 12.3.4.Material Testing Wet analysis technique (gravimetric and volumetric): To find out ferrous and nonferrous based alloys Non-ferrous based alloys (% of Si, Cu, Zn, N, Mg) Ferrous based alloys( % of C, Mn, Si, S, P, Cr, N, Mo) 12.3.5.Mechanical Testing Universal testing machine UTM (50 Tons) Rockwell hardness testing machine Brinell hardness testing machine Vicker hardness tester with micrometer Impact tester 12.3.6.Metallographic and Micro-Structure Microscope (magnification 500) Specimen preparation equipment 12.3.7.Metrology Coordinate measuring machine (CMM) Universal measuring machine (UMM) Involute gear tester Rolling gear tester Profile projector Surface analyzer Slip gauges Height gauges and height meter Hole tester 12.4. Coordinate Measuring Machine (CMM) Quality of precision machined parts both in house manufactured and vendors supplied is ensured by the use of CMM, CMM caters for precise measurement of linear and geometrical size and assures the dimensional integrity of complex parts with high speed, following parameters can be measured with CMM. CMM can measure upto half micron. Intricate sizes Positions Angles University of Agriculture Faisalabad Page 92
  • Millat Tractors Limited Diameters Squareness Flatness Parallelism Concentricity Roundness Straightness Co-axial ties Target Setting At Millat Tractor Millat Tractor Limited held monthly and annual based meetings to set the targets. There are different types of targets just like, production related, import related, supply related, quality maintenance, delivery, finance, manpower related targets. Proper budget is allocated to achieve these targets. There are some factors which considered at the time of setting targets.       What is the current sale level and what it was in past? What is company’s current profit level and what it was in past? What is the company’s current growth and what it was? Business success and failure? How many complaints company receive and among these how much it accept? Also consider how much time and cost it will take? There is two-way communication in order to set the targets. In this communication session two parties are involve. Top level management and middle level management. These targets are split in different targets and spread them to make these targets operationalize. Again monthly meetings are held in order to check the performance of the employees towards the achievement of these targets. There is incentive scheme to motivate the employees to achieve these targets. There are production bonuses and cash rewards. i. Cash Reward / Profit Sharing Plan 22% of the company’s profits are shared among the employees. ii. Production Bounces Production standards are set, i.e. 28000 tractors / annum. On meeting and exceeding these targets they are given production bonuses. In order to meet the sales targets, MTL also give the incentives to dealers but considering these tractors that factors are  That past performance (Low, medium and high performers).  Financial cost of incentives scheme  What was the result/output of the last incentive schemes University of Agriculture Faisalabad Page 93
  • Millat Tractors Limited After that MTL done the cost benefit analysis. If the targets are not achieved then they held the brain storming session. In this session front line field officer (regional officers) give the monthly reports, share the problems with the market executives. Internal Problems Analyzed At Millat Tractors Limited Millat Tractors Limited is not facing any problem regarding finance but following problems are identified at Millat Tractors Limited 1) 2) 3) 4) 5) 6) 7) 8) 9) Product development Weak in aggressive marketing. Unsatisfied delivery procedure. Lack of proper survey (Market research). Delay in tractor delivery. No team work. Totally centralized decision making. Time consuming procedure. No customer dealing department in real meaning. 14.1. Product Development (Operational Level Problem) On the basis of 58% - 60% market share, Millat Tractors Limited considers itself as a market leader but in order to retain and improve its market share by prevailing in overall Pakistan tractors market instead of its current market (upper Punjab and upper Sindh) through changing phrase “We better know what customer requires”. As “What actually customer wants”. It is true that Millat Tractors Limited is producing new products (generating sets, fork lift trucks and prime movers) and modifying its available products (Tractors) but it should modify tractors by introducing those features which customer requires and create a sustainable competitive advantage. University of Agriculture Faisalabad Page 94
  • Millat Tractors Limited Now the question arises, Why people in lower Punjab prefer 480 (Fiat Tractors) rather than models introduce by Millat Tractors? The answer of this question is that the farmers of these areas mostly use Rotavator which does not work well with the MF240 Model of MTL. It efficiently works with the 480 of Al-Ghazi Tractors. So in order to capture this market MTL should introduce those models of tractor which efficiently work with the Rotavator 14.2. Weak in Aggressive Marketing Marketing personnel have a view in their minds that when any customer comes to the market to buy tractors knowing already what they have to buy either Fiat or MF, so there is no need of marketing. They do not realize that changing the minds of the customers is essential in order to survive in a market. Due to poor marketing, lack of interaction with the customers and incompetent marketing personnel, Millat Tractors Limited could not penetrate in Bahawalpur and other markets of lower Punjab as well. Millat tractor limited is enjoying as a market leader but it should be noted that FIAT has been gaining a lot of market share for some years. So there should be change in the marketing strategies and efforts should be invested in marketing. 14.3. Unsatisfied Delivery Procedure Millat Tractors Limited is more relationship oriented than customer oriented. It shows the biasness and discriminatory behavior with their customers. Company is following the policy to deliver the product to those customers who are higher in status e.g. if customer has placed and order month ago and when MPA places an order now then MPA’s order is given priority and the tractor is sold to him ignoring the customer who is already waiting for delivery. This should be noticed by top management and amendments should be made in policy. 14.4. Lack of Proper Survey There is no proper procedure being followed by MTL to find out following types of problems:     What type of problems organization is facing? What problems are being faced by clients? Whether client needs are changing or not? What are the reasons, Millat tractors is not capturing the market share in lower Punjab, lower Sindh and other areas. Even they are providing a better package of after sales service?  What MTL competitors are doing? So market research is a better solution for all these problems. University of Agriculture Faisalabad Page 95
  • Millat Tractors Limited 14.5. Delay Tractor Delivery There is another problem regarding long delivery period and availability of tractors to be sold to the clients. Clients always face difficulty in getting the tractors on time. 14.6. No Team Work At Millat Tractors Limited people do not work in a team. Everyone is working for their own interest. The top management should create an atmosphere in order to change the attitude of the employees so that better result can be obtained. 14.7. Centralized Decision Making Basically all the decisions are made by higher authority regarding all the procedures in the office e.g. purchase, sales, production etc. all the decisions regarding employees are taken by the top management and they are not allowed to participate in any decision. Most of the time first line employees know better than middle and top level management. 14.8. Time Consuming Procedure Every procedure takes a lot of time to be completed if anything required in office e.g. even smallest purchase have been made it takes a hell of time to complete the purchasing process. Another example is that if the company requires smallest equipment for office it takes a lot of time to get an approval from head office e.g. if a printer is required in office. 14.9. No Customer Dealing Department in Real Meaning There is no customer dealing department to deal with the customers face by face. Every client or a new customer to comes to the office for obtaining the information or for purchase of any MTL products has to meet the marketing personnel. The marketing personnel only focus on the job they are assigned. Market Analysis 15.1. Problems regarding the quality According to the dealers, the overall quality of the tractors was not found satisfactory the reasons are summed up below. The performance of Fuel Injection Pump is not good it consumes more fuel due to the rotor clearance. The major problem was of Differential System (Crown Pinion). University of Agriculture Faisalabad Page 96
  • Millat Tractors Limited There is a problem of Rear Rim distortion in shape and early rusting of the rims. Pressure is not maintained under loaded conditions in the Hydraulic System due to the manufacturing fault. Turbo charger oil kit leakage in MF-260. The chassis is not properly painted due to which sometimes it rusts. When the temperature reaches near 400C the seals of tractors standing in showroom leaks. 15.2. Reasons for Market Downfall The downfall pattern shown graphically above in local market due to the following reasons: 10% Tax increase the prices. High price of tractors. Green Tractor Scheme and Sindh Government tractor scheme. High fuel price. Suggestions and Recommendations There is no doubt that MTL is the leading tractor company in Pakistan from last 40 years If we study its history then it became clear that they always satisfied their customers by providing good quality products.But here are some suggestions which we have observed during our internship. That cannot only make much development but they can also minimize the future threats 1. The importance of Quality Management System should be realized at all levels starting from the top. There is a need to realize that the real benefits of QMS are not in certification but in the proper implementation and use. A genuine visible effort in this regard would be very helpful in making other people believe in this globally successful system. 2. The focus should be on the proper implementation and utilization of the Enterprise Resource Planning system. Proper training of personnel involved in this program is necessary. We have observed that company employs don’t take it seriously enough for various reasons. 3. The company should put more effort in taking care of its workers especially daily wages and contractual workers so that they are satisfied with their jobs and give more quality output. These workers are very hard working and financial situation is really a very serious distraction for them. University of Agriculture Faisalabad Page 97
  • Millat Tractors Limited 4. Marketing is called s back bone of an organization. a poor marketing of a good product can disaster results while good marketing of bad product can make me rich other rights. There is a lot of room of improvement present in the marketing development regarding marketing research to identify where the problem (what is the reason of sales decline) & which section of an organization is weak dealing with the customer in this regard special improvement in booking section is required. The best way at booking section. The problem is due to the job of persons at booking section. To show the problem course covering the topic how to deal with the different people should be organized. 5. They should change their thinking that they will always remain leader of tractor industry but they should understand that every business has to face the decline stage as well in order to remain at maturity, it is necessary they should capture those markets in which they still did not penetrate & The competitor analysis thoroughly. 6. Another area which demand attention is that of job rotation. Employees are not so much productive, motivated and efficient because of their routine job. 7. They also are allowed the operational level employee in decision making process especially when the decision are taken about the labour force because most of the time they better know about what is beneficial and suits to them. 8. The delivery time period at MTL is 21-days arrangement should be made to decrease the delivery time so that service level can be improved. 9. More focus should be put on the improvement in the processes rather than keeping them as they are now. 10. The Quality Circles should be introduced among workers so that their participation in the improvement process increases and they really own this process. 11. Although there product lines are good in Pakistani industry, but if it is compared to foreign established industries then there product numbers are very low. 12. Worker safety should be taken under consideration at the TAP (tractor assembly plant). Millat should work on getting certification for the employee safety. 13. Different machines performing the same operation must be checked and their number must be reduced. 14. The production efficiency could be increased by increasing worker’s efficiency. This can be done by giving some kind of incentives to the worker. 15. Old machines must be replaced by automatic plants. It will enhance the rate of production, better finishing quality, reduce the labor cost, consume less energy and would be space efficient as well. 16. To economize the fuel, improvement of the rotor should be made in fuel injection pump or it should be made plunger type 17. Sensors should be there for over heat indication so in case of overheat it may shut safely. 18. The painting quality must be improved to avoid rusting. 19. There must be a strict check and balance on QA dept. University of Agriculture Faisalabad Page 98
  • Millat Tractors Limited 20. There is some need to change the working environment of organization. HR should be the most valuable person in the marketing department. 21. There is a need of rotating personal between different departments at early stages rather than at the early stages; it helps in finding the right person for the right job. 22. Organization should take care about the work going on, and about the wages of the workers. 23. I have observed during my period of internship in MTL, that there was lack of competition with foreign tractor industries. 24. There are almost about 1000 workers in MTL, from which 200‐300 are permanent and others are temporary, there is need to increase the number of permanent workers. 25. Do not just use newspaper or conferences for advertisement but there should be proper publicity of the product so that people should be aware of Millat. 26. Although production in MTL is high but is still not meeting the demands of thenation. 27. Prices are also getting higher, which is not basically the requirement of the farmer. 28. Greater demand than the supply is not only creating problem but causing the latedelivery which irritates the costumer. 29. A proper ventilation system is required and heating system for the workers workingin cold night shift. 30. CNC machine is required in OP‐53 on lube oil sump line because 0.064 tolerancecannot be controlled by manual Mill machine. 31. An alternate source is required for casting of lube oil sump due to casting problems. 32. There should be proper training time for the trainee engineers. 33. There should be complete R & D development department in company. Thisdepartment should do market research and providing guideline for developing new products and modifying existing ones. 34. The company should provide medical facility to each worker. 35. The company should provide conveyance facility to every employee so that it willbeconvenient for the worker to come to office in time. 36. Proper orientation should be given to students for internship. 37. Research work should be with the help of university students. 38. There is need of preventive maintenance in machining plant and tractor assemblyplant. 39. There is need of technical innovations in the plant. 40. MTL should be quality conscious rather than quantity conscious. 41. QA dept. should work more precisely and accurately to ensure the best quality of the vendor’s product. Suggestions for Task 1 1. It is the duty of the QA department that not to allow the bad quality part fed to the assembly line. 2. The inspector should be on line for timely rejection of parts. University of Agriculture Faisalabad Page 99
  • Millat Tractors Limited 3. Supervisor should always focus on new workers and he should instruct them properly. 4. There should be optimum production load on the workers so the mishandling should be limited. 5. Good quality tools should be used so components can be saved. 6. Proper tools should be used for proper jobs. Like to align the stud by hitting on the threads should not be done this action was seen on line while visiting. 7. Training workshops should be conducted. Suggestions for Task 2 1. An electronic Fork lifter should be provided because it is compact in size an d produce no smoke. 2. Proper training should be given to workers to give them awareness to avoid the piling of segregated material at work stations. 3. The number of bins should be increased. This will reduce Mishandling and time of production. 4. Proper training should be given to worker to avoid mishandling 5. Material Management (MM) store should not be there within the plant area. It should be in a separate building. This will release some space and it could be utilized in a better way. 6. Fork lifters and stillage should be increased in number to make sure that each part should reach its station on time. 7. Racks should increase in number in order to minimize the time lost in movement. 8. Rejection Bins should be increased to avoid wastage of time. It should be provided in easy reach of each worker or station. Suggestions for Task 3 1. Training workshops should be carried out in TAP to give awareness to the workers about their safety and health. 2. It should be made mandatory for the workers to wear safety nasal masks during painting. 3. Training workshop should be carried out time to time in order to improve the worker’s skills in order to enhance the painting quality. 4. Painting precision and accuracy should be improved in order to minimize the paint losses. University of Agriculture Faisalabad Page 100
  • Millat Tractors Limited Conclusions 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. We are pretty sure that company has ability to achieve its goals as stated in vision statement. After our internship in Millat Tractors Limited and doing market analysis we reach at the same conclusion that they are "LEADERS ALL THE WAY". MTL should not compromise on the quality. There must be a strict check and balance on QA dept. if MTL wants to be at the peak.The management is very effective and their plans are mostly about their future. Therefore we conclude that Millat Tractor has going on concern and it will progress further and they have ability to overcome risks and prosper. References Marketing Division MTL Machining Division MTL Engine Assembly Plant (EAP) Tractor Assembly Plant (TAP) Quality Assurance Dept. Usman Enterprises (Ferozewala Dealer) Rana Tractors Farm (Beghumkot) Madina Traders (Beghumkot) http://www.millat.com.pk/ http://www.googlesearchengine.com/ Annual Report (2012) University of Agriculture Faisalabad Page 101
  • Millat Tractors Limited Future Outlook Pakistan's agricultural sector will remain stagnant unless we optimize our farm power level through extensive use of agriculture, machinery and tractors. The Company feels that the tractor market would remain at the same level in 2012-2013 as in the current year. MTL will strive to maintain its market share and play a positive role aimed at boosting the agricultural sector. The Company expects that the tractor industry will grow further due to restructuring of ZTBL recently being taking place, formation of political Government in May, 2013 and Afghan potential i.e. participation of Pakistan in the rehabilitation of Afghanistan. Habib Bank Ltd. and The Bank of Punjab are already extending tractor loans and improving their share in the tractor industry which shall reduce dependence on ZTBL. University of Agriculture Faisalabad Page 102