Internship Report @ Millat Tractors Limited (MTL) 2013

Millat Tractors Limited

2013
INTERNSHIP REPORT

Azlan Zahid
4/1/2013 to 5/16/2013
University of Agriculture Faisalabad

Page 1


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.


Page 2


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.


Page 3


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

Page 4


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

HR Dept.
Report Submission

29-04-2013
02-05-2013

Manufacturing

Full Day

Tractor Assembly Plant (TAP)

Visit of Assembly Lines


Khawaja Ali Hassan

SaeedIkram
Muhammad Akmal
Dy. Manager (Production)

Page 5

03-05-2013

Full Day


Mishandling Survey

06-05-2013

Full Day


Material Flow Analysis

07-05-2013

Full Day


Paint section survey

Muhammad Akmal

08-05-2013

Full Day


Rear AxleBuild Line

Muhammad Akmal

09-05-2013

Full Day


Chassis Build Line

Muhammad Akmal

13-05-2013

Full Day


Introduction to QA dept. and
its different sections

Mr. Athar GM (QA)

14-05-2013

Full Day


Testing Labs visit

Mr. Mansoor

15-05-2013

1st Half


CMM and UMM

Said Noor

16-05-2013

2ndHalf

HR Dept.

Report Submission

Muhammad Akmal
Muhammad Akmal

SaeedIkram (HR Manager)

Office Stamp


Page 6


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

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


Page 7


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


51
51
51
53
54
55
58
58
61
63
63
66
71
71
72
74
81
81
81
81
82
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84
85
88
88
88
91
91
91
91
91
91
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92
92
92
92
93

Page 8


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


Page 9


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


Page 10



Page 11


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.”


Page 12


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,


Page 13


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.


Page 14


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


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Page 22


Marketing Network of MTL


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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.

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


Page 31


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.

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

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.


Page 32


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


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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


Page 34


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


Page 35


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


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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.


Page 37


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


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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.


Page 39


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.
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.
In this operation both right and left side of the transmission case
are finished by milling machine.


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 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.


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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.


Page 42


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


Page 43


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


Page 44


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

Page 45


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


Page 46


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.


Page 47


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.


Page 48


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
.


Page 49


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.


Page 50


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.


Page 51


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


Page 52


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


Page 53


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.


Page 54


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.

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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
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
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:
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:
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.


Page 56


Operation No 90:
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:
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.


Page 57


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:


Page 58


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


Page 59


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.


Page 60


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.


Page 61


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.


Rectification

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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.

Page 63


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


Page 64

OP.100


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)


Page 65


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


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2. OP 20
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
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
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
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


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Bolt the sump
Build the House pipe
Torque the Cylinder head
6. OP 70
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
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
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
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

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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.


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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.


Page 70


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


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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


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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.


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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


Page 74


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

Page 75


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

Page 76


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.


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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.

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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.


Page 79


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.


Page 80


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.


Page 81


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.


Page 82


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.


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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


Page 84


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


Page 85


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


Page 86


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.


Page 87


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.


Page 88


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.


Page 89

Internship Report @ Millat Tractors Limited (MTL) 2013

Internship Report @ Millat Tractors Limited (MTL) 2013

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Internship Report @ Millat Tractors Limited (MTL) 2013