SHREE BALAJI PHOTO STATE ALWAR 9667198261

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PROJECT REPORT
On
“Skill Development Modules for Different Operating Levels”
(July 2015)
TAFE MOTORS AND TRACTORS LIMITED
(EICHER TRACTORS, MANDIDEEP, BHOPAL)
Submitted To:
Mr. Vaibhav Harsh
Asst. Manager, Production
Eicher Tractors, Mandideep
Bhopal, Madhya Pradesh
Submitted By:
Mukul Kaushik
4th
Semester, B.Tech. (Hons.)
Production & Industrial Engg.
National Institute of Technology,
Jamshedpur, Jharkhand

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DECLARATION
I hereby declare that the project work entitled “SKILL DEVELOPMNT MODULES FOR
DIFFERENT LEVEL OF OPERATORS (DETs & PERMANENTS)” is an authentic record of my own
work carried out at (EICHER TRACTORS) under the guidance of Mr. Vaibhav Harsh during July
6, 2015 to July 31, 2015.
Mukul Kaushik
Date: ___________________
Certified that the above statement made by the student is correct to the best of our
knowledge and belief.
Mr. Vaibhav Harsh
Asst. Manager, Production
Eicher Tractors, Mandideep
Bhopal, Madhya Pradesh

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Acknowledgements
First and foremost I would like to thank my college for allowing me to pursue my Project
Semester Training at Eicher Tractors for 26 Days.
Then, I would like to thank my training manager Mr. Vaibhav Harsh for his unflinching desire
to know what was going on in my projects and for those millions of opportunities he gave me
to share his ideas and knowledge in a large variety of settings. I am very much thankful to
them for his wise and synergetic help throughout my training period.
I also express my gratitude to all the other employees of Eicher Tractors for making my
training at the company a wonderful experience.
In the end I will like to pay my gratitude to HR Department, Eicher Tractors for their support.

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Contents
1. Company Profile
2. TMTL
3. Take Over Eicher Tractors
4. Eicher Tractors
5. Overlook into system of company
6. Tractor Assembly Process Flow Sheet
7. Process Layout
8. Project Work
9. Conclusion

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TAFE Profile
TAFE MOTORS & TRACTORS LIMITED
Tractors and Farm Equipment Limited (TAFE) is a unit company of the Amalgamations group,
one of India's largest light engineering groups with diverse interests in diesel engines,
automobile components, tractors and related farm machinery, lubricants, panel instruments,
hydraulic pumps, engineering tools, storage batteries, paints, engineering plastics, automobile
franchises and printing apart from interests in agribusiness, book selling and publishing. The
group's leadership technology, built on foreign know how has been nurtured through
indigenous efforts.
TAFE was established in 1961 to manufacture and market a range of Massey Ferguson tractors
and related farm equipment in India. One of the largest tractor manufacturers in India, TAFE's
vision is to be the first choice of customers in India and to also move towards a growing
presence in the international markets. TAFE has collaboration with AGCO Corporation,
headquartered in Duluth, Georgia, which is one of the largest manufacturers, designers and
distributors of agricultural equipment in the world. Its products are sold in more than 140
countries. With a network of more than 500 dealers, branches, service outlets as well as its
own sales offices and depots covering the entire width and breadth of India, TAFE is
committed to providing complete farming solutions to its customers and empowering them to
work towards increased farm productivity, prosperity and profits.
Tractors and Farm Equipment Limited (TAFE), has been a pioneer in the mechanization of the
Indian farms. Beginning with the popularizing of tractors in agriculture in the early 60s, TAFE
has many firsts to its credit. TAFE was the first company to market a total package of Tractors
and farm equipment to not only provides farm power but also interfaces to transform the
farm power to increased farm productivity. TAFE was also the first to introduce the Direct
Injection technology in India, thereby initiating considerable fuel saving and the resulting
economies in tractor operations cost to its customers. TAFE was also the first Indian
manufacturer to launch a 75 HP tractor to cater to the emerging needs of very large farms and
agri-businesses. With three manufacturing locations at Chennai (Sembiam), Madurai
(Kallidaipatti) and Bangalore (Doddaballapur), TAFE has a large manufacturing base. Its
Madurai plant, the latest and possibly the largest such plant in the country is specially tailored
to take on short run production batches to the exacting standards demanded by advanced

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countries. All its plants and sales offices are linked by VSAT links providing fast and efficient
communications and data linkage another first of its kind in India.
Tractors and Farm Equipment Limited (TAFE), is also involved in the following areas, apart
from its core business of manufacturing and marketing tractors.
 TAFE has developed a range of matching trailers, implements and accessories. These are
marketed through TAFE's dealer network by a totally owned subsidiary,
 TAFE is also involved in the marketing and distribution of lubricants and greases for tractors
through its dealer network.
 TAFE is also involved in the packaged power industry through its Power Source Division.
 TAFE has in-house facilities for the manufacture of hydraulic pumps and gears for tractors.
A related facility for the manufacture of panel instruments, not only for captive use but also
for the growing automobile industry in India is an integral part of the company.
 TAFE has also diversified into Engineering plastics and production of tools and dies for this
industry.
 TAFE's vision is not just wishful thinking but based on recognized engineering, marketing
and financial strengths, built up over the past four decades. In all that it does, TAFE pursues
excellence.
 To achieve the distinction of the first choice among the farming community of India and
ensure a growing presence in international markets through setting leadership standards of
performance and customer care in the agricultural machinery business.
 "To us in TAFE, excellence is not something that we engineer, input or inspect into our
products. It is an innate desire that inspires our hearts at work and at home and ripples out
into the world around us. "

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TMTL
TMTL- a wholly owned subsidiary of TAFE (Tractors and Farm Equipment Limited).TAFE is a
unit company of the Amalgamations Group, one of India's largest Light Engineering Groups
with diverse interests in Diesel Engines , Automobile components , Tractors and related farm
machinery, lubricants, panel instruments, hydraulic pumps, Engineering Tools , Storage
Batteries, Paints , Engineering Plastics , Automobile franchises and Printing apart from
interests in Agribusiness , book selling and publishing. The group's leadership technology, built
on foreign know how has been nurtured through indigenous efforts.
TMTL has three divisions in India–
1) Tractor Division, Bhopal – Manufacture and Assembly of Tractors
2) Engine Division, Alwar – Manufacture and Assembly of Auto & Stationary Engines.
3) Transmission Division, Parwanoo – Manufacture of various Transmission Components
like Spur Gears, Helical Gears, Spline Shafts, Crown Wheel Pinion, Cam Shaft and Housings.
Tractor Division at Bhopal viz. Eicher Tractors is a leading Tractor manufacturer in India and
manufacturing and selling “EICHER” brand of tractors. Eicher Tractors, a pioneer in Tractor
TAFE Motors and
Tractors Limited
Tractor Division
BHOPAL
Engine Division
ALWAR
Transmission
Division
PARWANOO

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manufacturing in India, rolled out its first Indian Tractor in 1959 with the collaboration of
Gebr-Eicher, Germany in 1960. The other group company TAFE too is amongst the oldest
tractor manufacturer in India and is manufacturing and selling Massey Ferguson and TAFE
range of Tractors. TAFE and TMTL as a group is the second largest Tractor manufacturer in
India. Jointly, we have more than 25 tractor models and 100 variants, which is the largest
range being offered by any Tractor manufacturer in India.
Eicher Tractors has manufacturing and design facilities in Mandideep in Madhya Pradesh and
producing 14 base models ranging from 24 HP to 85 HP. We are the only company, which
offers a choice to the customers between Air-cooled, and Water cooled technology. Eicher
range of tractors enjoys unique advantages in terms of phenomenal fuel efficiency, its easy
maintenance, higher pulling capacity, reliability and suitability for farm & commercial
applications. It has been our endeavour to offer the best technology and upgraded tractors to
the farmers to meet their changing requirements. In this context we have entered into
technology transfer agreement with VALTRA Inc. of Finland and RICARDO of UK.
TMTL’s Engine Division produces wide range of stationary and automotive Engines from 22 HP
to 85 HP. These find applications in varied fields of industrial and household applications.
TMTL’s Transmission Division manufactures Gears required for Transmission Drive Lines &
supplies to Eicher Tractors Bhopal as well as to Auto Manufacturers like Eicher Motors & JCB.
To serve our customers better, we operate through 12 Regional Marketing Offices for tractors
and 3 offices for engines in various cities of India. Head Office for tractor marketing is at
Mandideep, Bhopal and for engines at Alwar, Rajasthan. A strong network of over 450
authorized Dealers / 400 authorized service centres and over 250 Stockiest help in providing
prompt services.

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Take Over Eicher Tractors
The Chennai based tractor major, Tractors and Farm Equipment Limited has been taking over
of Eicher’s tractor division near Bhopal, engine division at Alwar and gears division at
Parwanoo, in the biggest such acquisition in the history of the Indian tractor industry. TAFE,
already the second largest manufacturer of tractors in India, with this approval, comes within
striking distance of market dominance in the domestic tractor industry. Speaking at a media
meet, TAFE’s Director, Mrs. Mallika Srinivasan said, “This move was a well-deliberated
strategic move on our part. This acquisition will provide strong synergies of growth in the
future to help achieve market dominance”.
‘Tafe motors and tractor limited’ company’s director Mrs. Mallika Srinivasan decided to take
over Eicher tractors. She went on to add “TAFE has long held a significant presence in the 30-
40 HP segment and the Eicher brand holds substantial market shares in the below 30 HP
segment.
The respective brands have a strong brand presence and equity in the customers’ minds. This
coming together of the brands with strengths in individual segment forms a perfect fit to take
on the tractor market which is currently on an upswing. It is in this scenario that this coming
together of two major brands in the industry becomes highly significant. This also represents a
giant leap for us in our vision to become the farmers’ first choice”.
With this acquisition, TAFE’s combined market share is 22 per cent and a combined volume of
about 53,000 tractors. TAFE already has large number of products and variants to suit the
changing demand patterns of tractor customers across the country. With the addition of the
portfolio of products offered under the Eicher Brand, this new venture will offer to its
customers the best in terms of product range, value for money, quality, and innovation in
design and assured post sales product support. The move will also result in TAFE having a
combined distribution network of over 2000 dealers, branches, service and parts outlets and
customer contact points which is the largest in the industry.
TAFE and Eicher tractors will retain their individually strong identities at the brand level and
distribution level. The potential synergies of growth made possible by this move will translate
into positive benefits to the employees, vendors and dealers and provide them ample growth
opportunities. With its major focus being on the tractor business, TAFE aspires to be the
number one player in the domestic market and the growing presence in the international
market. TAFE buys Eicher's tractor, engine & gear businesses for Rs 310 crore. The Eicher
Motors board has cleared the sale of the company’s tractor, engine and gear businesses to

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Tractors and Farm Equipment’s, TAFE, for Rs 310 crore. TAFE will purchase the Eicher facilities
through an SPV called TAFE Motors & Tractors.
The SPV, a 100% subsidiary of TAFE, will run the Eicher tractor unit and the gear & engine
businesses as a separate entity with separate brand identity but operational financial control.
The acquisition would improve TAFE’s geographical spread across markets like MP, UP and
Bihar where Eicher is strong — alongside Rajasthan, Gujarat, AP and Karnataka where TAFE or
stable mate Massey Ferguson are strong.
"In fact, the board of directors of EML granted approval for the sale on a going concern basis
of the tractors, engines and gears divisions of the company at Mandideep, Alwar and
Parwanoo to TAFE Motors and Tractors for a total consideration of Rs. 310 crore," With the
acquisition of the Eicher unit, TAFE — the second largest manufacturer of tractors in India —
will eye market dominance. According to industry data available for the April-December 2004,
TAFE registered sales of 24,191 units, while Eicher sold 13,670 tractors.
Brief description of the units of this takeover is as follows:
Eicher Tractors
 Pioneer Manufacturer in India since 1960.
 Technology from GEBR Eicher, Germany &Valtra, Finland.
 Over 3, 50,000 satisfied owners.
 Market leader in <30 HP segment.
 First Tractor Company to produce Air cooled as well as water cooled tractors.
 Current range 24, 30, 35, 42, 51 & 61 HP - Annual capacity is over 40,000 numbers.
 51, 61 and 70 HP-New products under introduction.
 Exported to Europe, U.S.A., and Africa & South Asia.
 First Indian company to be awarded with ISO 9001 certificate
 Fully integrated R&D Centre.
Eicher Transmission
 QS 9000, ISO 14000 & ISO 9002 certified facilities.
 Manufacturing unit Parwanoo.
 Manufactures a wide range comprising Spur Bevel & Helical Gears, Crown Wheel Pinion,
Transmission Shaft & Rear Axle Gears
 Caters to OEM & Replacement Market.
 Exports to Europe, Asia & US.

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Eicher Tractors
Eicher Tractors is one of the newly added in the companies of the TMTL Group. Tractor
operations are divided in Bhopal and Faridabad for manufacturing facilities, Eicher Tractors
Engineering (R&D unit) and Marketing functions. Mr. R. C. Banka is Chief Operating Officer of
the Tractor Business Unit.
The tractor operations are located at Bhopal plant. The combined production capacity is about
25000 tractors per annum. Eicher tractors manufacture and markets tractors from 24 HP to 61
HP range. Company has its own distribution network in most agrarian states and has 350
dealers. Marketing network is spread across the country and there are 35 area offices in
smaller cities of the country. Eicher offers 2 years warranty on the tractors against any type of
manufacturing defect & efforts are made to upgrade the service network by providing
doorstep service to the farmers.
The company gives high thrust to its employees, which are encouraged to acquire knowledge
in their work area and are given ample freedom. There are about 1100 employees in Eicher
Tractors. There are 100 executives, 350 staff and 550 operators in the company. Eicher offers
equal opportunities to learn perform and grow to all employees. Employees are encouraged to
acquire knowledge are permitted for job diversity within organized units of work. Specific care
is exercised for ensuring safety and health of the employees including contract employees.
Eicher has state of art R&D centre at Bhopal facility, which has Pro/E, Adams, Hyper mesh
work stations, simulation rigs, mechanical test beds and mock shop for developing new
products. The manufacturing plants have very good paint shops and assembly lines, Co-
ordinate Measurement Machines and conveyers for various product lines. These plants are
very flexible to roll out any of 68 variants within a short time as low as one week after putting
an order of customized tractor.
Eicher puts a lot of emphasis on technology up gradation of its service network as well.
Company uses IT as a business excellence enabler and its home portal EPIC is widely used for
all in-house daily management processes of information sharing, leave planning, performance
appraisal and progress tracking etc. ERP package of SAP was established in 1999, which helps
smooth transactions in supply chain management processes from supplier raw material
planning to tractor delivery at sales outlets and demand forecasting.
Key customer groups of Eicher Tractors have typically included the small land holding farmer,
which wanted a small tractor in past 3 decades. The company has changed its perception now
and offers tractors from smaller 24 HP to premium segment of Valtra. The selling price of the
products varies from Rs. 2 lakhs to 5.5 lacks depending upon the specifications. Today 50 %

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revenue comes from higher horsepower models. Customers specifically for the low cost of
maintenance like Eicher’s tractors as Eicher’s tractors consume minimum fuel in Indian
farming and driving conditions.
Eicher Tractors Bhopal being basically tractor assembly operations, most items except a few
critical engine parts are bought from outside suppliers to design made by Eicher. The heavy
dependence on bought out items puts a very high focus on the supplier quality management
processes, which we will discuss in detail later. Suppliers play a valuable role in the value
creation process and Eicher R&D Takes suppliers input on cost as well as manufacturability of
new designs from the suppliers in concurrent engineering environment.
Eicher has a strong supplier and customer relationship and communication mechanism.
Suppliers can access the ERP system on line and can get knowledge of their inventory levels,
production schedule adherence and tentative future production levels apart from quality
inspection status and bill payment processes. Customers have access to 24-hour help line and
special service desks spread across India to serve them better. Customer is assured of getting
the tractor attended within 6 hours of his complaint. Company is also making some channel
partners such as ITC& other grain buying houses, Fertilizer & Pesticides companies to enhance
bonding with the customers and to increase loyalty towards Eicher.

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Policies of Eicher Tractors

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EICHER PRODUCT RANGE:
• Tractor Models:
241 Xtrac 24 HP Tractor Single Cylinder Air Cooled Engine
242 Xtrac 24 HP Tractor Single Cylinder Air Cooled Engine
278 27 HP Tractor 2 Cylinder Air Cooled Engine
312 SDI 30 HP Tractor 2 cylinder Air Cooled Engine
333 SDI 35 HP Tractor 3 Cylinder Water Cooled Engine
364 SDI 35 HP Tractor 2 Cylinder Air Cooled Engine
368 SDI 37 HP Tractor 3 Cylinder Air Cooled Engine
380 SDI 35 HP Tractor 3 Cylinder Water Cooled Engine
485 SDI 42 HP Tractor 3 Cylinder Air Cooled Engine
480 SDI 42 HP Tractor 3 Cylinder Water Cooled Engine
548 47 HP Tractor 3 Cylinder Air Cooled Engine
557 50 HP Tractor 3 Cylinder Water Cooled Engine
5150 SDI 47 HP Tractor 3 Cylinder Water Cooled Engine
5660 52 HP Tractor 3 Cylinder Water Cooled Engine
• Stationary Engines:
222ES / 222HS 18 HP SINGLE CYL, 1500 RPM Rating
322 ES 24 HP TWO CYL, 1500 RPM Rating
422 ES 34 HP THREE CYL, 1500 RPM Rating

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An Overlook into the System of Eicher
Tractors
There are following basic departments in EICHER Tractors.
1. EICHER TRACTORS ENGINEERING CENTER:
This department is responsible for designing the products to be manufactured by the
different vendors. The department has been divided into different areas like
transmission, which looks after the gear designing, tractor, which looks after general
parts of the tractor, hydraulics, which is responsible for looking after the ADDC and the
components related to hydraulics, product development, which looks after the various
field issues and improving the present products.
2. FINANCE AND ACCOUNTS DEPARTMENT
This Department is responsible for all the financial transforms that are carried out in the
company such as payments for all the incoming material, salaries of all the employees,
all the records for expenditures and Credits to the company are maintained by this
department.
3. SALES AND MARKETING DEPARTMENT
This Department is responsible for consolidating the position of the company in the
market every year. Every year these people get some new strategies so as to increase
the share of the company in the market. Most of the Sales of the company are
dependent on the working of this department thus being one of the most important
departments.
4. MATERIALS/VENDOR DEVELOPMENT
This department is responsible for all the incoming material from the vendor. This
department is further divided into two departments:
a. Vendor Development: All the new samples and in fact all the new components are
developed by this department. All the components developed are not consumed as a
part of the regular production but implemented as a trial only and consumed in
regular production only after these components are regularized.
b. Purchase Department: This department is responsible for all the incoming material
brought in that is used in regular production.

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5. STORES DEPARTMENT
This department is responsible for the handling of the incoming material, supplying the
material on to the line and also the dispatch the rejected materials back to the vendors.
Thus stores have got a huge task to do and that can’t be performed as a single
association and thus has been divided into different sections as per the need such as
Incoming Material Stores named as Group 1,2,3 Stores, main stores, ETE Stores,
Rejection Stores etc.
6. QUALITY ASSURANCE DEPARTMENT
This department is responsible for overall Quality Control of the incoming components
and Assurance about the Quality of the Tractor to the customer. This department is
further divided into Sub-Departments, which is discussed separately later on.
Quality can be defined’ as ‘fitness for use’ when we talk of quality it means that product
should be fit for use and it is the user who judges and decides what qualities he wants in
the product.
The quality characteristics can be grouped into 4 categories:
a. Quality of design: The design must meet all the requirements of the customer. If he
wants a motor of say 5 HP, you can’t design your motor for 4.5 HP. The designer
should aim at a design which fulfils all the qualities, or almost all the qualities desired
by the customer. He should also make a product, which would become more
competitive.
b. Quality of conformance: The degree or extent to which a product actually conforms
to in accordance with the specification and drawing is called the ‘Quality of
Conformance’.
c. Availability: This includes such characteristics as reliability, maintainability and length
of life. All these indicate as to what extent the product will be available for use.
d. Customer Service: This includes the extent to which customer can get assistance from
the manufacturer or to keep the product in continuous use.
7. PRODUCTION DEPARTMENT
This Department is responsible for carrying out all the assembly operations. This
department is further sub-divided into some of the parts as per different assembly lines
such as Hydraulics Assembly line, Transmission line, Pre-painting line, Paint kitchen, Post
painting line, PDI etc.

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a. Maintenance department: For regular & preventive maintenance of machines &
any other equipment used for assembly, this department provides its services.
b. Store: Store assures regular and continuous supply to avoid line stopping. All the
materials purchased are stored here systematically and items that can be rusted
are applied with rust preventive oil once in a week and in season twice in a week.
The assembly line has been categorized depending upon the operations they are
performing. They are namely:-
 ADDC Line
 Transmission Line
 Pre Painting Line
 Paint Shop
 Post Painting Line
8. MFG. ENGINEERING & PROJECTS:
This department deals with the shop floor problems and identifies the potential areas
for improvement by studying the existing facilities which leads to layout modification,
structure modification and also lead to the designing of trolleys and tackles. It also
participates in discussion for selection and finalization of new machine tools, which
involves the studying of tooling requirement and then makes the tooling available and
establish them.
Capacity enhancements like building new storages, new assembly areas, and offices as
per the future plan of the plant are also one of the works done by our dept. Nearly all
kinds of machines, presses, wrenches etc. are handed over by Engg. Department.
9. MAINTENANCE DEPARTMENT
This department is responsible for carrying out all the maintenance work to be carried
out in the plant. Any kind out of repair work or maintenance such as electrical
maintenance, this department carries out working of equipment on the assembly line
etc.

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10.SERVICES:
This department is responsible for providing all the services and repair works to the
customers after tractors have been sold. Many new methods and strategies have
been adopted in the past to provide need full service to the customers and full care
has been taken to take care of their valuable suggestions and feedback.
11.HUMAN RESOURCES DEPARTMENT:
This is the most important department of any organization. As we all know that 3 M’s
are most vital for any production unit. These 3 M’s are Men, Materials, and Machines.
Out of all the, Men or Human Resource is the most complicated or important resource
for any organization, the department which performs all the functions relating to the
human resources is known as HUMAN RESOURCE MANAGEMENT. Human resource
department is divided into 3 parts:
 Corporate HR
 Plant HR
 Marketing HR
The department is responsible for each and every function regarding the human
resources.
12. IR (Industrial Relations)
The department main function is arranging the workmen for the company, also look for
the factory act, take care of the canteen, First Aid Box etc.
13.ADMINISTRATION
The department look for the reception of the company, Security of the plant, greenery
of the plant, transport facilities etc.
14.MANUFACTURING & BUSINESS EXCELLENCE DEPARTMENT
The function of the department is creating the work culture in the company. Look for
the certification of the company. Currently have TS 16949:20-02 and ISO 14001-2004
and going for the OHSAS 18001:2007 and the vision of the department is to get Deming
Prize.

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Tractor Assembly Process Flow Sheet
RAW MATERIAL IN FORM OF CASTING AND FORGING SHALL BE INSPECTED FOR
PARAMETER AS PER SPECIFICATION / DRAWING AND SENT TO STORE. COMPONENT
VIZ. MUD GUARD, RIM, BONNET, ETC. SHALL BE PAINTED WHILE OTHER COMPONENT
SHALL BE SENT FOR GEAR BOX, SUB ASSEMBLY PRIOR TO TRACTOR ASSEMBLY. THE
ASSEMBLY TRACTOR SHALL BE TESTED PRIOR TO ITS DISPATCH AS FINAL PRODUCT.
DISPATCH
RECEIPT & INSPECTION
STORE
TRACTOR ASSEMBLY
TESTING OF FINAL PRODUCT
PDI BOOTH
PAINT SHOP TRANSMISSION
ASSMEBLY
MATERIAL

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Project Work: Skill Development
Module
The skill development modules are prepared under the project Specific Measurable
Acceptable Reach Time Bound (SMART) Training. This project is intended to increase the
productivity without any major change in the infrastructure by enhancing the skills of the
existing manpower. Eight skill development modules were prepared under this project:
1. Assembly Aggregates
2. Assembly Line Facility
3. Maintenance and utility
4. Industrial Engineering
5. Manufacturing Basics
6. Quality Aspects
7. Power tools and equipment
8. Environment, Health and Safety
Module: Manufacturing Basics
Why manufacturing Basics?
This module of manufacturing basics will explains all the processes, activities which are
carried out in Eicher factory and it will also help to know the various properties,
advantages and uses of components and elements used in the factories so that the
operators can apply their knowledge in the practical line and make the processes more
effective and efficient which will lead to a quality product.
Focus Points:
A. Fasteners
B. Tightening and Torqueing
C. Bearings
D. Oil Seals, O-Rings & Gaskets

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1. FASTENERS
What is a fastener?
Anything which can be used to hold/join two parts mechanically is a fastener.
Why do we use fasteners?
• They simplify manufacturing process. Because of their complexity, many components &
assemblies cannot be made in one piece.
• They simplify repairs & maintenance. By removing fasteners an assembly can be
separated into individual parts for inspection, necessary maintenance, repairs or
replacements.
• They provide safety. They hold parts together and thus serve as safety devices such as
lock washers, cotter pins etc. Further in case of over loads they fail themselves and
hence prevent fracture or failure of more important and costly parts.
Types of Fasteners:
a. Permanent Fasteners: When parts are joint to be held together permanently these
fasteners are used. If in case parts joint by this method are disassembled, they get
damaged in the process and must be repaired or replaced by new parts. E.g. weld, rivet,
solder, nail, etc.
b. Temporary Fasteners: When parts are to be held together temporarily or frequently
assembled and disassembled these fasteners are used. When parts joint by such
fasteners are disassembled they are not distorted or destroyed and can be reused again.
These can be divided into two categories:
i) Threaded Fasteners: A threaded fastener is a discrete piece of hardware that has
internal or external screw threads. They are usually used for the assembly of multiple
parts and facilitate disassembly. They include bolts, screws, studs, nuts, etc.
ii) Non Threaded Fasteners: Fasteners not using screw threads for their action. They
include keys, pins, clips, washers, lock wires, etc.

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Thread Terminology:
a. External (male) thread: A thread cut on
the outside of a cylindrical body.
b. Internal (female) thread: A thread cut on
the inside of a cylindrical body.
c. Crest: The peak edge of a thread.
d. Root: The bottom of the thread cut into a cylindrical body.
e. Thread angle: The angle between threads faces.
f. Major diameter: The largest diameter on an internal or external thread.
g. Minor diameter: The smallest diameter on an internal or external thread.

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h. Right-hand Thread (RH): Thread that will assemble when turned clockwise. Most
treaded part and fastener have right handed threads but where the rotation of shaft
would cause a conventional right handed nut to loosen rather than tighten due to
fretting induced precession.
i. Left-hand Thread (LH): Thread that will assemble when turned counter-clockwise.
j. Pitch: The axial distance between adjacent threads on a helix or screw.
k. Lead: The axial advantage of a helix angle or screw during one complete revolution. The
lead of a screw thread is the axial travel for a single revolution.

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Types of Thread:
 Threads are sometimes identified as "fine" or "coarse“.
 A fine thread will have a relatively small pitch measurement, and the threads will be
closer together.
 A coarse thread has a relatively larger pitch measurement, and the threads will be
further apart. Fine pitch threads are sometimes used to make adjustments.
Fine Thread Advantages
 Fine threaded bolts are stronger than the corresponding coarse threaded bolts
of the same hardness.
 Fine threads have less tendency to loosen under vibration due to their having a
smaller helix angle than coarse threads.
 Fine threads because of their finer pitch allow for finer adjustments in those
applications that need this characteristic.
 Fine threads can be more easily tapped into difficult to tap materials, and thin
walled sections.
 Fine threads require less tightening torque to develop equivalent preloads to
the corresponding coarse thread bolt sizes.
Coarse Thread Advantages:
 Coarse threads are more durable and have greater resistance to stripping and
cross-threading.
 Coarse threads are less susceptible to being nicked or damaged, so they do not
have to be “handled with care” as much as fine threads.
 Coarse threaded fasteners install much faster than fine threaded fasteners.
 Coarse threads are not affected by plating build-up as much as fine threads.
Terminologies of Bolt:

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Metric Threaded Fasteners:
 Threads when measured in centimeter and millimeters are known as
Metric threads.
 Other than this they are also set standards and graded by SAE and
ASTM.
Temporary Fasteners in Brief:
A. Bolts:
 A screw, or bolt, is a type of fastener, typically made of metal, and characterized by
a helical ridge, known as a male thread (external thread) or just thread, wrapped
around a cylinder.

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 Some screw threads are designed to mate with a complementary thread, known as
a female thread (internal thread), often in the form of a nut or an object that has the
internal thread formed into it.
 Other screw threads are designed to cut a helical groove in a softer material as the
screw is inserted.

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B. Nuts:
 A nut is a type of fastener with a threaded hole.
 Nuts are almost always used opposite a mating bolt to fasten a stack of parts
together.

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C. Washers:
 A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle)
that is normally used to distribute the load of a threaded fastener, such as
a screw or nut.
 Other uses are as a spacer, spring, wear pad, preload indicating device, locking
device, and to reduce vibration (rubber washer).
 Washers usually have an outer diameter (OD) about twice the width of their inner
diameter (ID).

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D. Studs:
 A metal rod with threads on both ends and no head is known as a stud. One end is
screwed into a part, other parts are assembled over the studs and screwed in place
with a nut.
 The advantage of stud over bolts is primarily in manufacturing practice as they can
act as pivots for things with holes to quickly slip down rather than stacking things
with aligned holes and then fixing a bolt, and thus, help in aligning holes together.
Differences between Bolts, Screws & Studs:

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 Bolts are threaded metal rods which are used to hold parts in compression together
through the hole (non-threaded) in parts locked on other side with a nut.
 Screw is a threaded metal rod which is used to clamp parts (with through holes:
threaded or non-threaded) to another fixed object or part with a blind threaded
hole. Thus it does not require any nut on the other side.
 Studs are metal rods without head threaded on both end. They are used in
replacement to bolt and screw when a stack of parts need to be clamped in
compression and aligned simultaneously. One end is put into a fixed part with
threaded blind hole while the other end is tightened with a nut.
Differences between Bolts and Screws:
Bolts are threaded metal rods which are used to hold parts in compression together
through the Bolt and screws are actually same. These words can be used
interchangeably except at some places, e.g. “screw” is more common in case of Allen
head, it is called “Allen screw” and not “Allen bolt” and “eye bolt” is never called “eye
screw”.
Generally, bolts and screws can be differentiated in 4 ways:
 Bolt is used with a nut and screw is used without nut, it is used in threaded holes or
is self-tapping, i.e. threads its hole itself.
 Screw has threads on its full length, whereas a bolt is threaded only up to a specific
length.
 Bolt is tightened with a wrench, and screw is tightened with a screwdriver.
 Bolt is inserted into an internally threaded hole, whereas a screw makes its mating
hole itself.
Clearly, these four classifications are mutually conflicting, as there is no clear boundary.
So it’s not advised to generalise “screw” and “bolt.”
E. Pins:
 Cotter Pin
 Clevis or Headed Pins
 Dowel Pins
 Pivot Pins
 Spring Pins
 Spring Locking Pins
 Lynch pins

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F. Snap Rings/Circlips:
Snap ring or a circlip is a fasteners that holds components and assemblies onto a shaft
or in a housing/bore when installed in a groove. Their shape helps distribute the axial
load evenly.

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2.TIGHTENING AND TORQUEING
A.Tightening
Tightening is the process of installing threaded fasteners to hold or clamp parts
together in a rigid manner causing a preload or tensile stress in the fastener
and compressive stress in the parts.
Equipment used for tightening:
a. Wrenches: Fasteners would be useless without a quick, easy means of installing or
removing them. Wrenches have a head to fit the nut or bolt to be tightened, and the
body is made long to multiply the applied force.

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 Open End Wrenches: An open end wrench has jaws on both ends, usually of
slightly different sizes. The sizes of the openings are the distances across flats on
the bolt head or nut, they are not the bolt diameter.
The head of an open end wrench is generally offset at 15 or 22.5 degrees to the
body, as the offset allows more swing space.
 Box Wrenches: The openings on the end of a box wrench completely surround
the bolt head or nut thus providing a firmer grip than the open end wrench.

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 Ratchet Spanner: This is a type of box wrench fitted with a ratchet (just like
sprocket of bicycle) so that they can tighten a nut when rotated and do not loosen
the nut if rotated back.
 Adjustable open end wrench: In this wrench, the space between flats can be
adjusted by an adjusting screw.
Adjustable open end wrenches come handy when odd sized bolt or nut is
encountered, but it is not as firm as open end wrench, so it can’t replace that.
b. Power Tools: Power tools use external source of power to tighten the bolts or nuts.
They reduce human efforts, reduce time taken, and thus make job easy.
Since power tools are expensive and require maintenance, they are mainly used at
places of heavy and frequent use, such as a production unit.
 Pneumatic Guns: These guns are pneumatically controlled, i.e. they work on air
pressure. These decrease the tightening time and thus make the process fast.
 90 Gun: 90 Gun is also a pneumatic gun, but the head is at right angle to the
body. It is used at places which are difficult to access by a normal pneumatic gun.
 Oil Pulse Gun: These guns are controlled by hydraulic pressure of oil. They
produce very less noise as compared to air guns. These guns also use air pressure
for power.

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Pneumatic Guns
90 Gun
Oil Pulse Gun
Silencer

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 DC Nut Runner: These guns have an electric motor fitted to the socket using
Direct Current. They are used for tightening bolts with high and precise torque,
which can be adjusted by a computer program, thus the nuts tightened by DC nut
runner do not need torqueing.
c. Sockets and Extensions: Sockets are used
in special types of wrenches called socket
wrenches.
Different types of sockets can be fitted into a
single wrench depending upon the size and
shape of the nut.
Also, most of the power tools require
sockets.
Sockets have same top end which fits into the
wrench and the other end is of different
shape and size to mate with different bolts or
nuts.

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Sockets are available for all sizes and shapes, such as
hexagonal, Allen head, Philips head, etc.
Sometimes, if a socket and extension are used
together frequently, they are manufactured in one
piece only, which reduces the number of components.
An extension with Allen head
Sockets
Extension and socket in one
piece

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What is standard procedure of bolt tightening?
 Cross Tightening: Cross Tightening is a process of tightening the bolts in which bolts
are tightened diagonally so that there will be a proper contact between the mating
parts.
Cross tightening pattern for different number of bolts

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How to measure preload, and how much is to be applied?
 A loose nut will lead to excessive vibrations, and
exposes the parts to shear loads. It is also prone to
loosening, and the parts may get separated.
 An over-tight nut will “neck” the bolt permanently,
and the bolt might fail in the operation. Also, it will
create embedment in the parts to be fastened.
Over tightening of a bolt can induce cracks and will
lead to early failure of the bolted joint, or even the
parts.
Methods of measuring preload:
 Rotation of nut: In this method, we measure the angle rotated by the nut. Generally,
we count the number of turns or the length travelled(as in case of a castellated nut).
This method fails if there is slippage of bolt. So, it is used at places where bolt cannot
rotate.
 Extension in bolt (stretch): This method is the most accurate method to measure
preload tension. The bolt stretches on increasing tension, and the stretch is directly
proportional to preload tension.
Since this method involves precise instruments, so it is expensive and very slow.
 Torque applied to the nut: Generally, we give preload to the bolt by applying torque
on the wrench. It is seen that 50-80% of the applied torque is consumed in
overcoming friction and the remaining 20-50% contributes to the preload tension.
In most of the cases, torque corresponding to the required preload tension can be
known.
The process of giving preload using this method is known as “Torqueing.”

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B. Torqueing
Torqueing is the process of tightening fasteners according to set standards in
the industry to induce correct preload tension and ensuring that loosening
will not occur.
Standard Bolt Tensions Standard Tightening Torques
Standardization To establish company standards of tightening torque.
Conformation of present
tightening torque
To establish present tightening torque and conform it.
Method based on
braking torque
(Determination of lower
limit)
To adopt 70% of the breaking torque as the tightening torque for
the screw joints.
Note: Breaking Torque to be used is may be of bolt, as well as
the parts, whichever is lower.
Method based on
braking torque
(Determination of upper
limit)
To adopt 130% of the minimum required tightening torque, the
level that prevent loosening as the tightening torque.
6.8 8.8 10.9 12.9
M3 169 217.6 305.8 367.5
M4 254 382.2 534.1 641.9
M5 479 622.3 877.1 1049
M6 675 882 1235 1480
M8 1240 1337.7 2274 2734
M10 1975 2567.6 3616 4341
M12 2879 3753.4 5292 6321
M14 3954 5145 7252 8673
M16 5442 7154 9996 12054
M18 6613 8624 12152 14504
M20 8504 11172 15680 18816
M22 10632 13818 19502 23422
M24 12245 16072 22540 27048
M27 16129 21070 29596 35574
M30 19655 25676 36064 43316
Bolt Size
Strength Grade (Kg)
4.6 6.8 8.8 10.9 12.9
3 0.5 5.5 0.051 0.101 0.135 0.19 0.227
4 0.7 7 0.095 0.191 0.254 0.357 0.429
5 0.8 8 0.228 0.456 0.609 0.856 1.03
6 1 10 0.392 0.785 1.05 1.47 1.77
8 1.25 13 0.948 1.89 2.53 3.55 4.27
10 1.5 17 1.91 3.81 5.09 7.15 8.68
12 1.75 19 3.26 6.51 8.69 12.2 14.6
14 2 22 5.19 10.4 13.9 19.5 23.4
16 2 24 7.99 16 21.3 29.9 35.9
18 2.5 27 11 22 29.3 41.3 49.5
20 2.5 30 15.6 31.2 41.6 58.5 70.2
22 2.5 32 21.1 42.2 56.3 79.2 95
24 3 36 27 53.9 71.9 101 121.3
27 3 41 39.8 79.5 106 149 178.9
30 3.5 46 54 108 144 202.5 243
Bolt Size
mm
Pitch
mm
Bolt Hex
mm
Strength Grade (Kg-m)
Method for determining tightening torque

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Equipment Used in Torqueing
a. Computer Controlled Tighteners:
These tighteners are controlled by
computer programs, and have sensors for
torque applied. Pre-determined value of
torque is fed to the system and it tightens
the bolt/nut up to that value only.
One such tightener is used to fasten the
crown wheel to differential casing.
This method is most accurate and reliable
but it is too expensive. So it is used at the
places where tolerance limits are narrow
and critical.
b. Torque Wrench:
Torque wrenches are
wrenches fitted with a dial
indicator for measuring
torque, which helps the
operator for torqueing.
Most commonly used torque
wrenches have a click alarm, which
clicks when the operator exceeds the
torque limit. The click alarm may be
adjustable and may not be.
Torqueing by a torque wrench is the
most common method used for
torqueing as it is cheap and sufficiently
reliable.
Torque wrenches are actually socket
wrenches, which are fitted with a click
alarm.

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Torque Wrench
Hydraulic Lock: An obstacle in Tightening and Torqueing
Hydraulic Lock occurs of when a volume fluid
(water, oil or adhesive) gets trapped in a
blind hole, and it may give false torqueing
and can induce cracks in the body.
To avoid this situation, some precautions
may be taken:
 Use pre applied adhesives as far as
possible.
 If lubrication or adhesive application is
necessary, apply it on bolt, and NOT
in the hole.
 Bolts with a hole drilled along its axis may be used when this situation cannot be
avoided.

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3.BEARINGS
Bearing is a mechanical device used to support shafts or any rotating part, and
reduce friction.
Types of Bearings:
a. Ball Bearings:
Ball bearing is a bearing assembly which uses spherical balls as the rolling elements.
These bearings are good to impart rotational motion. However they are not efficient
when loaded and failed easily under vibrational loads.
b. Cylindrical Roller Bearings:
As technology progressed, need of bearings which could bear more load was felt. This
was possible by increasing the contact area and thus roller bearings were designed.
These had higher contact area and were much more efficient than ball bearings.
Roller bearings use cylinders instead of spheres that means the contact between the
inner and outer race is a line not a point. Thus the load is spread over a larger area
enabling the bearing to handle greater loads than ball bearings.
These bearings can bear much more radial loads than ball bearings but fail under axial
loads.

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Cylindrical Roller Bearing
Note:
 Axial Load: Load along the axis
 Radial Load: Load along the radius, or perpendicular to the Axis

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c. Taper Roller Bearing:
Tapered roller bearings use conical rollers that run on conical races.
 Unlike other roller bearings, they support both radial and axial loads, and are able
to carry higher loads.
 The conical geometry of tapered roller bearings provide a larger contact patch,
which allows greater loads to be carried as compared to spherical (ball) bearings.
 Tapered roller bearings can bear loads in one direction only.
Tapered Roller Bearing
d. Needle Roller Bearings:
Needle roller bearings are special roller bearings having slender cylindrical rollers that
enable them to bear highest load capacity for a given radial space of all rolling-element
bearings.
 Ideal for applications where high radial load carrying capacity is required but
radial space is limited.
 Such bearings also suit applications where high rotational speed is involved but
cannot accommodate axial loads.

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Tapered Roller Bearing
Comparison among Bearings:
Bearing Type Radial Load Capacity Thrust Load Capacity
Ball Bearing Good Good
Cylindrical Roller
Bearing
Excellent Poor
Tapered Roller
Bearing
Excellent Excellent
Needle Roller Bearing Excellent(Where radial
space is limited)
Very Poor
Bearing Lubrications:
 Self-Lubricated Bearings: Bearings which get lubricated by
the oil present in other components like gear box, axle tubes
etc.
 Externally Lubricated Bearings: Bearing which requires
external application of lubricant like grease is known as
externally lubricated bearing.

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4. OIL SEALS, O-RINGS AND GASKETS
a. Oil Seals
Oil seal is a device mounted on shafts to prevent leakage of lubricants from one
chamber to another.
A: The flexible material component of the seal which produces the lip. In this design
there is only one lip, the primary sealing lip.
B: The outer shell of the seal holds the seal in place.
C: The garter spring (found in most seal designs) is a coiled wire spring that provides a
controlled radial load over time.
Functions and Application of Oil Seals:
 The first job of the seal is to keep the oil in and the dirt out.
 It can also be used to separate fluids and to with stand different pressures.
 They also stop harmful contaminants from entering machinery.
 Oil seals protect all types of precision-constructed, close-fitting ball, sleeve and
roller bearings.
 Vital components of practically every type of machine and vehicle in operation.
b. O-Rings:
An O-ring is a torus, or doughnut-shaped ring, generally moulded from an elastomer,
although O-rings are also made from PTFE and other thermoplastic materials, as well as
metals, both hollow and solid.

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O-rings
How does an O-ring Work?
An O-ring seals by blocking any potential leak path of a fluid (liquid or gas) between two
closely spaced surfaces. The O-ring is generally installed in a machined groove in one of
the surfaces to be sealed. As the two surfaces are brought together, forming a gland,
they squeeze the cross section of the O-ring. This squeezing action results in a
deformation of the O-ring cross section. With O-rings, the greater the squeeze, the
larger the deformation. They deform such that all surface irregularities and gap are
occupied by the ring. Hence leakage is not permitted

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Material of O-rings: Elastomers
Nitrile rubber (NBR, HNBR, HSN): a common material for O-rings and oil seals because of
its good mechanical properties, its resistance to lubricants and greases, and its relatively
low cost. The physical and chemical resistance properties of NBR materials are
determined by the acrylonitrile (ACN) content of the base polymer: low content ensures
good flexibility at low temperatures, but offers limited resistance to oils and fuels.
Standard grades of NBR are typically resistant to mineral oil-based lubricants and
greases, many grades of hydraulic fluids, aliphatic hydrocarbons, silicone oils and
greases and water to about 80 °C. NBR is generally not resistant to aromatic and
chlorinated hydrocarbons, fuels with a high aromatic content, polar solvents, glycol-
based brake fluids and non-flammable hydraulic fluids (HFD).
Note : O-ring material cracks if exposed to atmosphere. So, to prevent this, they are
kept in oil.
O-rings vs Oil Seals:
 Function of Oil seal and O-Rings are same they made for sealing but they are
different in construction and application. Some oil seals are made of high Sulphur
content rubber instead O-Rings are made up of special rubber materials.
 Oil Seals are used generally with rotating and sliding components whereas the O-
Rings are used with the stationary parts.
 They are dipped in oil for their proper handling so that the material of Oil seals
and O-Rings does not effected by the moisture and dust particles.
c. Gaskets:
A gasket is a compressible material, or a combination of materials which is clamped
between two stationary members to prevent the passage of the fluids or dirt from
outside those members into the machinery.

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Purpose of Gaskets:
 To confine gas, oil, water or any fluid.
 Seal out foreign objects such as; Dirt, Water.
 Must withstand heat, cold, pressure, erosion, corrosion, moisture and oil.
Types of Gaskets:
 Metal Jacketed Gaskets
The gasket consists of a soft filler encapsulated with a metal cover. The metal
jacket provides compressive strength and blow out resistance. The filler provides
compressibility and resilience.
 Rubber Gaskets
These type of gaskets are generally made by silicon rubber (vulcanized rubber).
They have excellent weather/UV resistance and have a very long life under high
temperature and pressure.
 PTFE (Polytetrafluoroethene gaskets)
PTFE provides an outstanding chemical resistance and has excellent anti-stick and
Dielectric properties. Usually the leak rates of PTFE gaskets are remarkably low
the only drawback of PTFE is creeping and poor mechanical properties.

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Conclusion
 The Purpose of the skill development module is to develop a structured process for the
development of the operators of different level.
 It will help in identifying the skills to be developed specifically at particular stations for
various categories of operators available.
 It would provide the basis for the manpower planning and skill development for
operators.
 This projects aims towards developing a structured process for recruitment, training,
and development of operators through station -wise task analysis and skill requirement
assignment.
 This will classify the workstations in terms of skill requirement.
 These modules will increase the awareness and knowledge of different level of
operators which results the production of more quality product with greater efficiency.
 These modules will help in reducing wastages, accidents and enhances the product
quality with the same man-power.
 Assess each activity at each station as per skill requirements in five different categories
in increasing gradient of different level (Criterion Development).
 Mark each station in terms of skill requirements.