Automatic gear transmission system is the most advanced system in which drives mechanical efforts are reduced very much and different speeds are obtained automatically. This system is generally also called hydramatic transmission. It contain epicyclic gear arrangement, fluid coupling and torque converter.

1. How automatic gear box works

2. Classification
rear wheel drive
Front wheel drive

3. Introduction

4. PROJECTINDEX
1.SELECTION OF PROJECT
2.DEFINITION OF PROJECT
3.ANALYSIS OF PROBLEM
4.CAUSE AND EFFECT ANALYSIS
5.DEVELOPMENT OF SOLUTION
6.REGULAR IMPLEMENTATION
7.CONCLUSION

5. SELECTION OF PROJECT
 TO REDUCE BORE UNCLEAR REJECTIONS IN
SMALL END OF THE CONNECTING ROD
 PART NAME:CONNECTING ROD
 COMPONENT:BACR13

6. DEFINITION OF CONNECTING ROD A rod connecting two moving parts in a mechanism
, especially that between piston and the crank shaft
in an engine or pump.
BIG END
STEM
SMALL END

7. ANALYSIS OF PROBLEM
RAW MATERIAL SPECIFICATION :
TEST METHOD=158811-1998
EQUIPMENT=OPTICAL EMISSION SPECTROMETER
CHEMICAL COMPOSITON
ELEMENT MIN. MAX.
CO 0.19 0.22
Mn 0.6 0.85
Si 0.15 0.35
S _ 0.03
P _ 0.03
Cr 0.9 1.2
Ni _ 0.2
Mo 0.17 0.3
Al _ 0.025
HARDNESS=230BHN Max.
BENDING THICKNESS=40microns Max.

8. ANALYSIS OF PROBLEM
PARAMETERS TO BE MAINTAINED IN
CONNECTING ROD:
 PITCH DISTANCE
 PERPENDICULARITY OR SQUARENESS
 OVALITY
 SURFACE FINISH
 WALL THICKNESS
BIG END TAPER , OVALITY , BORE UNCLEAR
SMALL END TAPER , OVALITY , BORE UNCL
SURFACE FINISH , PERPENDICULARITY , PITCH DISTANCE

9. DEFINITIONOF PROBLEMSETTING
OBJECTIVES
P-PRODUCTIVITY TO BE IMPROVED
Q-REJECTION PERCENTAGE TO BE REDUCED
C-OPERATIONAL COST TO BE REDUCED
D-ON TIME DELIVERY TO BE ACHIVED

10. GOAL SETTING
ACTUA
L
TARGET
BORE UNCLEAR REJECTION IN 3 MONTHS

11. PROCESSFLOWCHARTOFCONNECTINGROD
RAW
MATERIAL
FORGING
INWARD
INSPECTION
SMALL END
DRILLING
BIG END
ROUGH
BORING AND
CHAMFERING
INDUCTION
SOFTENING
SHOT
BLSTING
TEMPERING
CASE
HARDNING
OIL HOLE
DRILLING
2ND SIDE
CHAMFERING
SYMMETRY
INSP.AND
CORRECTION
FINISH
GRINDING
BOTH SIDES
BIG
END&SMALL
END HARD
BORING
OIL HOLE
DEBURGRING
SMALL END
CHAMFERING BIG END
HONNING
BIG END BORE
INSPECTION
SMALL END
BORE
INSPECTION
VISUAL
INSPECTION
CD,BEND&TWI
ST
INSPECTION&
CORRECTION
CLEANING
SMALL END
HONNING
BIG END
MARKING
SAMPLING
INSPECTION
PACKIMG
BAJAJ AUTO
LTD.

12. SMALL END DRILLING
SANSERA VERTICAL MACHINING(SVM)

13. SANSERA HORIZONTAL DRILLING MACHINING
(SHD)
DRILLING OF OIL HOLE DONE
HERE FOR OIL FLOW

14. CASE HARDENING
TEMPERING
SHOT BLASTING
INDUCTION SOFTNING

15. SYMMETRY CORRECTION
DIAL GAUGE

16. DOUBLE DISC GRINDING
 FACE GRINDING DONE HERE FOR
BOTH FACES OF CONNECTING ROD

17. BIG END BORING
SMALL END BORING
.
SANSERA FINE BORING MACHINE

18. FINISHED FINE HONING FOR BIG END & SMALL END
 VERTICAL HONING MACHINE

19. WASHING MACHINE
REMOVAL OF OIL AND WATER FROM THE
COMPONENT SURFACE
BENDING TEST-8microns
TWISTING TEST-12microns
CENTRE TEST-250 to 350mm
SMALL END BORE DIA.
CHECKING
BIG END BORE DIA.
CHECKING
VISUAL INSPECTION
DISPATCH

20. ALL THE PROBABLE CAUSES ARE LISTED
BELOW
MACHINE MEASUREMENT
MATERIAL
METHODMAN
FISH BONE
DIAGRAM

21.  MACHINE
FLOAT PAD MISMATCH
ARM SCREW OVERTIGHT
CENTRE HEIGHT POINT PROBLEM
IMPROPER INSERT
LOCATOR PROBLEM
INCORRECT FIXTURE
 MEASUREMENT
 WALL THICKNESS VARIATION
 DIAMETER VARIATION
 PITCH DISTANCE VARIATION
 MATERIAL SPECIFICATIONS

22.  MAN
UNSKILLED OPERATOR
LACK OF EXPERIENCE
LAZYNESS
LACK OF CONCENTRATION
URGENCY
 METHOD
UNCONVENTIONAL METHOD
INCORRECT TOOL SELECTION
IMPROPER PROGRAMMING
FLOT PAD MISMATCH

23. TRAIL SHEET
FIXTURE CALIBRATION REPORT

24. Through trials we have
concluded that unclear
occurs during boring and
honing operations

25. actual CAUSES FOR UNCLeaR
 Float pad mismatch of the work piece
 Arm screw over tight
 Variation in Centre distance
 Power failure problem
 Smaller end arm tool problem
 Locator problem
 Incorrect component loading
 Incorrect fixture
 Butting , improper resting of work piece (The piece get crossed
or work piece move sideways)
 Offset setting changes

26. SUGGESTION TO REDUCE UNCLEAR
 Arm screw should be properly tightened, otherwise
component lifts
 There should be frequent supply of power, otherwise taper,
step lines and unclear occurs
 Insert should be changed within 150 in number, otherwise
undersize occurs
 If insert is changed NT system should be controlled
properly
 After face grinding symmetry must be checked once again
 Operators should be well trained