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Attachment Word Millat
Attachment Word Millat
Attachment Word Millat
Submitted to:
HR Millat Tractors Limited
Submitted by:
• Ali Arshad
• Muhammad Shahid Hussain
• Ali Raza Saeed
• M. Awais
• M. Touseef Shoaib
• Saad Hassan
• M. Nouman Zahid
• Asad Rehman
• M. Rizwan Akram
• Ijaz Ali
• Ammar Hassan
• M. Sheraz
• Usama Abdul Qadeer
• M. Waqas
• M. Ahmad
• Usama Yaseen
• Shabaan Anjum
Discipline:
MECHANICAL ENGINEERING
Duration:
July 29, 2019 to August 25, 2019
MILLAT TRACTORS LTD.
Table of Contents
✓ Introduction .......................................................................................................... 4
Summary .................................................................................................................................................. 4
Industrial Products................................................................................................................................... 5
Agricultural implements .......................................................................................................................... 5
✓ Machining Division ................................................................................................ 5
Transmission Case Gear Box .................................................................................................................... 6
Raw casting vendors ................................................................................................................................ 6
Material ................................................................................................................................................... 6
Process ............................................................................................................................................. 6
OPERATIONS .................................................................................................................................... 6
Center Housing .................................................................................................................................... 8
SECTION # 1 ..................................................................................................................................... 8
SECTION # 2 ..................................................................................................................................... 9
Cylinder Head ...................................................................................................................................... 9
Cylinder Block .................................................................................................................................... 10
Axle Housing (Material SG-Iron) ........................................................................................................ 12
✓ Engine Assembly Plant ......................................................................................... 13
Diesel Engine:................................................................................................................................. 13
Size of Engine ................................................................................................................................. 13
Diesel Engine types ........................................................................................................................ 14
Types of Models ............................................................................................................................. 14
Sections .......................................................................................................................................... 14
Engine Assembly Line ............................................................................................................................ 15
Imports........................................................................................................................................... 15
Test Shop ........................................................................................................................................... 16
Rectification ....................................................................................................................................... 17
Quality Assurance .................................................................................................................................. 18
▪ Mechanical Testing Lab ......................................................................................................... 18
▪ Metrology Lab ........................................................................................................................ 18
▪ Chemical Analysis and Metallography Lab ............................................................................ 18
✓ Tractor Assembly Plant ........................................................................................ 19
Axle Assembly .................................................................................................................................... 19
▪ Engine .......................................................................................................................... 23
▪ Chassis Phosphate Unit ............................................................................................... 23
INTERNSHIP REPORT 2
INTERNSHIP REPORT 3
MILLAT TRACTORS LTD.
Introduction
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).
As in mechanical engineering; there is a lot of practical work. University tries its best to create
a healthy environment for students.
But still there are subjects of interests which should be addressed through industrial tours. In
industries one can gain a lot of practical knowledge about different subjects of mechanical
engineering like Thermodynamics, Mechanics of Materials, Machine Design, manufacturing
processes, engineering management and a lot more practical and applied knowledge related
to the field.
Millat Tractors Ltd. gave us an opportunity to have a complete survey of different areas of
industry to learn and to understand the practical knowledge of the things we studied in class.
This report is a basic overview of the pros & cons of the internship. And in order to give a brief
overview of the industry.
Summary
This report is based on the activities performed during the internship at Millat Tractors Ltd.
Internship duration was almost of two weeks and it provided practical knowledge of working
in professional environment. This learning experience is described in detail and the various
sections of this report. In the first section, there is some detail about the company. The history
and present status of the company is explained. The organization structure and the details of
its operations along with its location are also discussed. I have also discussed the
manufacturing sequence and the important departments of the company.
The second section provides information about the activities that I performed during the
internship. I worked as an internee in marketing and production department.
INTERNSHIP REPORT 4
MILLAT TRACTORS LTD.
Industrial Products
• Millat Generating Sets
• Massey Generating Sets
• Fork Lift Truck
• Prime movers
Agricultural implements
• Chisel Plough (MT-01)
• Disc Plough (MT-765)
• Mould Board Plough (MT-02(M))
• Mould Board Plough (MT-02(H))
• Tine Tillers (MT-38/ 9 tines)
• Tine Tillers (MT-38/11 tines)
• Tine Tillers (MT-38/13 tines)
• Front Blade MF-08/1 (for MF240/MF260)
• Front BladeMT-08/2 (for MF375E/MF385)
• Multi-Purpose Rare Blade (MT-21)
• Agriculture Loader MT-11/2 (for MF 385)
• Farm TrailerMT-12/2 (for MF240/MF260)
• Farm Trailer MT-12/3 (for MF375E/MF385)
• Swinging Draw Bar MT-15
• Jib Crane MT-16
• Post Hole Digger MF-815
Machining Division
There are nine lines in the machining division listed below
INTERNSHIP REPORT 5
MILLAT TRACTORS LTD.
Material
• Grade 14
• Hardness (189-229)
• Weight(87 kg before machining)
(83 kg after machining)
Process
• Material management
• Balancing
OPERATIONS
✓ Front face
✓ Top
✓ Rear
✓ Bottom
✓ Right
✓ Left
INTERNSHIP REPORT 6
MILLAT TRACTORS LTD.
✓ Boring of central main shaft holes and starter motor edge facing are performed in
this operation.
✓ Final boring and reaming of dowels and forward and reverse gears with 20 microns
accuracy.
✓ Bottom face
✓ Drilling and Tapping
✓ Oil leakage hole
INTERNSHIP REPORT 7
MILLAT TRACTORS LTD.
Center Housing
Here balancing by receiver gauge for cutting allowance.
It is divided into four sections.
SECTION # 1
▪ Operation # 20 (Semi-Auto PLC Face Milling Machine)
✓ Lug facing is performed on this machine.
INTERNSHIP REPORT 8
MILLAT TRACTORS LTD.
SECTION # 2
Four operations are performed in this section.
▪ Operation # 140 (Double X Milling Machine)
✓ Duplex
✓ (Side cover) right & left milling operations are performed here.
Cylinder Head
▪ Operation # 1 (Plant # 756)(Milling Machine)
✓ Joint face
✓ Cover face
✓ Rough cut
✓ Final cut
▪ Operation # 4
INTERNSHIP REPORT 9
MILLAT TRACTORS LTD.
✓ Reaming
✓ Tapping of cast hole & threading
▪ Operation # 6
▪ Operation # 8
✓ Final milling
✓ Tapping of inlet & outlet
✓ Fixing of water jacket in head
▪ Operation # 9
▪ Operation # 10
✓ Valve fixing
Cylinder Block
▪ Operation # 1 (Radial drill machine)
▪ Operation # 3 (1554)
✓ Holes in head face and sum face (Dowel) which is used in water jacket.
✓ Complete operation on head & sum face by drilling, tapping and reaming.
✓ Hydraulic conveyor is used here for transportation.
▪ Operation # 4
Three types of gauges are used here for inspection.
✓ 1- plug gauge
INTERNSHIP REPORT 10
MILLAT TRACTORS LTD.
✓ 2- thread gauge
✓ 3- width gauge
▪ Operation # 5
▪ Operation # 7
✓ Rear and Front end facing & boring are performed in this operation.
▪ Operation # 8
▪ Operation # 9
✓ Finishing operations to make the sizes accurate up to 25 microns.
▪ Operation # 10 (5939)
▪ Operation # 16-17
✓ Oil holes production on bearing face
▪ Operation # 18
The all in one machine (works using reference points)
✓ Cam for lift pump
✓ Spring steal sealing caps (knock tight) for water gallery.
▪ Operation # (6270)
▪ Operation # (6403)
INTERNSHIP REPORT 11
MILLAT TRACTORS LTD.
▪ Operation # (749)
▪ Operation # 30A
✓ Outside turning
▪ Operation # 30B
✓ Outside turning
✓ Double head stock (left and right side)
▪ Operation # 40
▪ Operation # 50
✓ Facing of large end.
▪ Operation # 60
INTERNSHIP REPORT 12
MILLAT TRACTORS LTD.
▪ Operation # 90
✓ Drilling of Fendral boxes hole (for mud guard)
✓ Coolant used here: Cutting oil # 52
▪ Operation # 100
✓ Tapered drilling
Size of Engine:
There are three size groups of Diesel engines.
▪ Small - Under 188 kW (252 hp) output
▪ Medium
▪ Large
INTERNSHIP REPORT 13
MILLAT TRACTORS LTD.
3- Cylinder Types
▪ Model-240: Simple diesel engine model
▪ Model-260: Diesel engine with Turbo Charger
4- Cylinder Types
▪ Model-375
▪ Model-385
4- Cylinder engine block are imported from China
Types of Models:
▪ MF 240 (50 hp)
▪ MF 260 (60 hp)
▪ MF 350 (50 hp)
▪ MF 375 (75 hp)
▪ MF 385 (85 hp)
▪ MF 385 4W (85 hp)
Sections:
The Engine Assembly plant is divided in to four main parts:
▪ Segregation
▪ Assembly Line
▪ Test Shop
▪ Rectification
Segregation:
After the machining process on engine block the engine block is forwarded to
the Assembly Plant where it is washed in the washing machines at 80 C of
temperature. This machine is also called Degreasing Machine. In this process
Crankshaft also washes in the temperature of 60 C and the chemical which is used
for washing is Trio- lone. This process is known as segregation.
Pre-Assembly Operations:
All parts of engines, incoming for Engine Assembly are oiled.
1. First operation on parts is Poly ethylene washing
2. Second operation is Air blowing
INTERNSHIP REPORT 14
MILLAT TRACTORS LTD.
TAP
OP-40 OP-30 OP-20 OP-10
Imports
4-Cylinder engine block are imported from China
Crank shaft from turkey
Operation # 10
▪ Assembly and grading of bearing shells, crank shaft, thrust washers and adapter
▪ Assembly of cam-shaft, Pin dowels, Studs, and screw
Fixing of crank-shaft
Shift the block to trolley
▪ Assembly of tappet drain plug and trolley support, torque the crank shaft
Operation # 20
▪ Punching of Engine Number
▪ Assembly and tightening of Cam-shaft gear
▪ Alignment of timing case and tightening of bolts
▪ Assembly and tightening of water jacket, bridge piece and timing case.
Operation # 30
▪ Assembly and tightening of main oil seal and bearing shells
▪ Insertion of piston
▪ Tightening and torque check of Con-rod, Assembly of main oil seal with bolts
INTERNSHIP REPORT 15
MILLAT TRACTORS LTD.
Operation # 40
▪ Alignment of balancer
▪ Assembly of balancer section pipe, fuel pump and sump stud
▪ Assembly of fuel pump gear and timing mark
▪ Tightening and torque check of gears and balancer
▪ Checking of back lash.
Operation # 60
Operation # 70
Operation # 80
▪ Coloring, Alignment and torque check of timing case
▪ Assembly, tightening and torque check of Injector (Code-HL) and pressure pipe.
Operation # 90
▪ Assembly, tightening and torque check of crack pulley, induction manifold hose pipe
(inlet and outlet) and side plate.
▪ Assembly and tightening of oil filter with head and cooler, return pipe, water outlet and
thermostats
Here (Engine ---> oil filter head ---> Cooler ---> oil filter)
Operation # 100
Test Shop
In the Test Shop there are different testing beds which are used for testing the
Engine R.P.M, Oil leakage and tappet setting .Different ranges are given below
INTERNSHIP REPORT 16
MILLAT TRACTORS LTD.
This table shows the ranges of testing values. If the engine performance is
between these values then the engine is passed but if the values greater than the
engine is rejected and forwarded to the Rectification.
Rectification
In Rectification section, following errors are removed:
▪ Water Leakage
Check water pump, Head Gasket, Water Plug, Drain Plug and Cylinder
Head rear plate.
▪ 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.
▪ Fuel Leakage
Checking of Fuel injection Pump, fuel injection pressure and Fuel lift pump.
▪ Sound Testing
Proper checking of all the Timing gears and Knocking.
▪ Appearance
Checking of Missing and Vibration.
INTERNSHIP REPORT 17
MILLAT TRACTORS LTD.
Quality Assurance
Quality assurance department ensured the quality and reliability of the products by
exercising the quality control rules in all departments in order to achieve the
customer satisfaction.
There are several sections which ensure the quality of the product, each of these is
discussed here:
QA – BOF
Here all the products which are bought from the vendors are tested to
check whether it meets the required criteria or not. A sample of each
component is selected from the lot for the test.
▪ Metrology Lab
In this lab following instruments are used:
1) Involutes Gear Tester-It is used to check
➢ Vertical profile of gear
➢ Involutes profile of gear
2) Involutes Gear Tester -It is used to check
➢ Tooth error
➢ Total composite error
➢ Total tolerance error
3) Universal Measuring Machine (UMM)-It is used to
➢ Calibrate the gauges
INTERNSHIP REPORT 18
MILLAT TRACTORS LTD.
➢ Thermostat test
➢ Oil immersion test for rubber
➢ Heat treated test for rubber
➢ Glassy test for paint
➢ Drop point test for oil and lubricants
➢ Viscosity test for lubricants and oils
➢ Flash point test
➢ Metallography
✓ QA – TAP
Similarly QA section in the TAP takes the complete audit of each tractor to
ensure the quality and reliability.
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.
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.
INTERNSHIP REPORT 19
MILLAT TRACTORS LTD.
Engine Attachment:
The most important part “the engine” of the tractor is attached here. Engine is
attached and the contacts are provided to the gear box.
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.
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.
Procedure:
Assembled engines and all other parts from machining division are sent to the tractor
assembly plant for assembly of tractors. Tractor assembly plant is divided into the
following sections:
▪ Rear Axle Belt
▪ Assembly Line 1
▪ Assembly Line 2
▪ Assembly Line 3
INTERNSHIP REPORT 20
MILLAT TRACTORS LTD.
Front /Rear
Axle Assembly
Flash Off Paint
Area Booth
Assembly
Hydraulic pump
Axle Housing
Assembly Fuel Tank
Hydraulic
lift Test Assembly
Central Housing
Seat
Assembly
Assembly
Fender Battery +
Star Gear Wire Con.
Assembly
Assembly
INTERNSHIP REPORT 21
MILLAT TRACTORS LTD.
✓ Axle Assembly
There are two types of axle assemblies.
Assembly line 1
Here three main components are attached to the center housing. These
components are as follows:
▪ Gear Box
Gear Box is assembled in a sub-assembly named as “TRANSMISSION SUB ASSEMBLY” where
the following components are attached:
INTERNSHIP REPORT 22
MILLAT TRACTORS LTD.
➢ Reverse Gear
➢ Counter Shaft
➢ Clutch Shaft
➢ Main Shaft
➢ Rail Shaft
➢ Rear Main Drive Shaft
➢ Small & Big Pinion Gear
➢ Lock & Fork
➢ Carrier Ring
➢ PTO Coupler
➢ PTO Gear
➢ Steering Mechanism
➢ Gear Levers
Assembly line 2
▪ Engine
Engine is attached ahead of gear box. Engine is assembled in a subassembly named as
ENGINE PREPARATION. Then foot board is assembled
which is prepared in a sub-assembly named as FOOT BOARD. Then brake pedal
is assembled which is prepared in a sub-assembly named as BRAKE PEDAL.
INTERNSHIP REPORT 23
MILLAT TRACTORS LTD.
▪ Drying Oven
After the water raise unit, the chassis is sent to the drying oven under temperature 68 C.
▪ Paint Booth
The assembly is then sent to the paint booth where grey paint is sprayed.
Assembly line 3
This line is also called the Cosmetic Line. Here the remaining parts are assembled. These
parts with their sub-assemblies are mentioned under:
▪ Radiator
It is assembled in the RADIATOR ASSEMBLY.
▪ Fuel Tank
It is assembled in the FUEL TANK ASSEMBLY.
▪ Rear Fender
It is assembled in the FENDER ASSEMBLY.
▪ Top Hood
It is assembled in the HOOD ASSEMBLY.
▪ Front Grill
It is assembled in the GRILL ASSEMBLY.
▪ Oil Filter
Here oil filter is fitted.
▪ Generator
Here generator is attached.
INTERNSHIP REPORT 24
MILLAT TRACTORS LTD.
▪ Side Hood
Side hoods are attached here which are coming from different line.
▪ Battery
Then battery is attached.
INTERNSHIP REPORT 25