TRAINING REPORT

OF

SIX WEEK INDUSTRIAL TRAINING, UNDERTAKEN

AT

“SML ISUZU LIMITED”

IN

“TOOL DEPARTMENT”

SUBMITTED IN PARTIAL FULFILLMENT OF THE SIX WEEK

INDUSTRIAL TRAINING

IN

MECHANICAL BRANCH

Under the Guidance of Submitted by:

Name: Mr. Manoj Kumar Name: Deepak Kumar
Designation: Manager College Roll No: 1320351
Department: Tool Department

RAYAT INSTITUTE OF ENGINEERING AND INFORMATION

TECHNOLOGY RAILMAJRA
SBS NAGAR NAWANSHAHR Punjab
 ACKNOWLEDGEMENT

I am highly grateful to the Rayat Institute of Engineering & Information Technology for
providing this opportunity to carry out the six week industrial training at SML ISUZU LTD.
ROPAR.

This Training program has been a collective effort of several individuals. It is therefore my
foremost duty to acknowledge their efforts that helped me to complete my training.

I express my heartfelt gratitude towards Mr. Manoj Kumar (Senior Manager, Tool
Department) & for guiding me through my training program.

His enthusiasm and optimism made this training enjoyable and rewarding. Most of novel ideas
and solution in this work are a result of our numerous stimulating discussions. Their feedback
and editorial comments were invaluable.

I express gratitude to other faculty members of Mechanical Engineering department of IET for
their intellectual support throughout the course of this work.

Deepak Kumar

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 PREFACE
Industrial training is the bridge to the student that takes him from the words of theoretical
knowledge to the world of practical knowledge. By undergoing training in the industry, a
student can narrow down the gap between the institute, workshop & industry.

The main purpose of industrial training is to expose ourselves to the industrial environment
which cannot be possible in the classroom. Keeping in view this thing, students are sent to the
various organizations for getting the practical training. The present report is a report that has
been done as an industrial training project over a training period of six weeks of B-Tech.
(Mechanical Engineering) at SML ISUZU LTD. ROPAR.

During this training, I got exposure to various equipments & machines, their maintenance &
technologies, related to manufacturing of trucks.
Hence, industrial training was assisted in developing self-confidence. The training helped me
in having view of implementing my theoretical knowledge to the actual industrial
environment. The training at SML ISUZU LTD. is definitely going to play an important role
in developing an aptitude for hard work and self confidence necessary for my successful
future.

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 OBJECTIVES OF TRAINING:-

The major objectives of training are as follows:

1. To impart knowledge to new recruits.
2. To impart skills to the new employees which are needed by the organization.
3. In developing better behavior patterns which are appropriate to their jobs and
responsibilities.
4. To increase efficiency and morale.
5. For promotion, to provide successors.
6. To increase potential.

TRAINING means :-

T= to be in time on your seat.

R= remain attentive all the time.
A= actively participate.
I= interact for clarity
N= note points difficult to memories.
I= improve listening habit.
N= never neglect the program.
G=gain as much as you can.

Training should be continuous and progressive designed to increase the individual potential of
maintenance staff members and to form them into a technically qualified and well-organized
efficient team.

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 TABLE OF CONTENTS

SERIAL NO. PARTICULARS PAGE NO.

1. Corporate Profile 5-9

2. Evolving Journey Of SML ISUZU 10-11
3. Share holding pattern present 12
4. 5S Activity in SML ISUZU limited 13
5. Organizational set up of SML ISUZU LTD. 14
OrSml
Variousisuzu limited Shop
Departments Classification
of SML ISUZU LTD. 15
7
8 Flow diagram of the SML ISUZU plant 16
Paint Shop
9 Tool Department 17-20
11 Quality Engineering Department 21
12 Metrology lab 22

13 Standard Room 23-26

14 conclusion 27

15 Bibliography 28

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 SML ISUZU LIMITED
Corporate Profile

SML ISUZU limited was promoted in 5th October 1984 in technical and financial
collaboration with Punjab tractors limited, Mazda motors corporation and Sumitomo motors
corporation, Japan, for manufacturing of light commercial vehicles (LCV’s). SML ISUZU
limited represents two powerful brands: SML- symbolizing best Indian technology and
engineering and ISUZU- an international player. Mazda Motors Corporation of Japan,
established in 1920, is an enterprise of international repute. Mazda started manufacturing
trucks as back in1931. Today this enterprise has the distinction in being the only company in
the world producing petrol and diesel engine as well as the revolutionary rotary engines.
ISUZU is ever seeing the new areas of product excellence and innovation. It adheres
audaciously to 2000 check point before declaring any vehicle road worthy. The use of robots,
latest technology and world class production enables Isuzu to produce vehicles of outstanding
quality and performance. No wonder Sml isuzu limited has won appreciations all over the
world for the quality products that are rolling out its plant.
The assembly unit of Sml isuzu limtied is located at village Asron district Nawanshahar
(Punjab) near the city of Ropar and at a distance of 40kms from the capital city of Chandigarh
the plant has a captivating site. It is spread over a quaint, sprawling 100 acres of land ringed
by shiwalik hills on the three of its sides and river Satluj on the other.

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About ISUZU
Isuzu Motors Ltd., is a Japanese car, commercial vehicle and heavy truck manufacturing
company, headquartered in Tokyo. In 2005, Isuzu became the world's largest manufacturer of
medium to heavy duty trucks. It has assembly and manufacturing plants in the Japanese city of
Fujisawa, as well as in the prefectures Tochigi and Hokkaido. Isuzu is famous for producing
commercial vehicles and Diesel engines. By 2009, Isuzu had produced over 21 million diesel
engines, which can be found in vehicles all over the world Isuzu diesel engines are used by
Renault,Opel and General Motors.
In most of Asia, Africa and Europe, Isuzu is mostly known for trucks of all sizes, after Isuzu
small automobile sales drastically plummeted and Isuzu had to drop all sales of sedans and
compact cars in the late 1990s. In 2009, Isuzu abandoned the United States consumer market
due to lack of salesIsuzu has a contract with Budget Truck Rental to manufacture their rental
trucks. This contract is also shared with Ford,GMC, and Navistar International.
On November 7, 2006, TOYOTA acquired 5.9% of Isuzu, making them the third largest
shareholder behind ITOCHU and MITSUBISHI CORPORATION.

Discipline and its right enforcement is an important hallmark of the Sml Isuzu. It is a great
significance in evolving work culture. All the employees, irrespective of their position or
status, have to punch their position or status, when they report for duty. As a result strict
punctuality has become a way of life and work with them.

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To ensure industrial peace i.e. absence of the strikes and lockouts, Sml isuzu limited believes
in creating a contented labour force with a very low rate of absenteeism and turn over.
Reasonably fair wages and various perks like subsidized uniform and transport, mess facilities
go a long way in creating identification with the job. Earnestness, sincerity and spirit of co-
operation pervade the entire atmosphere of the company.
No politics of confrontation is found in Sml Isuzu. Problems if any are sorted out through
mutual negotiations in an amiable atmosphere of give and take. These positive steps have been
instrumental in evolving work ethos. The happy absence of industrial disputes in the enterprise
speaks volumes for the success of these and cultivation of work culture. Work culture of work
ethos is given high priority. It is fully recognized that the objective of the enterprise – higher
and higher production, productivity and indigenization can be attainted through commitment in
to commonness of goal in each and every member of Sml isuzu family. The entire planning is
undertaken in such a way as to inculcate the spirit of dedication in each member whether he is
a semi-skilled worker or belongs to the managerial cadre. Many effective steps are taken to
bring this about and important among them are:
Common canteen and mess for all. Same meals are served to all and in identical utensils.
Everybody has to stand in a queue to get his or her meals.
Common uniform is there for all new members irrespective of their status.
No separate cabins for the members of a higher hierarchy. All the members of a department or
a section there of sit and work in one hall with the manager.
The LCV’s are manufactured in five colours- Santos red, Nile blue, Light Beige, White and
Golden Yellow. In addition to this other colours can be made on demand. The most distinguish
feature of these vehicle is that beneath the design and sleek looks are the study box section
tubular crossed braced chassis. The chassis are more than three times stronger than other
vehicle on the road. Sml isuzu vehicles are not only stronger on the road but also fuel efficient.
Fully loaded they give an average of 13.5 Km/l at 45 Km/hr. A hydraulic assisted diaphragm
reduces the clutch pressure by 37 percent. A low RPM high torque engine assures long life and
hanging speed for uphill driving. A spacious three seater cab with three level air vents make
the cab extremely comfortable and driving a treat
Prominent among the load carriers Sml isuzu limited is also manufacturing:
4 wheel drives;

Page | 8
Extended wheel base long chassis mini buses which carry up to 44 passengers.
Deluxe buses carry up to 40 passengers.
Ambulance developed with active involvement of senior specialist from post graduate institute
of medical science and research, Chandigarh.
Hydraulic operated dumpers.
Dual cabin load carriers.
Integrated garbage collection and disposal system for urban centers.
Sml isuzu limited vehicles population today stands over 70,000. Sml isuzu limited gives due
attention to the marketing part and the employees are highly qualified and trained to fit the job.
Sml isuzu limited has a vast network of over 128 dealers spread throughout the country
including the A & N Island. Zonal office opened in Chandigarh, Lucknow, Calcutta,
Ahemdabad, Mumbai, and Chennai. This helps substantially in sales promotion, especially for
hi-tech products, is also being emphasized.Discipline and rigid enforcement without
discrimination are important hallmark of Sml Isuzu. It is of great significance in involving
work culture. All the employees, irrespective of their position and status, have to punch their
cards when they report for duty; as a result, strict punctuality has become a way of life and
work with them. To insure industrial peace, i.e. absence of strike and lockouts Sml isuzu
limited believes in making a contended labour force with a very slow rate of absenteeism.
Reasonably fair wages and various perks like subsidized uniform and transport, mess facilities
go a long way in creating identification with the jobThe entire planning is undertaking in such
a way so as to inculcate the spirit of dedication in each member, whether he is a skilled or
semi-skilled worker or belongs to the managerial cadre. The corporate profile of SML ISUZU
LTD. projects a bright future for the company. It is adding its share to the real assets and job
opportunities in the areas thus bringing socio-economic reforms in whole of Punjab.

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 Evolving Journey of Sml Isuzu limited
1983: SML vehicles limited (SVL) in corporate in July.
1984: joint venture and technical assistance concluded between Punjab tractors limited, Isuzu
motors corporation and Sumito corporation Japan.
1985: Project set up with the capacity of 5,000 LCV’s at a capital outlay of 200 millions.

1985: Trail production and test marketing of SML truck WT-48 WT- 49 WT-50 LCV’s
commenced.
1986: commercial operation started.
1988: Introduction of indigenously developed bus.
1989: In-house tooling of local production of chassis long member.
1990: In-house developed second truck model (SWARAJ MAZDA Super) launched.
1991: Transmission components indigenized.
1992: Components of trucks supplied to ministry of defense (MOD). 500 vehicles supplied to
defense.
1993: Third truck model (SWARAJ MAZDA PREMIUM) launched.
1994: Declared a sick company under SICA (due to rupee devaluation of 1991-93)
1995: BIFR approves rehabilitation.
1996: 4- wheel truck developed.
1997: Company ceases to be a sick industrial company on the basis of positive net worth. 4-
years of BIFR scheme projection.
1998: complete wipe of accumulated losses.
1999: Bharat Stage-1 emission norms compiled.
2000: Maiden dividend declared @ 10% technical assistance agreement with Isuzu extended
up to October 2004.
2000: Cumulative sales crosses 50.000 vehicles, 4- wheel drives ambulance launched in
March, economy truck “SARTAJ” launched in August, and CNG bus for NCR Delhi launched
in October, and Bharat Stage 2 emission norms compiled.
2002: Profit before tax for FY-2002 crosses Rs100 million and dividend raised to 25%.
2003: Cumulative vehicles sales reached 68,000, profit before tax for
FY-2003 grows 115% to Rs 225 millions, dividend enhanced to 45%.

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Page | 11
Share Holding Pattern Present

Page | 12
 5S Activity in Sml Isuzu limited

In order to achieve the goals set up by the concerns effectively and efficiently the organization
follows the 5S activity that is:
SIEIRI: Classify the things into necessary ones and unnecessary ones. Discard the
unnecessary ones.
SEITION: Put the things in order so that they are available when needed.
SEISO: Keep the work area and the machine /tool clean so that abnormal conditions are
detected.
SEIKETSU: keep the work area clean as well as the personal cleanliness. The conditions of
the company should be hygienic.
SHITSUKE: There should be all around discipline. The workers should be taught to work in a
disciplined manner.

The result of all this has been rapid increase in output of vehicles and sharp reduction in cash
loses. The turn over for 2007-2008 exceeds Rs. 300 crores. Today the company manufactures
light commercial vehicles like trucks, buses, police vans, water tankers, ambulance, and
special vehicles and also exports to the countries like Nepal, Zambia, Bangladesh, Kenya, Sri-
Lanka and Jordan.

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ORGANIZATIONAL SET UP OF SML ISUZU LIMITED
MANAGING DIRECTOR

EXECUTIVE DIRECTOR

VICE PRESIDENT ASSOCIATIVE

VICE
PRESIDENT

GENERAL MANAGER DEPUTY

GENERAL
MANAGER

SENIOR MANAGER CHIEF MANAGER

MANAGER

ASST MANAGER

ENGINEER SENIOR ENGINEER ASST ENGINEER

JUNIOR ENGINEER

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 Various Departments of SML ISUZU Limited
 Personnel Department
 Research and Development
 Quality Engineering Department
 Technology Department
 Tool Department
 Accounts Department
 Purchase Department
 Maintenance Department

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 Flow Diagram of the Sml Isuzu Plant

ENGINE BODY CABIN CABIN & CARGO

ASSEMBLY SHOP WELDIN ASSY & PAINTING
G
CABIN PRE
ENGINE COMPONENTS LONG MEMBER PARTS FROM TREATMENT CARGO BOX
FROM WASHING STORAGE STORE & BLACK FROM STORE
MACHINE DIPPING

TEMPORARY PART FLOOR BAKING CARGO BOX

ENGINE ASSEMBLY SETTING ASSEMBLY. ASSEMBLY
AND TESTING

SEALANT AND SLEEPER

TACK/FULL CABIN PRIMER ASSEMBLY
WELDING ASSEMBLY APPLICATION
T/M ASSY
LINE CARGO BOX
WELDING
STRAIN RELIEVING DOOR WELDING BAKING
& ASSEMBLY

TRANSMISSION
COMPONENTS FROM CHASSIS PAINTING FINAL CARGO
WASHING MACHINE FINAL FITTING PAINTING WASHING
AND FINISHING SEALANT
APPLICATION

TRANSMISSION BAKING
ASSEMBLY AND BAKING
TESTING TO PAINT SHOP
VEHICLE
ASSEMBLY
INSPECTION
LINE FINAL
PAINTING

PAINTED
FRONT/REAR AXLE & PRE DELIVERY CABIN TO
DIFFERENTIAL ASSY. INSPECTION VECH. ASSY.
BAKING

ROAD/SHOWER
TEST CABIN
AXLE COMPONENTS DRESSING INSPECTION
FROM WASHING WITH SUB
MACHINE ASSEMBLY
CARGO BOX
MOUNTING

AXLE
ASSY LINE RUST PREVENTIVE
APPLICATION

VEHICLE TO
STOCK YARD

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 TOOL DEPARTMENT
This department is one of the most important and crucial department. The responsibility of this
department is to prepare a tool according to the demand for different work and the quality of
incoming and outgoing components. There is a tool room. The oldest and most concrete sense of
the word toolroom is simply a room where tools are stored. The evolution of IT and its
integration into manufacturing is changing the questions and equations still further. For
example, CNC and robotics have led the way to rapid prototyping and instant manufacturing,
which shift the toolroom-production division by giving an up-front toolroom investment the
flexibility to be quickly and easily used for any product design, with batch size irrelevant.
Various machines are used for tool and die work such as drilling machines, shaper,
lathesmachine etc.

Tool and die makers are specialized machinists in the manufacturing industry who make
dies, machine tools, cutting tools and form tools , gauges, and other tools used in manufacturing
processes. Depending on which area of concentration a particular person works in, he or she may
be called by variations on the name, including tooling specialist, tool designers, mold designers,
tool designer or tool and die specialists. Tool and die makers work with engineering and work
primarily in tool rooms environments, sometimes literally in one room but more often in an
environment with flexible, semipermeable boundaries from production work. They are
skilled artisans (craftspeople) who typically learn their trade through a combination of academic
coursework and hands-on instruction, with a substantial period of on-the-job training that is
functionally an apprenticeship (although usually not nominally today).

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Tool making

Tool making typically means making tooling used to produce products. Common tools include
metal forming rolls, lathe bits, milling cutters, and form tools. Tool making may also include
precision fixtures or machine tools used to manufacture, hold, or test products during their
fabrication. Due to the unique nature of a tool maker's work, it is often necessary to fabricate
custom tools or modify standard tools.

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Die making
Die making is a sub-genre of tool making that focuses on making and maintaining dies. This
often includes making punches, dies, steel rule dies, and die sets. Precision is key in die making;
punches and dies must maintain proper clearance to produce parts accurately, and it is often
necessary to have die sets machined with tolerances of less than one thousandth of an inch.

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Jig maker
A jig maker is a field under tool and die maker,in woodworking or in the metal industries. The
standard differentiation of jigs from fixtures is that a jig is what mounts onto a workpiece,
whereas a fixture has the workpiece placed on it, into it, or next to it. A jig maker needs to know
how to use an assortment of machines to build devices used in automation, robotics, welding,
tapping, and mass production operations.
They are often advised by an engineer to do the per-planned work of making the devices. In a
production shop they need to know an extensive assortment of machines, tools, and materials,
and are often the most experienced toolmakers and woodworkers. The reason jig makers need to
be experienced is so they can make efficient alterations and needed repairs. They sometimes
assist and monitor the progress of the jig or the fixture's gauging, locating, and innovative ability.
Those who graduate to the level of jig and fixture makers.

The ongoing evolution of computerized design and control technologies, such

as CAD/CAM, CNC, PLC, and others, has changed the nature of the requirements for jigs in
manufacturing, in many cases reducing the need for jigs.

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 QUALITY ENGINEERING DEPARTMENT
This department is the most crucial department. The responsibility of this department is to ensure
the quality of incoming and outgoing components. Structure of quality engineering department is
as shown in figure. This department is to ensure that s has passed the various manufacturing,
checked and controlling facilities for quality production.

STRUCTURE OF QUALITY ENGINEERING DEPARTMENT

1. Quality Manufacturing:An LCV in brief has to pass through strict test numbering about 250.
Similarly, at sub assembly states etc. Like body shop, paint shop, day to day report of quality
goes to department for necessary action.
2. Quality Development:Quality development has given more stress on prevention of defects
rather than setting it right by rectification. In quality development for proper insurance of
quality, reliability, service and other aspects in manufacturing products through and scientific
activities. The job of evaluating the companies with respect to quality, reporting the result of
evaluation to all concerned department for necessary action and information.
Quality Engineering (receipt): It is responsible for every item that is being received at the
receipt store from various vendors. Since it is not possible to check each and every item,
therefore random sampling is done.

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Quality Engineering Lab : This department is responsible for all type of lab work in the
organization her all the critical dimensions are checked in the standard room with sophisticated
aides, and precision instruments. Various gauges like height gauges, dial indicators, profile
projector, thread gauges are used. Hardness test and tensile tests are conducted in this lab. Also
chemical compositions of various components are checked.
Metrology Lab:

Metrology lab is the place where all the material testing like hardness, chemical composition of
the materials and microstructure of the materials is done. Quality parameters which are tested
under this lab are:
Hardness: In the hardness test mainly components which are forged, casted, induction hardened
and carburized hardened have been checked.
a) Rockwell hardness machine: Rockwell hardness machine is used for harder materials. In this
machine there are three scale RC scale, RB scale and RA scale. Through this scale we find the
hardness number of the material.
1) On RC scale the load is 150 kg and indenter is of diamond
2) On RB scale load is 100 kg and indenter is of steel ball of diameter 1/16 inch.
3) On RA scale the load is 60 kg and indenter is of diamond.
b) Brinell hardness tester (BHN): This machine is used for testing material which is less harder
than which are tested under Rockwell hardness machine. In this hardness is finding as Brinell
hardness number (BHN). Load is 3000kgs and the indenter is steel ball of diameter 10 mm or
5mm.
c) Micro hardness tester: This tester machine is used for carburized components to check the
case depth of the components.

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Standard Room
As the name indicates standard room it’s the room where all the instruments are standard and all
the instruments which are used for measuring the dimensions of the parts of the components of
body parts of trucks assembly are calibrated with these instruments. There are some standards
instruments which are used for measuring the dimensions of engine parts and for calibration of
the other instruments which are as follow.

1. PROFILE PROJECTOR: Profile projector is the machine which is used for

projecting the projection of very small parts in the magnified way on the projector. It has vertical
optical axis and the image formed is inverted and reversed. Projection lenses have the
magnification of 5X, 10X, 20X, 50X, and 100X. It has the magnification accuracy of upto.05%of
contour illumination and .075% of surface illumination. Its weight is 800kg.it has 3 lens of screw

2. Coordinate measuring MACHINE: AS we know that micrometer vernier

caliper and height gauges are used for measuring only one direction and profile projector

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measure two dimensions in spite of these entire coordinate measuring machines is used for three
dimensions of the components of engine in X, Y, Z direction. Coordinate measuring machine is
also used for measuring the dimension of any part with respect to some other dimension.
Suppose we have to find the pitch circle diameter of the part with respect to some other point it
give us that dimension. It also helps to calculate the diameter of circle accurately as it is
electronically operated.

3. UNIVERSAL LINEAR MEASUREMENT MACHINE: this machine is

used for the calibration of the ring gauges and plug gauges. It is mainly used for the measuring
the pitch of the gears. It is also known as light machine as it is optically operated.
4. TORQUE WRENTCH TESTER: It is the instrument which is used for the
calibration of the torque wrench. (Torque wrench is the device which is operated up to specify
torque it means that if torque wrench has the specification of 10kgm then in tightening bolt after
10kgm it becomes free.)It is electronically operated.
5. AIR GAUGES AND BORE GAUGES: these are mainly used for measuring
the internal diameter of any part. Air gauge are operated by air by air pressure and bore gauges
are operated mechanically or by hands. Bore gauges has the range from12mm to 300mm.

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6. STANDARD PINS AND SLIP GAUGES: These are the standard ones and
used for measuring the accurate dimensions of any parts and used or calibrated other
instruments. Slip gauges are used for measuring the width of any parts and has the range 300mm.
and standard pins are used for measuring diameter of any hole and it has the range from.5mm to
300mm.

7. ELECTRONIC AND MECHANICAL HEIGHT GAUGES: These are

mainly used for the height of any part .mechanical height gauges has the range up to 300mm and
electronic height gauges has the range up to 600mm.

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 HEIGHT GAUGE

8. SQUARNESS TESTER: It is used for checking the perpendicularity of two

surfaces of the components.
9. HEIGHT MASTER: It is the master which is used for the calibration of the height
gauges. It has the least count of 1 micron.
10. BARO PROTECTOR: It is the additional accessory which is used for
measuring the helix angle of the gear and threaded parts
11. VERNIER AND MICROMETER: Last but not the least vernier and
micrometer are the instruments which are used for measuring the dimension.

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 CONCLUSION

After doing my training at SML ISUZU LTD,ROPAR, I felt the importance of training in the
industry and its practical applications, when I was studying the theories of different concepts I
was thinking how these all will be implemented. But after the training, I learnt how all these
could be put in good use. It was the result of training only that I got to see the objects in real and
practical use, which I had only read and about and seen as 2D objects in the book.
During my training at SML, I got chance to expose to the industry culture and
work environment. In other words, these days of training in SML were learning experienced all
the way. These happen only due to co-operation of staff and the management who helped me in
gaining whatever knowledge I have today about the production and management.
In the end, I would like to conclude that the training is an essential part of the
education programme. We should always pursue for the theoretical as well as the practical
knowledge, both of which are must for the production of high building.

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 BIBLIOGRAPHY
Departments at SML consulted:-
1) Technology
2) Quality
3) Production
4) Spare Parts Division

List of websites consulted:-

1) www.howstuffworks.com
2) www.wikipedia.com
3) www.google.com

List of books consulted:-

1) Automobile Engineering- Kirpal Singh
2) Automotive Engineering- Crouse and Anglin
3) Industrial Product Finder
4) Industrial Engineering

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