FINAL TRAINING-CUM-PROJECT REPORT

Name of Company/Organisation : SML ISUZU Ltd.

Address : Vill.Asron, Distt.S.B.S Nagar (Punjab)
Name of the Project(s) Done : 1. Fuel Audit
2. Assembly trials of WC-29
3. Material Handling
4. Time Study
Period of Training : from 5 January, 2024
to 14 Febuary, 2024

TRAINING MANAGER/GUIDE SUBMITTED BY

Name: Shahid Javaid Name: Dinesh kumar Branch: Automobile Engineering
Designation: DGM Univ. Roll No: 2102746
Department: Technology Date of Submission:
E-mail: shahidjavaid725@gmail

1. Acknowledgement

The internship opportunity I had with SML Isuzu Limited, Ropar was a great
chance for learning and professional development. Therefore, I consider myself as
very lucky individual as I was provided with an opportunity to be a part of it.

Bearing in mind previous I am using this opportunity to express my deepest

gratitude and special thanks to Mr. CM Sharma (DGM, Technology Department),
who in spite of being extraordinarily busy with his duties, took time out to hear, guide
and keep me on the correct path and allowing me to carry out my projects at their
esteemed organization and extending during the training.

I extend my gratitude to my Project Guide Mr. Hari Krishna Maurya who assisted
me in compiling the projects.

I would also like to thank all the faculty members of CTIEMT, Shahpur,
Jalandhar for their critical advice and guidance without which this internship would
not have been fruitful.

I perceive as this opportunity as a big milestone in my career development. I will

strive to use gained skills and knowledge in the best possible way, and I will continue
to work on their improvement, in order to attain desired career objectives. Hope to
continue cooperation with all of you in the future.

Sincerely,
Shahid Javaid
Roll No-2102746
Branch-Automobile Engineering

2. ABSTRACT

“NO LEARNING CAN BE COMPLETED WITHOUT PREFACE”

As a part of our curriculum for bachelor of Automobile Engineering, I am required
to undergo industrial training. The objective of this training is to gain an inside
information about the functioning of technical departments with respect to an
organization. The practical orientation of technical student is must to quality as
potential engineer.

I got an opportunity to undergo this training is esteemed organization like SML

ISUZU Limited, Asron.

Entering in the industry is like stepping into the world ever concept which is
taught in the class room is practical in different dimensions in the industry and the
study on the subject practice in the organization gives a deep insight into the
practical side of technique and industry itself.
 Table of Contents

S.No. Topic Page No.

• Acknowledgement 2

• Abstract 3

• Introduction to company 5-10

• 5S Activity in SML ISUZU Ltd. 11

• Vehicles Mfd. At SML ISUZU Ltd. 12-24

• Various Departments of SML ISUZU Limited 25-29

• Various assembly line and Shops 29-49

• Projects

8.1 Material Handling and Inventory of Parts 63-65

 8.2 Working procedure 66-68

8.3 Assembly Trials of WC-29 and Tool Design 69-86

8.4 Time Study 87

8.5 Bibliography 88

3. Introduction to Company

SML ISUZU LTD. (SWARAJ MAZDA)

Corporate Profile

Swaraj Mazda 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). Swaraj
Mazda represents two powerful brands: SWARAJ- symbolizing best Indian
technology and engineering.

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.
Mazda 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 Mazda to
produce vehicles of outstanding quality and performance. No wonder Swaraj
Mazda has won appreciations all over the world for the quality products that are
rolling out its plant.

The assembly unit of Swaraj Mazda limited 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 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. The desolate slit hill has been levelled for construction.
The construction at this Rs.50 crores plant, commenced on 16th January 1985.work
mat the plant at a great tempo and the first vehicles rolled out at the production line
in a record time of one year of laying the foundation stone.

ABOUT Mazda

Earlier known as Toyo Kagyo co. ltd; Mazda Motor Corporation of Hiroshima is
the seventh largest automobile company in the world. This company has the
distinction of developing the ‘wankel rotary engine in 1967. It produces 1.2 million
Vehicles annually manufactured at its plant set up in 16 countries that include
Korea, New Zealand, India and Pakistan.

The main products of Mazda include passengers cars (RX-7,929,323ETC),vans (T-

2000,T-3500,E-1400 etc.),pickups(B-1600,B-2000,E-2200 ETC.) and trucks(T-
2600,

T-3000, T-3500 etc.). Other products include machine tools, rock drills and gauge
blocks etc.

In Japan, Mazda has its plant at Hiroshima, Hofu and Miyoshi. Recently, FORD
Motors of U.S.A has collaborated with MC to manufacture vehicles in the U.S.
Mazda’s high standard R&D quality is reflected in the numerous competitive
awards it has won. Mazda savanna RX-7 got the “car of the year” award in 1978
and Mazda famila323 won the “JAPENESE CAR OF THE YEAR” award in the
year 1981. Mazda RX-7 racing car with a rotary engine has won the prestigious
SAFARI CAR RALLY innumerable number of times. Mazda cars, considered
Rothmans car rally, too.

Mazda 323 4WDs have made a fantastic start in the early rounds of the 1987 world
rally championship(WRC), taking first place in overall in the Swedish rally and
fifth overall in the Monte Carlo rally. The Mazda RX-7 has won a record sixth
GTU crown since 1982 in the famed Diatona 24 hour race in Florida, U.S.A.

Discipline and its right enforcement is an important hallmark of the Swaraj Mazda.
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, have to punch
their when they report for duty. As a result strict punctuality has become a way of
life and work with them.
To ensure industrial peace i.e. absence of the strikes and lockouts, Swaraj Mazda
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 corporation pervade the entire atmosphere of
the company.

No politics of confrontation is found in Swaraj Mazda. 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
Swaraj Mazda 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.
 • Facing the staff. Every employee carries his or her files, thus inculcating the
spirit of dignity of labour in the staff.

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. Swaraj
Mazda 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. A short turning radius gives Swaraj Mazda an excellent
manoeuvrability and congested and hill roads.

Prominent among the load carriers Swaraj Mazda is also manufacturing:

• 4 wheel drives;
• Extend wheel base long chassis mini buses which carry up to 44 passengers;
• Deluxe buses carries 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 centres
Swaraj Mazda vehicles population today stands over 70,000. Swaraj Mazda gives
due attention to the marketing part and the employees are highly qualified and
trained to fit the job. Swaraj Mazda 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 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 Swaraj Mazda
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 job. Earnestness,
sincerity and spirit co-operation pervades the entire atmosphere of the company.
The happy absence of industrial disputes in the enterprises speaks volume for the
success of the firm and cultivation of work culture.

Work culture or work ethos is given very high precedence. It is fully recognized
that the objective of the concerns – higher and higher production, productivity, and
indigenization can be attained through commitment into commonness of ‘GOAL’
in each and every member of the Swaraj family. The entire planning is undertaking
in such a way so as to in culcate the spirit of dedication in each member, whether
he is a skilled or semi-skilled worker or belongs to the managerial cadre. Many
effective steps are taken to bring this about. Important amongst them are:

The corporate profile of SWARAJ MAZDA LTD. projects a bright future for the
company. That is how it should be considering its importance for our economy. It
is adding its share to the real assets and job opportunities in the areas thus bringing
socio-economic reforms in whole of Punjab

4. 5S Activity in SMLISUZU

In order to achieve the goals set up by the concerns effectively and efficiently the
organization follows the 5 S activities that are:

• 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 turnover for 2000-2001 exceeds Rs. 271 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.

5. Vehicles Manufactured at Sml Isuzu Ltd

5.1 ECOMAX
Wheelbase Overall
2815 2100
(mm) Width(mm)

BSIII Mech- 75 Kw @3000 Mechanical /Power

Max. Engine
rpm BSIV CRDi- 75 Kw Steering
Output Steering
@2800 rpm

BSIII Mech - 315Nm@1500- Hydraulic Vacuum

Max. Torque 1750 rpm ;BSIV CRDi - Brakes
296Nm@ 1500 ± 50 rpm assisted

Overall
5548 No. of Seats 13+1/12+1(Optional)
length(mm)

Front Overhang Type of 2 x 1 , High back

1044
(mm) Seats reclining seats

Rear Air
1689 Yes
Overhang(mm) Conditioning

5.2 EXECUTIVE BUS

Wheelbase Overall
2815 2155
(mm) Width(mm)

BSIII Mech- 75 Kw @3000

Max. Engine
rpm BSIV CRDi- 75 Kw Steering Power Steering
Output
@2800 rpm

BSIII Mech - 315Nm@1500- Hydraulic

Max. Torque 1750 rpm ;BSIV CRDi - Brakes
296Nm@ 1500 ± 50 rpm Vacuum assisted

Overall
5875 No. of Seats 13+1
length(mm)

Front Overhang Deluxe Push

1370 Type of Seats
(mm) Back Seats

Rear Air
1690 Optional
Overhang(mm) Conditioning

Right Hand Drive & Left Hand

Drive Type
Drive ( For Exports)
5.3 S7 SCHOOL BUS

Wheelbase Overall
3335/4240/5100 2262
(mm) Width(mm)

BSIII Mech- 75 Kw @3000

Max. Engine
rpm BSIV CRDi- 75 Kw Steering Power Steering
Output
@2800 rpm

BSIII Mech - 315Nm@1750 -

Max. Torque 2000 rpm ;BSIV CRDi - Brakes Hydraulic/Airbrake
296Nm@ 1500 ± 50 rpm

Overall
9280 No. of Seats 20 to 50 Seats
length(mm)

Front Standard School

Overhang 1180 Type of Seats
(mm) type (3X2)

Rear Air
3000 Optional
Overhang(mm) Conditioning

Right Hand Drive & Left Progressive

Drive Type Suspension
Hand Drive ( For Exports) Suspension
5.4 FR 1318

Wheelbase (mm) 5400 Overall Width(mm) 2590

BSIII - 127.6 kW
Max. Engine
± 2 % @ 2600 Steering Power Steering
Output
rpm

500 Nm @ 1500-
Max. Torque Brakes Airbrake with ABS
2000 rpm

Overall length(mm) 10940 No. of Seats 41+1 / 37+1

Front Overhang
2300 Type of Seats Deluxe Push Back Seats
(mm)

Rear
3240 Air Conditioning Yes
Overhang(mm)
5.5 LT 134

Overall
Wheelbase (mm) 6260 2600
Width(mm)

BSIII - 169 kw @
Max. Engine Output Steering Power Steering
2500 rpm

704.2 Nm @ 1500
Max. Torque Brakes Airbrake with ABS
rpm

Overall length(mm) 11995 No. of Seats 45+1+1

Front Overhang
2280 Type of Seats Deluxe Push Back Seats
(mm)

Rear Overhang(mm) 3425 Air Conditioning Yes

5.6 EXECUTIVE LX

Wheelbase Overall
4240 2262
(mm) Width(mm)

BSIII Mech- 75 Kw
Max. Engine
@3000 rpm BSIV CRDi- Steering Power Steering
Output
75 Kw @2800 rpm

BSIII Mech -
315Nm@1500-1750
Max. Torque Brakes Air Brake
rpm ;BSIV CRDi -
296Nm@ 1500 ± 50 rpm

Overall
8291 No. of Seats 20/29/31
length(mm)

Front Overhang 1550 Type of Seats Reclining Push back/Semi

(mm)
 Reclining Push Back /Semi

Reclining Push Back

Rear
2500 Air Conditioning Yes , Ductable AC
Overhang(mm)

5.7 Sartaj HG72

`
Wheelbase Load body
3335 3740(12'.3")/4260(14')
(mm) Length (mm)

Load body
GVW (Kg) 7200 2080 (6'.8 ")
width (mm)

BSIII Mech- 75 Kw @3000

Max. Engine Fuel Tank
rpm BSIV CRDi- 75 Kw 90
Output (Litres)
@2800 rpm

BSIII Mech - 315Nm@1500- Hydraulic Vacuum

Max. Torque 1750 rpm ;BSIV CRDi - Brakes
296Nm@ 1500 ± 50 rpm Assisted

No of Tyres 4+1 Tyres Size 8.25" X 16" - 16 PR

Displacement Mechanical /Power
3455 Steering
(cc) Steering (Optional)

Right Hand Drive & Left

Drive Type
Hand Drive ( For Exports)

5.8 Samrat HD19 Truck

Wheelbase (mm) 3940/4300 Load body Length (mm)

GVW (Kg) 12990 Load body width (mm)
Max. Engine Output BSIII Mech- 75 Kw @3000 rpm Fuel Tank (Litres)
Max. Torque BSIII Mech - 315Nm@1500-1750 Brakes
rpm ;BSIV CRDi - 296Nm@ 1500
± 50 rpm
No of Tyres 6+1 Tyres Size
Displacement (cc) 3455 Steering
Drive Type Right Hand Drive & Left Hand
Drive ( For Exports)
5.9 Super 12.9 XM Truck

Load body
Wheelbase
3940/4300 Length 5240(17'.19")/5800(19'.02")
(mm)
(mm)
Load body
GVW (Kg) 12990 2280 (7'.48")
width (mm)
Max. Engine BSIII Mech- 75 Kw Fuel Tank
180
Output @3000 rpm (Litres)
BSIII Mech -
315Nm@1500-1750
Max. Torque rpm ;BSIV CRDi - Brakes Air Brake
296Nm@ 1500 ± 50
rpm
No of Tyres 6+1 Tyres Size 8.25" X 20" - 14/16 PR
Displacement
3455 Steering Power Steering
(cc)
Right Hand Drive &
Drive Type Left Hand Drive
( For Exports)
5.10 4x4 Truck

Load body Length

Wheelbase (mm) 2845 / 3365 3740
(mm)

GVW (Kg) 6990 / 6450 Load body width (mm) 2080

Max. Engine BSIII Mech- 75 Kw @3000 rpm BSIV

Fuel Tank (Litres) 90
Output CRDi- 75 Kw @2800 rpm

BSIII Mech - 315Nm@1500-1750

Max. Torque rpm ;BSIV CRDi - 296Nm@ 1500 ± 50 Brakes Airbrake
rpm

9.0" X 20" -
Gradeabilty (%) 47 Tyres Size
16 PR

Displacement Power
3455 Steering
(cc) Steering
5.11 5252 XM

Load body
Wheelbase (mm) 2515 2800(9'.18")
Length (mm)

Load body
GVW (Kg) 4990/5220 1860 (5'.9 ")
width (mm)

BSIII Mech- 75 Kw
Max. Engine Fuel Tank
@3000 rpm BSIV CRDi- 70
Output (Litres)
75 Kw @2800 rpm

BSIII Mech -
315Nm@1500-1750 Hydraulic Vacuum
Max. Torque Brakes
rpm ;BSIV CRDi - Assisted
296Nm@ 1500 ± 50 rpm
 No of Tyres 4+1 Tyres Size 7.00" X 16" -14 PR

Mechanical /Power
Displacement
3455 Steering
(cc)
Steering (Optional)

5.12 Samrat 21

Load body
Wheelbase (mm) 4760 Length 6610(21'.7")
(mm)

GVW (Kg) 10250 Load body 2080 (6'.8 ")

width
 (mm)

Max. Engine BSIII Mech- 75 Kw @3000 rpm Fuel Tank

90
Output BSIV CRDi- 75 Kw @2800 rpm (Litres)

BSIII Mech - 315Nm@1500-

Max. Torque 1750 rpm ;BSIV CRDi - Brakes Air Brake
296Nm@ 1500 ± 50 rpm

No of Tyres 6+1 Tyres Size 8.25" X 16" - 16 PR

Displacement Mechanical /Power

3455 Steering
(cc) Steering (Optional)

5.13Types of engine in Sml Isuzu Engine

S.NO. BS-III BS-IV C.N.G.

1. In BS-III In BS-IV engine In C.N.G.
engine hole does not have engine the
for feed feed pump. FI block does
pump are Pump is suck the not have a
provided on fuel hole for feed
the back of pump.
the engine

2. In this fuel In this engine In C.N.G.

injection common rail are engine
pump used used distributer is
is of rotary used
and
electronic
type

3. Here Here the M.P.F.I. In C.N.G.

 nozzles (MULTI Point engine spark
have smaller Fuel Injection plug is used
holes for System) used
spraying
diesel

4. It give s It gives power It gives

power of OF 75 B.H.P. At power OF
100 B.H.P. 2800 R.P.M 72 B.H.P. At
at 3000 3000 R.P.M
R.P.M
BHARAT STAGE NORMS
Note: - The Production of BS3 engine has been stopped as per rules &
regulations of Govt. Of India After 31st march 2017

6. Various Departments of SML ISUZU

(Swaraj Mazda)

• Technology Department
• Vendor Development
• Personnel Department.
• Research and Development.
• Quality Engineering Department
• Accounts Department
• Purchase Department
• Maintenance Department

• Technology Department

This department is headed by Mr. Arun Batra.

This department is sub divided into following department:

• Industrial engineering.
• Production engineering.
• Tool design.
• Job responsibilities of the department:

• Process engineering support for vehicle assembly :

• Line balancing

• Time study

• Method study

• Working procedure

• Capacity planning

• Budget planning

• Spare Part Division Process control

• Vendor Development

The Department is headed by Mr. Rajiv Puri (Deputy General Manager,

Vendor Development)

Vendor Development has to do with creating or making new vendors

(and not selecting out of the already established ones in the market). This is a
continual and an important activity of the Purchasing Manager and in large
organizations there is exclusively a Vendor/Source Development manager.
 Traditionally one of the reasons for developing new vendors is to build more
competition in the supply market (eliminating monopoly or oligopoly). The
company can then buy a material from a number of sources. Another traditional
reason for such multiple source buying (and, therefore, also for vendor
development) is to spread the risk of non availability or shortage of input
materials over a number of suppliers. In case, one of the supplier’s employees
go on strike (or if there is an explosion or fire in the supplying company), the
other suppliers can be relied upon to compensate for the shortage.

• Personnel Department

This department is headed by Mr. RS Nanda (General Manager)

Objectives of the personnel Department:

• Recruitment and promotion policies

• Welfare schemes
• Discipline and grievance redressal
• Security
• Canteen Services
• Introduction to labour laws

• Research and Development Department

Structure of R&D Department

• Chief Manager
• Manager
• Senior Engineer
• Engineer
• Junior Engineer
• Draft Men

Further plans of R&D Department

• Research on compressed natural gas (C.N.G) engines.

• To increase the diameter of clutch. Ultimately increase in size of clutch
housing.
• Installation of modified engine mounting pad test rig.
• Research on shifting of gears by cables.
• Bulletproof 4WD vehicles for army.

• Quality Engineering Department

This department is headed by Er Arun Handa (General Manager) is the most

crucial department. The responsibility of the whole department is to ensure the
quality of each incoming as well as outgoing products.

The department is divided in sub- department:-

 • QE(Receipt)
• QE(Lab)
• QE(Vendor)
• QE(Manufacture)

• Accounts Department

This department is headed by Mr. Sumir madan (Cooperate Manager)

Functions of accounts Department
• Sales Accounts.
• Purchase Accounts.
• Labour Accounts.
• Cost Accounts.
• Internal Audit.

• Purchase Department

This department is headed by Mr. Arun kamboj (General Manager).

Functions of Purchase Department
• Vendor selection and vendor development.
• To make list of suppliers.
• To organize purchase negotiations.
• Documents/reports generation and their utility.
• To record vendor’s performance and subsequent actions.
 • Maintenance Department

This department is headed by Mr. Sanjiv Gupta (Gen Manager)

Objectives of Maintenance Department

This main objective of this department is to proper conditions of machines and

other equipments and other equipments used in plant and inter- cooling of plant
supply of compressed air through the plant to drive the air guns.

7. Various Assembly Line and Shops

It is divided into following three shops:

• Body Shop
• Paint Shop
• Assembly Shop

7.1Body Shop

Body shop consists of three lines known as Frame line, Cargo line and Cabin line.
After assembly, cabin and cargo is sent to the paint shop and the frame to the
vehicle assembly shop.
7.1.1CARGO LINE

The SWARAJ MAZDA LIMITED has four types of cargo that are assembled and
mounted on the truck:-

1) HIGH DECK

2) SEMI DECK

3) DROP SIDE

4) FIXED SIDE
7.1.2Frame Line
In frame assembly line, six different chassis frames are assembled. These are WT
48, WT 49, WT 50, WT50L and WV26, ELWB. The assembly of these 6 different
chassis is completed through 5 different stations:

7.2 Paint Shop

In this shop painting and other surface treatment process are carried out on cabin
assemblies and cargo boxes.

This shop is divided into two stations.

In pre-treatment line various surface treatment processes are carried out on the
cabin assembly, which is received from the body shop.
Black dipping of the cabin is done to increase the strength of the part of the cabin
to increase the strength of the floor; only floor is black dipped in water soluble
black paint which is chemical resistant. The paint is maintained at a temperature of
30oc\

7.3 Vehicle Assembly Shop

• CABIN ASSEMBLY LINE

• AXLE SHOP
• ENGINE & TRASMISSION ASSEMBLY LINE
 • MAIN LINE
• PIT INSPECTION
• CARGO BOX ASSEMBLY
Cabin Assembly Line

In Cabin Assembly Line cabins received from the paint shop and various parts are
assembled to it. It has got 16 Station in 2017 with cycle time per station 7-8 min.
Few station working procedure as follow:-

• CABIN ASSEMBLY LINE:

The different types of cabin assembled on the cabin assembly line are:-

• CABIN SHELL W/O DOOR

• CABIN SHELL WITH DOOR
• CABIN SHELL DUAL CAB
• CABIN SHELL 4WD TRUCK
• COWL CABIN
• SIMPLER COWL
• FACELESS
FACELESS

• F-1 Station
This station is further divided into three shops.

BRAKE ASSEMBLY SHOP

This is the first shop in station F-1. In this shop brakes are assembled. The main
parts are as follows:-

Vacuum master: It is used in brakes to create vacuum. These are of two types:

• Big Vacuum Master-: It is large in size. It has 90mm dia. It has low power as
compared to the small Vacuum master.

Applications-: Big Vacuum Master is used in Swaraj Mazda’s SARTAJ 26 and 48

models.
 • Small Vacuum Master-: It is small in size as compared to Big Vacuum
Master. It is used in models except 48 and 26.

CLUTCH ASSEMBLY SHOP

In Swaraj Mazda’s LCV`s, Single disc or plate clutch is used. The main parts of
the clutch which are assembled in the clutch assembly shop are:

• Clutch Pedal
• Bracket with bush
• Hose lever assist BKT
• Clutch cylinder
• Electronic devices

HAND BRAKE ASSEMBLY SHOP

In this shop the hand brakes are assembled. They are also known as parking brakes,
power brakes.

Main Parts of the Hand Brake are:

• Hand brake assembly

• Unit control clip and switches
• Wiper motor Sub. Assy. fitment

• F-2 Station
This station is divided into two parts A and B.

Station F-2A

The following accessories are fitted to the cabin.

• Water pipe
• One air pipe / vent pipe / vent hole
• Tool box
• Jack lever clamp, Crank lever clamp, Seat locker.
• Roof sealing.

Station F-2B

• In this Station following attachments are fitted.

• Vacuum Master
• Acc. Assy
• Clutch Assembly
• Wiper motor sub assy and wiper linkage
• Hand brake assy

• STATION F-3
In this station instrument panel is fitted which contains a meter grill in which
Speedo meter, fuel meter, voltmeter and amp meter are attached.

• STATION F-4
In this station the following attachments are fitted

a. Washer Tank
b. Change Lever
c. Left hand side door trim
d. Right hand side door trim
e. Gear lever
f. Ventilator Grill
g. Room Mirror
h. Crank Rod
i. Room Lamp
j. Clutch Switch
k. Door Lock
l. Key Lock
m Lock Fastener
o. Steering Shaf
• STATION F-5
In Station F-5 following attachments are fitted:

a. Foot Step
b. Rear glass fitment
c. Front glass fitment
d. Left hand glass fitment
e. Right hand side door glass fitment
f. Lever fitment
After assembling all parts to cabin, it is sent to the station F-10 of main line, where
it is attached with the cabin

Axle Shop
In axle shop front axle, differential and rear axles are assembled. There are two
shops of rear axles, two shops for front axles and two for differential.
This shop also has a dip washing machine to wash the parts before assembling
them to remove any contamination of grease, oil etc. After assembling the axles,
these are passed to the leaf spring assembly line where leaf springs are attached
with axles.
Front Axle

The main parts of front axle are as below:-

• Axle beam
• Knuckle
• Steering Arm
• Tie rod
• King Pin
• Sim cap
• Shocker Bolt
• Brake drums

AXLE BEAM: It is made up of cast Iran and is fitted at the front side of chassis.
Axle beam is main part of the front Axle.
KNUCKLE: - It is joined with axle beam with the help of king pin. It has a hub
like shape. It is square in shape at the top and then it slopes or tapered down
towards the end where brake drums are mounted.

KING PIN: It is used to connect the knuckle with axle beam at both ends. It is
made up of Cast Steel.

ARM: It is also known as steering arm and is connected with the steering gear
with the help of drag link. It is also used to turn the vehicle. When we rotate the
steering wheel, it in turn rotates the steering gear with the help of steering shaft.
When steering gear rotates it in turn rotates the link which pushes the arm in
backward or forward direction and thus turns the vehicle left or right.

TIE ROD: It is used to connect the brake drums which are mounted on the both
ends on the axle beam for steering purposes and Toe in and Toe out purposes.

SHOCKER BOLT: It is used to connect the dampers with axle and chassis to give
shock resistance to the vehicle.

BRAKE DRUM: In the Brake drum assembly is mounted. On the brake drums
tyres are attached. In Swaraj Mazda Ltd. 90 mm dia and 110 mm dia size brake
drums are used.

The all upper parts when attached to the axle beam then it becomes a front axle.

7.2.2 Rear Axle Shop

CONSTRUCTION: - Rear axle is made from sheet steal of 10 mm thickness by

casting process. It is made in two halves and then joined with the help of seam
welding process. Rear axle consists of a differential casing in which gears are
attached.

DESCRIPTION: -Rear axle contains two brake drums, in which brake assembly
is mounted. On the brake drums tyres are mounted .It may be mentioned here that
the power is transmitted from the engine to the rear axle with the help of propeller
shafts. These shafts at one end are attached with engine’s transmission and at other
end, these are attached with differential.

From the rear axle shop the axles are passed to the leaf spring assembly line where
according to the model and load capacity leaf spring are attached to the axle.

When the engine starts up it rotate the crankshaft, which rotate the flywheel in turn
flywheel rotates the main shaft. From main shaft power is transmitted to
differential with propeller shaft. When the propeller shaft rotates it rotates a
differential gear which in turn rotates the wheel.
Differential Assembly

The differential gear is used in the rear drive of an automobile has following
functions:

• I It is used to transmit the motion from the engine shaft to rear driving wheels.
• II To rotate the rear wheels at different speeds while the automobile is taking a
turn

As long as the automobile is running on a straight path the rear wheels are driven
directly by the engine and speed of both the wheels is same. But when the
automobile is taking a turn the outer wheel will run faster than the inner wheel
because at that time outer rear wheel has to cover more distance than the rear inner
wheel. This problem does not arise with front wheels as they are greatly used for
the steering purposes and are mounted on the separate axles and can run at
different speeds. This is achieved by the epicyclic gear train with bevel gears.

Engine and Transmission Assembly Line

The Engine Assembly Line and Transmissions Assembly Line as it is clear from
the name it has two lines-Engine Assembly line and Transmission Assembly Line.
The detail of each line is given below:

Engine Assembly Line

It has 19 stations. Following is overview of various working done on different

stations-
• E-1 STATION
Crank caps are removed from the cylinder block. The cylinder block is placed on
the engine mounting fixture and also at this station engine No. is marked.

• E-2 STATION
The parts those fitted are: oil filter, oil pump, timing gear cover in line fuel
injection pump. The sub – assembly that is done here are: timing gear case and oil
cooler. Timing adjustment is also done here.

• E-3 STATION
The parts those fitted here are: cylinder Head, Water pump, Flywheel, Clutch Plate
, Lower and Upper Oil Pan.

• E-4 STATION
At this station the parts like Fuel Pipes, Injection pipes, Rocker Arm and Fuel
Filters are fitted here.

• E- 5 STATION
At this station the important assemblies includes Inlet Manifold, Fan Alternator,
Air Heater, Pulley and Vacuum Pump. After the assembly of engine, it is sent to
engine testing room on trolley for testing before being sent to the line.

Transmission Assembly Line

Transmission Assembly line also has six work stations. The detail of the parts,
those are fitted to complete the transmission assembly at different stations are
given below.

• T-1 STATION
At this station the counter shafts sub. assembly and main shaft sub assembly are
done.

• T-2& T-3 STATIONS

At these stations the sub assemblies of T-1 station are assembled in the
transmission case along with gear main drive. Counter shaft and main shaft form a
synchromesh gear system.

• T-4 STATION
At this station transmission case is mounted on a jig which moves on a pneumatic
conveyer. Also assembly of rear cover, transmission mounting bracket and shifting
fork is done.

• T-5 STATION
At this station bearing and clutch housing are assembled. After this the
transmission is subjected to a leakage test the case is them dipped in the water tank
to detect leakage from any point.

• T-6 STATION
At this station the assembly of brakes and brakes drum is done. Then it is taken for
noise test. After engine and transmission tests these are brought to the main line for
further assembly operations.

FILL ENGINE OIL PUT ENGINE ON HOT BED TESTING

MOVE ENGINE TO MAIN LINE FOR DOCKING WITH TRANSMISSION

7. Main Assembly Line

As the name suggest it is the important line because in this line all the parts which
comes from different shops are mounted on chassis whether it is cabin or engine
and other different parts are mounted.

This line has 9 stations from F-6 to F-15and a Pit Shop. The parts mounted on the
chassis are discussed station wise below:

• F 6 STATION
Here Front Axle and Rear Axle along with their assembly with leaf spring are
attached with chassis.

• F-7 STATION
Following jobs are performed at this station:

• Chassis number Punching.

• Vacuum Pipe Fitment
• Radiator Stay and Holder Rubber Fitment.
• Transmission Mounting BKT.
• Brake pipe, Hose, Protector Fitment.
• Rear Hook and Bypass Fitment.
• Three Way Pipe Joining Fitment.
• Park Brake and Speedo Cable Fitment.
• Rear Court Fitment.
• Front Brake Hose and Pipe Fitment.

• F-8 STATION
Following jobs are performed at this station:-

• Starter Fitment.
• Exhaust Brake Unit with Pipe.
• Engine and Transmission Mounting.
• Fuel Filter Mounting.
• Engine Transmission Docking.

• F-9 STATION
Following jobs are performed at this station:

• Gear and Pitmen Fitment.

• Oil in Gear and Pitmen.
• Radiator Mounting
• Fuel Cut Motor Mounting.
• Fuel Filter Mounting
• Fuel Pipe with Hose.
• Battery Carrier Mounting.
• Apron Wheel Fitment and Tightening.

• F-10 STATION
In this station following parts are attached to the chassis:

• Torsion bar Bush Fitment.

• Torsion bar Hinge and Assy.
• Torsion Bar with Cabin.
• Cabin Mounting on Chassis.
• Vacuum Tank Fitment.
• Battery Fitment.
• By Pass Pipe Fitment.
• Rubber Seal on Cabin.

• F-11/F-12 STATIONS
Following jobs are performed at this station:

• Propeller Shaft Yoke Greasing.

• Silencer Fitment.
• Centre Bearing Support.
• Propeller Shaft Bolts.
• Drum Centre Bolt
• Joint Sealer.
• Air Cleaner Fitment.
• Air Intake Hose Fitment.
• Fuel Tank Strap Fitment.
• Packing Alignment.
• Accelerator Wire Fitment.
• Lower and upper grill Fitment.
• Model Plate Punching.
• Antenna Hole Covering.

• F-13 STATION
Following jobs are performed at this station

• Head Lamp Fitment.

• Outer Mirror Fitment.
• Horn Connection
• Fender with Air Guide Fitment
• Front Bumper Mounting
• Number Plate Mounting.
• Model Plate Fitment.
• Jack plate Fitment.
• Spare Wheel hinge Fitment.
• Wiper Arm Nozzle Fitment.

• F-14/ F-15 STATIONS

Following jobs are performed at this station:

• Tyre Fitment
• Spare Wheel Fitment.
• Jack and Rod Fitment.
• Brake Bleeding.
• Engine Oil Level Checking.

PIT INSPECTION

Operation of warning lights, functions of instrument panel and levelling of engine

oil, coolant, transmission oil and differential oil etc are checked. Toe in and toe
out angles of wheels are adjusted as 31o + 1 o and 42 o + 1 o respectively. RPM of
the engine are checked by magnet type tachometer. Vehicle is also checked for any
defect of loose fitment/ wrong fitment
Shower test is performed by sprinting water from all the sides on the cabin with
pressure to check leakage inside the cabin.

After shower test the vehicle is taken for road test. The vehicle is taken to test track
to check brakes, emission, balance of vehicles, gears, steering control etc.

8. PROJECTS

8.1 PROJECT-1 (MATERIAL HANDLING AND

INVENTORY OF PARTS)

DONE UNDER THE GUIDANCE OF:-

MR. Gaurav Kumar

Location of material for trials: - Material handling is used to locate the parts in
such a way that each part is easy to locate during the time of assembly. The parts
are located in their specific locations and locations are given according to the
working procedure. The parts are located in their bins with assembly number, bin
number written in codes. Like a part is of assembly number 12 and the bin number
is 44 then the code written on the bin will be 12-B 44.The part number of the part
is also written on the bin. Additional information like rack number and floor
number are written on the rack itself. The record of material status is updated daily
with their quantity in which they are present whether local or CKD.
PURPOSE:-
Location Analysis is used to confirm the best positions to locate parts within trial
room with knowledge of material location, which can help facilities supplying
service or goods in the most effective and economic method. Location Analysis is
not only a location process, but also reduce efforts search parts here there.

LOCATION ENTRY PUCNHING:-

Location which is given to the item must be punched in organisation system. It
helps in easy searching of item and. It is like maintaining a small assembly line
area and keeping parts safe and in the proper locations.

Fig. Racks containing bins on each floor

Fig. Part number and code written on the bins
8.2 PROJECT-2 (TO PREPARE THE WORKING
PROCEDURE)

DONE UNDER THE GUIDANCE OF:-

MR. Hari Krishna Mayuria

Working procedures are basically the guiding tools for the workers to perform a
certain job. The working procedure provides the essential details of the task at hand
to the workers and guides them in the best possible way as designed by the
engineers to do that job. It is the job of an engineer of the technology dept. to do all
the work regarding the preparation of the working procedures. The engineer also
has to keep it in mind that the working procedure should be made in such a way
that even a layman can understand it.

These working procedures when released from the technology dept. are then sent
to the shop floors or the assembly lines and are fixed or hung there so that the
workers can take guidance from these Working sheets.

The working sheets are to make a work flow and established a line setup in order
to increase work rate and reduce load on workers by equalling dividing the work at
every station. Currently we are working on the tool design time study and working
procedure for new setup of Assembly line

Work Flow of WC-29:-

Sr.No. Activity
1 Set Brake Pedal to Jig
2 Checking procedure for Push Rod Clearance
3 Sub Assy Clutch pedal
4 Checking procedure for Clutch Pedal Clearance
Temp Attach Clutch Pedal Assy and Brake Pedal Assy
5
to cabin
6 Attach Brake ASM oil Pipe
7 Sub Assy and Attach of GHCV
 8 Attachment of Mat silencer
9 Attachment of wiper motor
10 Attachment of Hose ASM washer tank
11 Attachment of Nozzle
12 Attachment of Link Assy wiper
13 Attachment of Engine Hook Cover
Attachment of All grommets of F comb lamp head
14 lamp and Floor
15 Attachment of Brkt Heat protector
16 Attachment of Cover blower Hole
17 Attachment of Anchor Seat belt
18 Attachment of door switch harness
19 Attachment of Door switch
20 Attachment of wire Assy room lamp
Attachment of accelerator pedal and accelerator pedal
21
module
22 Steering shaft Sub assembly
Temp Attachment of steering shaft with brake pedal
23
and clutch pedal assembly
24 Attachment of Door Finisher
25 Mount and attach instrument panel
26 Attachment of oil tank hydraulic and brake hoses
27 Attachment of meter set and cluster Inst Centre
28 Sub assembly and attachment of Door
29 Attachment of Foot step
30 Attachment of Lever assembly Change
31 Attachment of gear console and cable shift, select
32 Attachment of Roof Trim
33 Attachment of Engine cover Band
34 Attachment of Bracket ASM Head Lamp
35 Attachment of lever Crank
36 Attachment of Jack
37 Attachment of Assist Handle Grip Front
38 Attachment of Seal Location Hole
39 Attachment of Seat belts Driver and Co driver
40 Attachment of Lower Pillar Trim
41 Attachment of Head Lamp
42 Attachment of Mirror Driver and Co driver
43 Attachment of Panel ASM LH/RH
44 Attachment of Lamp Combination LH/RH
 45 Attachment of Steering Wheel
46 Attachment of Cabin Lock Mechanism

These are just the main fitment headings. Due to company’s policies we were
denied to share company’s precious information like working procedure outside
the company.

In working procedure we corrected and managed the working procedure in

sequence like firstly which component is to be assembled and what are the tools
and torque required to assemble the part and after that which part is to be
assembled so that we should face any problem in assembling the next part.

8.3 PROJECT-3 (ASSEMBLY TRIALS OF WC-29 AND

TOOL DESIGN)
DONE UNDER THE GUIDANCE OF:-

MR. Gaurav Kumar

8.4.1 Assembly Trials: -We have done various trials during the training
period of each and every part that was used during assembly of cabin to
find the fitment method and fitment issues that need to be rectified. We
also find out various tool issues.
The following are the various fitment assembly of cabin with pictures:-

Fig. Sub-assembly of brake pedal & clutch pedal

Fig. Brake & clutch pedal assmbly fitment trial

Fig. Steering shaft fitment with brake pedal

Fig. Fitment of tilt mechanism :- tilt mechanism fouling the trolley

Fig. Assembled door of wc29 cabin with no fitment issue

Fig. Footstep with holes matching problem
Fig. Windshield & Ornament grill assembly
Fig. Cabin assembeled as per tria
SUGGESTIONS & RECOMMENDATIONS:-
• The final touch up paint shop should be made in such a way that dust
may not enter into it-

CURRENTLY- It is in open with only shed on top and open from two sides
with no doors.

REMEDY- The entrance and exit for the vehicles should be covered with
plastic slit type curtains, which provide a cheap alternative and prevents
dust.

• Proper torque wrenches should be used on assembly line-

CURRENTLY- The workers are not using the supposed tools and torque
wrenches at their correct place of use.

REMEDY- Provide adequate numbers of torque wrenches and tools and

strictly see to it that when torquing needs to be done, it is being done with
the correct torque wrench only.

• Wrong fitment and incomplete assembly needs to be prevented to

increase the production-

CURRENTLY- The workers are making wrong fitment and incomplete

assembly.
 REMEDY- The workers should be properly trained to eliminate more works
at the PDI dept. hence a lag in the production of a ready to deliver finished
product.

• The quality inspectors should use a better way to work under the
vehicles-

CURRENTLY- The quality inspectors lie down on the ground and are
having difficulty in checking the vehicles from the bottom side.

REMEDY- PDI should have a pit, so that quality inspectors can inspect the
vehicle ergonomically, and the operator can also work on defective
components easily, saving time, improving quality and working with safety.

• The quality check should be done at each station-

CURRENTLY- Quality Check is being done only at the quality gates,

which leads to a problem when the assembly is coming wrong from the first
station itself.

REMEDY- Workers should take the responsibility to do the quality check at

their level too to increase the productivity.

• The assembly should be done according to the best way described in the
working procedures displayed at each station-

CURRENTLY- Workers have adopted wrong assembly methods and the

guidance from the working procedure not being taken.

REMEDY- Workers should do the assembly according to the correct

sequence and should consider the working procedure for that.
 • The assembly of parts should be done at its prescribed station-

CURRENTLY- Workers are not assembling the parts at their prescribed

stations, which lead to lack in quality.

REMEDY- Workers should do the assembly at the correct station and

should consider the working procedure for the same.

8.4.2 TOOL DESIGN

As it was a new cabin trial so some new tools were required to tighten some new
parts.

Here is a list of new fixtures required for new cabin assembly.

• Fixture for windshield

• Fixture for brake paddle and clutch assembly

• Fixture for dashboard and instrument panel

• Fixture for back glass.

 Fig. Fixture of windshield (vacuum cups)

Tools used to carry out trials are shown in the figures below:

This process is done to find out the type of tools used for the assembly of one
cabin. While doing time study we noted the tool required for every procedure of
assembly. This is done to so as to determined the requirement of specific tool used
at specific procedure and to understand the quantity of tightening tool used at one
assembly line. The following are the few notable tools we determined while the
trials

1) Mainly socket of 10& 12 are used for tightening of bolts and nuts .Major
assembly where they are used are Dashboard attachment , wiper
motor ,headlamp attachment, footsteps,
2) The socket of 14 is used at seats attachment, brake pedal & steering shaft
column
3) For the screw attachment of mainly T-25 bit if torex set has been used.
4) Various fixtures have been proposed for the sub assembly of components for
e.g. Following list of fixtures

Fig. Torex Bit Set

Fig. Impact Wrench 212

Fig. Sockets
Fig. Tool box for WC-29
 Fig. Tools within tool box
Trials done for new tools
Makita battery operated gun
Bosch gun for fitment of instrument panel.
Makita battery operated gun
These were the trials done for the new tools required for fitment of various parts
but none of the trials was successful.

8.4 PROJECT-4 (TIME STUDY)

TIME STUDY:-

Main purpose of Trial of the assembly of cabin (WC-29) is to find out time for
every single assembly. For example for assembly of tilt mechanism. We find out it
take upto 5 min time cycle.

We did the time study by filming fitment of every part and processing every video
in the software “MOST”.
 9. BIBLOGRAPHY

Department at SML consulted:-

• Technology

List of websites consulted:-

• www.wikipedia.com

• www.smlisuzu.in

• www.ggole.com