msilproject

A PROJECT REPORTIn PRODUCTIONSubmitted by:‐

RAJARSHI BHATTACHARYA(B.Tech student of JALPAIGURI GOVT ENGG COLLEGE)

Prepared By:‐ Approved By:‐

RAJARSHI BHATTACHARYA Mr. RAHUL SHARMA Project Trainee (Mentor)(Roll no‐12101103036)

ACKNOWLEDGEMENT

One flower makes no garland; similarly accomplishment of a task is never a single‐handed effort. There are so many people attached to it directly or indirectly. And this project bears no exception to this fact. On the completion of this project I takeexception to this fact. On the completion of this project I take the opportunity to express my deep gratitude and sincere thanks to my project mentor, Mr. RAHUL SHARMA, mentor whose support and guidance had always been there since the start of this project to the end. I am highly grateful to him for his time‐to time feedbacks and precious suggestions He taught me howto‐time feedbacks and precious suggestions. He taught me how to ask questions and express my ideas and how to work in corporate world.

I cannot fully express my gratitude to Dr. D.C.Roy(HOD) for d h d h l k l d d lproviding me the required theoretical knowledge and clearing

my concepts prerequisite for undergoing this project .I would specially like to thank Mr. Asim Mahapatra and Mr. S Roy Chowdhury for guiding me at various instances.

Contents:d i1. Introduction

2. History3. Maruti Fundamentals

‐5S Principle‐3 K ‐Japanese Idea of Hansei‐Poka‐Yoke‐Kaizen

4.Maruti Suzuki Products and Services4.Maruti Suzuki Products and Services5. Quality Management

‐Principles‐Methods of Quality Improvement

6 ISO Certification6. ISO Certification‐Certification principles‐Certification Benefits

7.Transmission Systems8 Pl P l8. Plant Process layout9. Manufacturing Processes10. List Of Parts Manufactured11. Processes lines for manufacturing12. Heat Treatment and Hard Machining13. Assembly Operations14. Quality Room15. Terminologies commonly used for gears

MARUTI SUZUKI INDIA LTD.

Maruti Suzuki India Limited is a publicly listed automaker in India.It is the largest automobile manufacturer in South Asia. Suzuki Motor Corporation of Japan holds a majority stake in the company. It was the first company in India to mass‐produce and sell more than a million cars. It is largely

d d f h b h b l l d hcredited for having brought in an automobile revolution to India. It is the market leader in India and on 17 September 2007, Maruti UdyogLimited was renamed Maruti Suzuki India Limited. The company's headquarters are located in Delhi.

Maruti Suzuki India Limited

I d A iIndustry Automotive

Predecessor(s) Maruti Udyog Limited

Founded 1981

Headquarters New Delhi, India

Key people R. C. Bhargava(Chairman)

Kenichi Ayukawa (CEO & MD)

Products Automobiles

Revenue Rs. 43272 crore (US$7.3 billion)

(2013-14)

Net income Rs. 2469 crore (US$410 million)

(2013-14)

Employees 6,903 (2011)

Parent Suzuki

HISTORYMaruti Udyog Limited was established in February 1981, though the actual

d i d l i 1983 I d i h M i 800 b dproduction commenced only in 1983. It started with Maruti 800, based on theSuzuki Alto kei car which at the time was the only modern car available in India. Its only competitors were Hindustan Ambassador and Premier Padmini. Originally, 74% of the company was owned by the Indian government, and 26% by Suzuki of Japan. As of May 2007, the government of India sold its complete share to Indian financial institutions and no longerof India sold its complete share to Indian financial institutions and no longer has any stake in Maruti Udyog.

BeginningsMaruti's history begins in 1970, when a private limited company named 'Maruti technical services private limited' (MTSPL) is launched on NovemberMaruti technical services private limited (MTSPL) is launched on November 16, 1970. The stated purpose of this company was to provide technical know‐how for the design, manufacture and assembly of "a wholly indigenous motor car. After a series of scandals, "Maruti Limited" goes into liquidation in 1977.

Suzuki EntersIn 1982, a license & Joint Venture Agreement (JVA) is signed between MarutiUdyog Ltd. and Suzuki of Japan. At first, Maruti Suzuki was mainly an importer of cars. In India's closed market, Maruti received the right to import 40,000 fully built‐up Suzuki in the first two years, and even after that the early goal was to use only 33% indigenous parts.This 796 cc hatchback is based on the SS80 Suzuki Alto and is India’s first affordable car. In 1985 the Suzuki SJ410‐based Gypsy, a 970 cc 4WD off‐road vehicle, is launched. In 1986 the original 800 is replaced by an all‐new model of the 796 cc hatchback Suzuki Alto/Fronte. This is also when the 100,000th vehicle is produced by the company In 1987 follows the company's first export tois produced by the company. In 1987 follows the company s first export to the West, when a lot of 500 cars were sent to Hungary. Maruti products are being imported worldwide.

5S PrincipleSeiri(Sorting):‐ Separate necessary items from unnecessary items. Dispose off unnecessary items.Seiton (Systematic Arrangement):‐ Arrange necessary items in proper order ( y g ) g y p pso that they can be easily picked for use.Seiso(Cleaning):‐Clean your workplace &equipments.Seiketsu(Standardizing):‐Maintain high standards of above 3S at all times & strive to improve the current level.Shinseki (Discipline):‐Make a habit of observing the decided rules & train

l f ll d lpeople to follow discipline.

3 KSTypically, any task, regardless of industry, can qualify as a 3K job:‐Kitanai:‐refers to dirty jobsKiken: refers to dangerous jobsKiken:‐ refers to dangerous jobsKitsui:‐ refers to difficult jobs

Japanese idea of HanseiIt is a central idea in Japanese culture. It means to acknowledge your own mistake and to pledge improvement. Product design on today's markets hasmistake and to pledge improvement. Product design on today s markets has become increasingly complex since products contain more functions and have to meet increasing demands such as user‐friendliness, manufacturability and ecological considerations. With a shortened product lifecycle, development costs are likely to increase. Since errors in the estimations of market trends can be very expensive, companies therefore perform benchmarking studies that compare with competitors on strategic, process, marketing, and product levels. However, success in a certain market segment not only requires knowledge about the competitors and the performance of competing products, but also about the impressions which a product leaves to the customer. The latter requirement becomes much more important as products and companies getting mature Customers purchaseimportant as products and companies getting mature. Customers purchase products basing on subjective terms such as brand image, reputation, design, impression etc. A large number of manufacturers have started to consider such subjective properties and to develop their products that convey the company image.

Poka‐yokePoka‐yoke [poka‐yoke] is a Japanese term that means "mistake‐proofing". A poka‐yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid (yokeru) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur. The concept was formalized, and the term adopted, by Shigeo Shingo as part of the Toyota Production System. It was originally described as baka‐yoke but as this means "fool‐proofing" (ororiginally described as baka‐yoke, but as this means fool‐proofing (or "idiot‐proofing") the name was changed to the milder poka‐yoke.The term poka‐yoke was applied by Shigeo Shingo in the 1960s to industrial processes designed to prevent human errors. Shingo redesigned a process in which factory operators, while assembling a small switch, would often forget to insert the required spring under one of the switch g q p gbuttons. In the redesigned process, the worker would perform the task in two steps, first preparing the two required springs and placing them in a placeholder, then inserting the springs from the placeholder into the switch. When a spring remained in the placeholder, the operators knew that they had forgotten to insert it and could correct the mistake ff l leffortlessly.Shingo distinguished between the concepts of inevitable human mistakes and defects in the production. Defects occur when the mistakes are allowed to reach the customer. The aim of poka‐yoke is to design the process so that mistakes can be detected and corrected immediately eliminating defects at the sourceimmediately, eliminating defects at the source.

KaizenJapanese for "improvement" or "self‐changing for the best of all", refers to philosophy or practices that focus upon continuous improvement of processes in manufacturing, engineering, business management or any process. It has been applied in healthcare, psychotherapy, life‐coaching, government, banking, and other industries. When used in the business sense and applied to the workplace, kaizen refers to activities that

continually improve all functions, and involves all employees from the CEO to the assembly line operators. It also applies to processes, such as purchasing d l i ti hi h i ti l b d i i t th l h iand logistics, which cross organizational boundaries into the supply chain.

The Sino‐Japanese word "kaizen" simply means "good change", with no inherent meaning of either "continuous" or "philosophy" in Japanese dictionaries or in everyday use. The word refers to any improvement, one‐time or continuous, large or small, in the same sense as the English word "improvement"improvement .

Maruti Suzuki Power train

Earlier known as Suzuki Power train India Limited was a joint venture of Maruti Suzuki with Suzuki Motor Corporation, Japan at Manesar. It manufactures world class diesel engines and transmissions for cars. This diesel engine plant has a capacity to manufacture 300,000 diesel engines a year. Maruti Suzuki is confident that the future demand for diesel cars in the country will remain at about 40 per cent of total sales.To speed up addition of diesel engine capacity and reduce costs, Maruti'sboard approved the merger proposal of Suzuki Power train India Ltd (SPIL)board approved the merger proposal of Suzuki Power train India Ltd (SPIL) with itself.SPIL supplies about three lakh diesel engines a year to Maruti, while petrol engines are made in‐house. Currently, Maruti has a 30 per cent stake in SPIL, while the rest lies with Japanese parent Suzuki Motor Corporation (SMC).(SMC).With Maruti proposing a fresh issue of 13.17 million shares to SMC in lieu of its majority holding in SPIL, SMC's stake in Maruti will go up from 54.2 per cent to 56.2 per cent.Manufactures SX4 Engines & Swift diesel engines and in future all diesel engines are planned to be manufactured here. Almost Every Gearbox manufactured here.

The transmission plant manufactures the transmission assemblies for many vehicles of Maruti Suzuki like Swift, Swift Dzire, Celerio,SX4, WagonR. Despite it has 2‐W transmission and its assembly plant.

QUALITY MANAGEMENT

Quality management ensures that an organization, product or service is consistent. It has four main components: quality planning, quality control quality assurance and quality improvement Quality managementcontrol, quality assurance and quality improvement. Quality management is focused not only on product and service quality, but also the means to achieve it. Quality management therefore uses quality assurance and control of processes as well as products to achieve more consistent quality. For specific approach to quality management the term total quality management was used from 1980s.It considers the following 5 qua ty a age e t as used o 980s. t co s de s t e o o g 5factors:‐

PRINCIPLESThe International Standard for Quality management (ISO 9001:2008)The International Standard for Quality management (ISO 9001:2008) adopts a number of management principles] that can be used by top management to guide their organizations towards improved performance.Customer focusSince the organizations depend on their customers, they should understand current and future customer needs, should meet customer requirements and should try to exceed the expectations of customers.

LeadershipLeaders of an organization establish unity of purpose and direction of it. Th h ld f ti d i t f h i t lThey should go for creation and maintenance of such an internal environment, in which people can become fully involved in achieving the organization's quality objective

Involvement of peoplePeople at all levels of an organization are the essence of it. TheirPeople at all levels of an organization are the essence of it. Their complete involvement enables their abilities to be used for the benefit of the organization.

Process approachThe desired result can be achieved when activities and related resources are managed in an organization as a process.

System approach to managementAn organization's effectiveness and efficiency in achieving its quality objectives are contributed by identifying, understanding and managing all interrelated processes as a system Quality Control involves checkingall interrelated processes as a system. Quality Control involves checking transformed and transforming resources in all stages of production process

Continual improvementOne of the permanent quality objectives of an organization should be the continual improvement of its overall performance leveraging clear andcontinual improvement of its overall performance, leveraging clear and concise PPMs (Process Performance Measures)

Factual approach to decision makingEffective decisions are always based on the data analysis and information.

Mutually beneficial supplier relationshipsSince an organization and its suppliers are interdependent, therefore a mutually beneficial relationship between them increases the ability of both to add value.

METHODS OF QUALITY IMPROVEMENTThere are many methods for quality improvement. These cover product y q y p pimprovement, process improvement and people based improvement. These include:‐ISO 9004:2008 —Guidelines for performance improvement.QFD—Quality function deployment, also known as the house of quality approach.K i J d i h f h b hKaizen— Japanese word meaning change for the better; the common English term is continuous improvement.Zero Defect Program— Created by NEC Corporation of Japan, based upon statistical process control and one of the inputs for the inventors of Six Sigma.PDCA— Plan Do Check Act cycle for quality control purposesPDCA Plan, Do, Check, Act cycle for quality control purposes.Kansei Engineering— an approach that focuses on capturing customer emotional feedback about products to drive improvement.Quality circle—A group (people oriented) approach to improvement.TQM(Total Quality Management)‐ is a management strategy aimed at embedding awareness of quality in all organizational processes.Six Sigma— 6σ, Six Sigma combines established methods such as statistical process control, design of experiments and failure mode and effects analysis (FMEA) in an overall framework.Quality circle— A group (people oriented) approach to improvement.TRIZ—Meaning "Theory of Inventive Problem Solving".

ISO CERTIFICATION

ISO 9000 is a series of standards, developed andpublished by the International Organization for Standardization (ISO), that define, establish, and maintain a quality assurance system for manufacturing and service industries. The standards are available through national standards bodies ISO 9000 was first published in 1987 Itthrough national standards bodies. ISO 9000 was first published in 1987.It was based on the BS 5750 series of standards from BSI that were proposed to ISO in 1979The global adoption of ISO 9001 may be attributable to a number of factors. A number of major purchasers require their suppliers to hold ISO 9001 certification. China is the leading and India is at 8th position in terms of number of certificates being p gissued.ISO does not certify organizations itself. Numerous certification bodies exist, which audit organizations and, upon success, issue ISO 9001 compliance certificates.An ISO 9001 certificate is not a once‐and‐for‐all award, but must be renewed at regular intervals recommended by the certification body, usually once every three years. There are no grades of competence within ISO 9001: either a company is certified (meaning that it is committed to the method and model of quality management described in the standard) or it is not.Advantages include positive effect on investment, market share, sales growth sales margins competitive advantage and avoidance of litigationgrowth, sales margins, competitive advantage, and avoidance of litigation. Following are some of the advantages of this system:‐

1. Creates a more efficient, effective operation2. Increases customer satisfaction and retention3. Reduces audits4. Enhances marketing5. Improves employee motivation, awareness, and morale6. Promotes international trade7. Increases profit

Certification BenefitsStates to your customers that you have certain key Quality Assurance Systems in place and you are following these systems.Some customers may only do business with ISO 9001 companies.The ISO 9001 definition provides the basis for other certifications such as IS0 14000 (environmental), TS 16949 (automotive), and AS9100 (aircraft).It d i i t ithiIt drives improvement within your company.It could reduce customer audits of your facilities, processes and systems.It drives and changes your company to systematic method of management and work.

EIGHT ISO 9001 PrinciplesISO 9004 (a supporting standard of 9001) dictates the 8 principles that the ISO 9001 definition is based on. These are:

1. Customer Focus Organizationg2. Leadership3. Involvement of People4. Process Approach5. System Approach to Management6. Continual Improvement7. Factual Approach to Decision Making8. Mutually Beneficial Supplier Relationship

Principle Of Motion Economy

The principles of motion economy form a set of rules and suggestions to improve the manual work in manufacturing and reduce fatigue and unnecessary movements by the worker, which can lead to the reduction in h k l d D i i l fl i lthe work related trauma. Due to improper material flow it was also violating the Law of Motion Economy. This helped the organization in following ways:‐It helped in easy material flow from the forging section to the machining and to the heat treatment section.

It helped in better supervisor control over the lines assigned to him for supervision.

It also helped in easier and prompts addressing of any sort of problem in the line without suffering any production loss.

It also reduced the labour requirement for moving the material from forging to heat treatment plant.

These factors in turn helped in more production rate and easier hi t f d ti t tachievement of production targets.

Transmission System:

A machine consists of a power source and a power transmission system, which provides controlled application of the power. Merriam‐Webster defines transmission as an assembly of parts including the speed‐changing gears and the propeller shaft by which the power is transmitted from an engine to a live axle. Often transmission refers simply to the gearbox that uses gears andgear trains to provide speed and torqueconversions from a rotating power source to another device.

Th b i ll 2 t f t i iThere are basically 2 types of transmissionsystems, namely Automatic and Manual.

An automatic transmission (also calledautomatic gearbox) is a type of motor vehicle transmission that can automatically change gear ratios as the vehicle moves freeing the

A five speed plus reverse transmission system

automatically change gear ratios as the vehicle moves, freeing the driver from having to shift gears manually. Most automatic transmissions have a defined set of gear ranges, often with a parking pawl feature that locks the output shaft of the transmission stroke face to keep the vehicle from rolling either forward or backward.

A manual transmission, also known as a manual gearbox, stick shift (for vehicles with hand‐lever shifters), standard transmission, 4/5/6 speed (depending on gears) or simply a manual, is type of transmission used in motor vehicle applications. It uses a driver‐operated clutch engaged and disengaged by a foot pedal ( t bil ) h d l ( t l ) f l ti t t f(automobile) or hand lever (motorcycle), for regulating torque transfer from the engine to the transmission; and a gear selector operated by hand (automobile) or by foot (motorcycle).

Plant Process Layout:

Hot Forging (Gears)

Cold Forging (Shafts)

Machining of forged parts on several process lines

Hardening of machined parts by Heat Treatment

Minor Machining of hardened parts

Purification of metal parts by Sh Bl ihardened parts Shot Blasting

Transmission Assembly of partsSystems shipped

from storage area

ForgingRaw material in the form of round billets or rod is imported from Japan.The composition of alloy is SCr420H2V2.These rods are fed to shearing die machinesThese rods are fed to shearing die machines.There are 2 different types of Shearing die Machines:For cutting input & counter shaft.For cutting 4 types of gears.

Forging of ShaftsForging of ShaftsShearing dies are programmed for cutting both input & counter shafts of different sizes for various models.

Shot Blasting:After shearing process, the shafts are shot blasted because:The ends of the shafts were too sharp such that it is injurious to hands of the workers.More over the surface of the shafts were too smooth so it was difficult to coat chemical and lubrication over it.So after the shot blasting process the surface is rough it can easily retainSo after the shot blasting process the surface is rough it can easily retain the chemical coat & lubricant. This is required so as to reduce the chances of scratching of dies & also prevents tearing of shaft material. Moreover if the surface is having burrs over its face or on its edges then the component will not clamped over the machine.Both input and counter shafts are cold forged in cold forging die machine.p g g gThere are various types of dies & machine is computer numerically controlled, as per the operations the dies changes according & machined is programmed for various types & sizes of shafts.To maintain quality shafts are inspected, every shaft is visually checked for the scratches over its surface, and then their dimensions are checked by GO & NO GO gauges to control the dimension.If some scratch is found over the shaft then dies are inspected for scratches and if found they are lapped to remove scratches but still keeping the dimensional accuracy.

Dies are used until they are cracked or their dimension is changed a lot.Now after cold forging, the shafts are isothermally annealed to remove internal stresses.

Isothermal Annealing:Material is fed to the chamber were it is pre‐heated by indirect heating, and then it goes into the furnace chamber where it is heated to temperature of 900° Celsius.Then it moved to low temperature zone of about 600° CelsiusThen it moved to low temperature zone of about 600 Celsius.Then it is cooled in the furnace itself and a fan is employed to flow air over it.The grain growth takes place in this manner.After this shafts are dispatched for machining.

Hot Forging:Hot Forging:Gears are produced by hot forgingThere are 3 forging dies for 3 different types of gears namely Atsunyu, Ittai&Hira.The temperature during hot forging is 1200° Celsius because here the flow of material in the die is moreflow of material in the die is moreNow after hot forging the gears we get are not dimensionally accurate and many specifications are not up to the mark, so the gears are cold worked.

Cold Working of Gears:Cold Working of Gears:‐Specifications like internal diameter, external diameter, flange width and total thickness are controlled.‐Rib thickness is controlled.‐Groove for oil hole is formed.

Now we have controlled the dimensions but to improve the surface conditions gears are shot blasted.Shot blasting is necessary because it removes burrs from the surface and controls the surface roughness. This is important because if the surface is

having the burr of size of 0.2 mm then the component will not be clamped in CNC machine.

h l li i d b h h b ldNow Isothermal Annealing is done because the gears have been cold worked.Dog gear is directly produced by cold forging.

Die machining:As the name suggest this shop produces various dies for all

kind of forging operations for both hot & cold forging. The time involved in developing a die varies from 21 days to 45 days depending up on it its complexity and size.

Steps involved in die machining are as follows:Step 1: Firstly die blanks are cut from large billets of diameters rangingStep 1: Firstly die blanks are cut from large billets of diameters ranging from 30 mm to 220 mm on belt saw machine & then sent to die machine shop 1.Step 2: After cutting, they are machined on CNC lathes various operations like milling, turning, drilling, facing, step turning, boring, reaming etc are performed. Here only specifications like ID, OD, chamfer, g p y p , , ,etc are produced no intricate shapes are formed.Step 3: Now it is sent to die machine shop 2, here intricate tooth profile is generated on EDM machine, wire cut EDM machineDog teeth are created in EDM machine, it is the lengthiest process among all.Wire cut EDM machine is used to cut dies and punches of greater depth or thickness.Step 4: Now they sent to furnace to remove stress concentrations and for heat treatment to make it hard.Step 5: After heat treatment the dies are grinded both external as well as internal grinding is done to control its surface roughnessinternal grinding is done to control its surface roughness.

There are equipments like micrometer, surface roughness meter, microscope, etc to check the surface roughness.p gRegular inspection of dies are done to find scratches over it and if found they lapped to remove them without changing its specification much because in lapping surface roughness is controlled up to the value of 1.25 μm.

List Of Parts Manufactured:•Input Shaft: The input shaft receives power from the engine of the car and transmits it to the counter shaft. It has gears and sleeves fitted on it of varying sizes for different speeds.

C t Sh ft Th t h ft i di tl i t t ith th i t•Counter Shaft: The counter shaft is directly in contact with the input shaft via gears and receives power from it and delivers it to the final gear which carries the differential mechanism.

•ITTAI Gear: It is used as the 1st and 2nd gear on the counter shaft and the 5th gear of the input shaft.and the 5 gear of the input shaft.

•ATSUNYU Gear: It is used as the 3rd and 4th gear of the input shaft.

•HIRA Gear: It is used as the 3rd,4th and 5th gear of the counter shaft.

•DOG Gear: It is press fitted on the ATSUNYU Gear and is used for meshing purpose.

•Final Gear: It receives power from the counter shaft and is attached to the differential mechanism.

•Sleeve High Speed: It is used in the shifting mechanism for 3rd and 4th gear.

•Sleeve Low Speed: It is used in the shifting mechanism for the 1stand 2nd gear.g

•Sleeve 5th Speed: It is used in the shifting mechanism for the 5thgear.

Process Lines:

Input Raw Material

Process Layout:

Input Shaft:

T i

Facing and Centering Turning OP‐1 Turning OP‐2

Turning

Roll Forming OP‐1Roll Forming OP‐2

Two Spindle Gun Drilling Milling (Fuel Hole) Spline Forming OP‐1

Turning OP‐3

Gear Hobbing OP‐1 Turning OP‐4 (Grooves) Spline Forming OP‐2

Output Final Product

Gear Hobbing OP‐2 Deburring Gear Shaving OP‐1

Gear Shaving OP‐3 Gear Shaving OP‐2

Models Manufactured:•YR9•YC5•YE3

Number of Process Lines: 5

Production Rate: 42.85/hour

Process Layout:

Counter Shaft:

Input Raw Material

Turning OP 1Facing and Centering Turning OP‐1 Turning OP‐2

Roll Forming OP‐1Roll Forming OP‐2Turning OP‐3 (Grooves)

Two Spindle Gun Drilling Milling (Fuel Hole)

Gear Hobbing

Milling (Key Forming)

Thread FormingChamfering Gear Hobbing


Thread FormingChamfering

Gear Shaving

Models Manufactured:•YN4•YY4•YN2•YL8•YE3•YC5


Production Rate: 42.3/hour

Facing

Process Layout:

ITTAI Gear:

Input Raw Material

Turning OP‐1 Turning OP‐2 Drilling


Gear HobbingChamfering

&Deburring

Gear Shaving

Models Manufactured: Number of Process Lines: 11Models Manufactured:•YR9•YG4•YN4•YY4•YL8•YC5


Production Rate: 56/hour

YC5•YG8•YE3

Process Layout:

ATSUNYU Gear:

Input Raw Material

Turning OP‐1 Turning OP‐2 Gear Broaching



&Deburring

Gear Shaving

Models Manufactured: Number of Process Lines: 7

Broaching

•YR9•YN4•YY4•YL8•YP8‐D


Process Layout:

HIRA Gear:

Input Raw Material




&Deburring

Gear Shaving

Models Manufactured:•YN4•YY4



Hobbing Cutter

•YL8•YG4•YC5•YL7

Process Layout:

DOG Gear:

Input Raw Material



Models Manufactured: Number of Process Lines: 8Models Manufactured:•YN4•YR9•YC5



Final Gear:

Process Layout:

Input Raw Material

Gear Hobbing Chamferring& Deburring

Gear Shaving


Models Manufactured: Number of Process Lines: 5Models Manufactured:•YN4•YE3•YC5



Sleeve Low Speed:

Process Layout:

Input Raw Material

Broaching OP‐1 Roll Forming Milling

Broaching OP‐2V‐ChamferringOP‐1

V‐ChamferringOP‐2

Hobbing R‐Chamferring Shaving


Models Manufactured: Number of Process Lines: 4Models Manufactured:•YN4•YY4•YC5•YL7



Sleeve High Speed:

Process Layout:

Input Raw Material

Broaching Roll Forming Milling (Key Way)


Re Broaching V‐ChamferringOP‐1

ChamferringOP‐2

Models Manufactured: Number of Process Lines: 7Models Manufactured:•YN4•YL7



Sleeve 5th Speed:

Process Layout:

Input Raw Material

Broaching Roll Forming Milling (Key Way)


Re Broaching Chamferring

Models Manufactured: Number of Process Lines: 6Models Manufactured:•YN4•YE3•YC5



Input Shaft Hard:

Process Layout:

Input Raw Material

Distortion Correction Outer Grinding OP‐1 Outer Grinding OP‐2



Distortion Correction Outer Grinding OP 1

Checking

Outer Grinding OP 2

Outer Grinding OP‐3


Counter Shaft Hard:Process Layout:Process Layout:

Input Raw MaterialNumber of Process Lines: 4


Distortion Correction Outer Grinding OP‐1

Checking




HIRA Gear Hard:

Process Layout:

Input Raw Material



Gear Checker Production Rate: 76/hour

ITTAI Gear Hard:

Process Layout:

Input Raw Material

Internal Grinding Taper Grinding Gear Checker

Output Final ProductNumber of Process Lines: 10


ATSUNYU Gear Hard:

Process Layout:


Production Rate: 67/hourInput Raw Material


Spline Grinding Press Fitting Internal Grinding

Taper GrindingGear Checking

Sleeve (High and 5th Speed) Hard:

Process Layout:

N b f P Li 11

Input Raw Material

H d T i Number of Process Lines: 11


Hard Turning

Sleeve (Low Speed) Hard:

Process Layout:

Number of Process Lines: 11Input Raw Material

Output Final ProductHard Turning Gear Checking

Gear Identification and Classification:

•ATSUNYU Gear: Dog Gear is press fitted in process lines.

•ITTAI Gear: Dog Gear pre‐formed during forging.

•HIRA Gear: No Dog Gear is present.

Gear Checking Parameters:•PCD: Pitch Circle Diameter•OBD: Outer Ball Diameter•ID: Inner Diameter•Tooth Space Runout: Distance between each tooth should be constant•NICK: This cannot be visually detected. It is the deformation, too much of which causes a dent.•Roundness•Taper

Heat treatment:Heat treatment refers to the heating and cooling operations required t lt th ti f t l ll l ti d i t i lto alter the properties of metals, alloys plastic and ceramic materials. Changes in material’s properties result from changes made in microstructure of the material.During heat‐treatment of a metal piece, when it is heated to a definite temperature followed by cooling at a suitable rate, there occur changes in the micro‐constituents of the metal. These changes in the microin the micro constituents of the metal. These changes in the micro constituents of the metal may be in their nature, form, size and distribution in the metal piece. Obviously, temperature of heating and rate of cooling are the main controlling factors of changes in micro‐constituents.These changes in micro‐constituents then control the changes in physical and mechanical properties of heat treated metal specimen.The purpose of heat treatment is to achieve any one or more objectives cited as follows:(i) To remove strain hardening of a cold worked metal and to improve its ductility.(ii) To relieve internal stresses set up during cold working casting(ii) To relieve internal stresses set up during cold‐working, casting, welding and hot‐working treatments.(iii) To remove gases from castings, to soften a metal to improve its machinability, and to increase the resistance to wear, heat and corrosion.(iv) To improve the cutting ability, i.e., hardness of a steel tool, to (iv) To improve the cutting ability, i.e., hardness of a steel tool, toimprove grain structure after hot working a metal and to remove effects of previously performed heat‐treatment operations.(v) To improve magnetization property, especially of steels, for producing permanent magnets.(vi) To refine grain structure after hot working a metal.(vii) To soften and toughen a high carbon steel piece.(viii) To produce a single phase alloy in stainless steel, and to produce a hard, wear resistant case on a tough core of a steel part.

(ix) To harden non‐ferrous metals and alloys, especially aluminium alloys and to produce a single phase alloy in stainless steel.(x) To produce a hard, wear resistant case on a tough core of a steel part and to toughen a hardened steel piece at the cost of its hardness.

Mainly in this industry Carburizing is the main Heat treatment process being carried out to increase the surface hardness.

Heat treatment is done of the following parts:All input and counter shaft of all models.All types of gears both 2 & 4 wheeler.All types of sleeves.

Steps involved in Heat treatment:Step 1: Pre Washing:This is done to remove all cutting and coolant oil from the components using s solution called Super Cleaner 285 + Water at a temperature of 70°. Pre‐Washing is divided in 6 steps.70 . Pre Washing is divided in 6 steps.

Process Soak Shake Spray Drip Air Blow Exhaust

Time(in sec) 120 60 150 120 150 50

Step 2: De‐greasing:Material is held at 480° C for a period of 18 min 30 sec. As result all the liquid over the component gets evaporated, now the surface is free from any impurity and is ready to enter the furnace

Step 3: Pre‐heatingIn this material is held for 42 minutes at a temperature of 920° for pre heating the components. Although here there should be no CP (carbon potential) but it contains some as it leaks into it.Step 4: Carburizing 1:Here the components are held for 84 minutes at temperature of 930° C and the CP is 0.95.At thi t t th b d l th f th l tti i d hAt this temperature the bond length of the lattice increases and hence carbon atoms get into it.CP – Carbon Potential is the percentage of carbon in atmosphere of the chamberStep 5: Carburizing 2:Here the components are held for 84 minutes at temperature of 930° CHere the components are held for 84 minutes at temperature of 930 C and the CP is 0.95.This is done to reduce the cycle time because this process is more time consuming. Hence there are 2 Carburizing chamber to reduce the overall time.Step 6: DiffusingHere the components are held for 84 minutes at temperature of 930° C and the CP is 0.85. Carbon is allowed to get into depths.Step 7: Hardening 1Here the components are held for 18 minutes 30 sec at a temperature of 830° C and ideally there should be no carbon in atmosphere but some leaks into itsome leaks into it.This is also called case hardening. As the temperature reduces the lattice length reduces which results in trapping the carbon atom at the surface hence resulting in hardening of the surface.Step 8: Hardening 2Here the components are held for 17 minutes at a temperature of 830°p pC. This is done to reduce the cycle time.

Step 9: QuenchingAfter hardening material should be immediately sent for quenching g y q gwithin 40 sec otherwise whole material is discarded and sent to scrap.Quenching is done by oil by dipping it into oil, components on the jig are placed in the chamber then oil is filled in the chamber at very faster rate.It is very critical process for them, because in this change of micro structure is involved. Before quenching material is pearlite and after quenching it is martensite.During quenching temperature is 160°C and it takes 8 min.Step 10: Vacuum Washing:In this process, solvent Daphenic Cleaner is used. Since this oil is inflammable so it is not directly heated rather it is heated in heat exchanger by exchanging heat with thermic oilexchanger by exchanging heat with thermic oil.Solvent is heated up to the temperature of 160° C it done to remove the quenching oil from the components. The component are submerged in it for 1 hr. Solvent dissolves all the quenching oil from it, now with the help of vacuum pump all the solvent is extracted from chamber and vacuum is maintained, to break this vacuum Nitrogen is use to provide inert , g patmosphere because air contains moisture so it can react to form rust.Step 11: Tempering:It is done at 160° C & components are kept for 2 hrs in it.Note: Curtain flame is used when material comes out of quenching and tempering this is done so as to inhibit the air from atmosphere containing

i i id h fmoisture to enter inside the furnace.Step 12: Shot Blasting:In this, steel balls of diameter 2 mm imported from Japan are used. They are first pre‐heated & then sent to rotor which pushes the steel balls at very high speed over the components.

This increases the surface finish and also endurance limit by imparting compressive residual stress over its components and improves the fatigue performance. Shot blasting also removes the burrs.

After shot blasting components are sent for grinding.Input Shaft is treated up to STEP 12.But Counter shaft has threads so their thread portion is annealed.

Step 13: Induction AnnealingThis process is followed for only counter shaft.Annealing is done to make the material soft, increase its toughness & ductility and reduce relative stresses.The process is called Induction annealing because here the AC current isThe process is called Induction annealing because here the AC current is used. Coils surrounds the thread portion and when AC current is passed through coils it produces fluctuating magnetic field which in turn produces eddy current in the component as a result heat is generated in the component.Note: How fine carbon is produced?Answer: Propane gas reacts with air in the presence of catalyst at a temperature of 1080° C to produce Endothermic gas which is a mixture of CO2, CO, N2& H2O. This reaction takes place in Gas generator.Now this endothermic gas and propane is fed to furnace where they react and produced fine Carbon particles along with CO, CO2 and H2O.

Flow meter is used to measure the flow of propane and Endothermic gas.Using the Infrared CO2 Analyzing Device they measure the CO2 level in

Case Hardened Gear

Using the Infrared CO2 Analyzing Device they measure the CO2 level inCarburizing, Diffusion and hardening zone

Hard Machining ProcessThe material that comes after heat treatment process is then hard machined to meet the final specification of the product. Hard machiningmachined to meet the final specification of the product. Hard machining for the gears involve following processes:‐1.Taper outer grinding:‐It involves grinding of the outer face of the component. The jigs and fixtures used are base plate,pusher,collet,guidebar and locking nut.Base plate:‐It is the support on which the gear rests upon.Pusher:‐Pusher is used in order to tighten the collet so that the gear is held and grinding process could be carried upon.Collet:‐It is used to hold the gear from its ID since it has taper ID so as the rod is inserted inside the collet it expands and gear gets fixed on the collet and grinding process could be done.

Collet

2.Taper Inner Grinding:‐It involves grinding of the internal ID of the component. The jigs and fixtures used are Pin cage, Out chute, Fingers and Spacers.Pin cage: It is used for holding the gear from its outside diameter with

Collet

Pin cage:‐It is used for holding the gear from its outside diameter with the help of the fingers.Dressing Interval:‐It is time after which the grinding wheel is dressed.During the grinding process the grinding wheel gets blunt in order that we get better finishing the wheel is dressed after a specific interval of time which varies with the material that is grinded.g3. Gear CheckingGear that is hard machined is then checked for P.C.D. run out ,nicks and dents.P.C.D. run out:‐It is used to check whether the pitch circle diameter is within the specification mentioned. In order to check the P.C.D. the gear i h d i h h d h di l i h d hi his meshed with the master gear and the dial gauge is attached which measures the run out if it is not according to the spec. mentioned it is discarded.Besides that the gear is also checked for nicks and dents on its profile.Nick:‐Nick is the outward extrusion in the profile of the gear.Dent:‐Dent on the surface of the gear is also checked and if it occurs it isDent:‐Dent on the surface of the gear is also checked and if it occurs it is discarded.

Assembly OperationMainly there are 4 Transmission assembly lines along with hub andMainly there are 4 Transmission assembly lines along with hub and sleeve assembly, differential assembly, AMT assembly and GNT section.They use synchronous type of transfer system. In this the work carriers continuously move and the operators remain at their position and fit their parts. This builds a lot of pressure on the worker and in case of any delay or wrong pick the whole of the assembly line is halted for some time by the operator. To meet the demand supervisors had to be keep strict check on the workers & continuously replenish the demands of the components.During assembly operation transmission is continuously checked at various stations for its major faults.M i l h 2 t f t i i f t d MF 60 & MF 70Mainly here 2 types of transmission are manufactured MF 60 & MF 70, number represents the distance between the input & counter shaft. For heavy vehicles MF 70 is used for e.g. in diesel variant of most of the cars or in heavy cars like Ertiga, SX4, etc and for small cars like Alto 800, Astar, etc. MF 60 is used.

Quality Room:‐The first off piece checking is done in the quality room. The component here is examined for its various dimensions. The instruments used are:‐

Micrometer

Digital Depth Calliper

Profile Projector

Height Gauge

Bench CentreGO NO‐GO Plug Gauge

Snap Gauge

Other instruments used include CNC Gear tester, OBD micrometer, Roundness testing machine etcRoundness testing machine etc.Some of the Gear terminologies used are:‐Lead:‐Lead is the axial advance of a helix gear tooth during one complete turn (360°)Outer Ball Diameter(OBD):‐A ball of particular diameter is fixed on the micrometer and between the tooth diameter is examined which is referred to as OBD.Module:‐It is the unit of size that indicates how big or small a gear is. It is the ratio of the reference diameter of the gear divided by the number of teeth.Backlash:‐It is defined as the clearance between the mating gears.S i t i S i t i i th h f i f th t th' t ItSemi‐topping:‐ Semi topping is the chamfering of the tooth's top corner. It is done to reduce noise during teeth meshing.Helix angle:‐The angle between the axis of a helical gear and an imaginary line that is tangent to the gear tooth.

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