Industrial Training Report

ON

“Defect Analysis”

Completed at

Under guidance of
Mr. Tushar Korde
Deputy Manager
(VE Powertrain)

Submitted by:-
Aniruddha Verulkar
Priyadarshini Institute Of Engineering and
Technology,Nagpur
 CERTIFICATE

This is to certify that Mr.Anirudddha Verulkar, S/O-Mr. Satish

Verulkar, student of B Technology , PIET(Nagpur University),
Nagpur Maharashtra, has successfully completed five weeks(From
22th May, 2018 to 22th June,2018) internship program at this
Branch/Company. During the period of his internship program with
us:
He has taken keen interest in understanding production line and
productivity enhancement.
He was found punctual, hardworking and inquisitive. We wish him
every success in life.

Mr. Tushar Korde

Deputy Manager
(VE Powertrain)
 ACKNOWLEDGEMENT

It is my proud privilege to release the feelings of my gratitude to several

persons who helped me directly or indirectly to conduct this project work.

I take this opportunity to express my heartfull indebtness and owe a deep

sense of gratitude towards the PIET, Nagpur University, Nagpur ,for
forwarding my training letter to VECV, Pithampur and also to Mr.Milind
Bugde (ETB) for referring my name as summer intern at VECV.
Further I would like to express my gratitude to Mr. Tushar Korde to
guide and encourage me throughout the training period. I duly
acknowledge the help, direct or indirect of the whole department and staff
members of the organization for providing all the facilities for the training.
Introduction

VE Commercial Vehicles Limited is 50-50 joint venture between the Volvo Group
(Volvo) and Eicher Motors Limited (EML). It is a partnership that brings together
Global leadership in technology, quality, safety and environmental care, along with
the deep knowledge and understanding of the Indian Commercial Vehicles (CV)
market. VE commercial Vehicles Ltd. (VECV) owes its inception to compelling
content of driving modernization in commercial transportation, in India and other
developing markets.

Mission
VECV aims to continuously improve transportation efficiency in India and
developing markets, thereby reducing logistics costs for goods and people – leading
to a higher enablement of specialization of manufacturing, agriculture and services,
thereby increasing the nation’s economic activity and productivity.
 We choose to do this in a sustainable manner by having the safest, most
durable and efficient products in the market.
 We care for our customers holistically by offering not just trucks and buses,
but also the best service and soft products to enable him to be the most
profitable.
 We work with the driver community to enhance their productivity and
overall working environment.
 We ensure a level of quality and innovation that will come continue to set
standards in the commercial transportation industry.
VISION

“To be recognized as the industry leader driving modernization in commercial

transportation in India and developing world.”

Value System

Respect-
“In an enabling environment that recognizes, embraces and celebrates differences,
at VECV respect to all our stakeholders is a central belief that makes us deliver on
our promises and hold ourselves accountable to all commitments.”
Fair and Ethical-
“To build and sustain our reputation for long term at VECV.” We strive to conduct
our business with integrity, treat everyone fairly and be reasonable and ethical in
all our dealings.
Excellence-
“Reflecting our power and heritage of delivering supreme quality and achieving
ambitious goals at VECV.” We constantly change ourselves to innovate for the
future and strive uncompromisingly to develop new standards for meeting and
exceeding customer expectations.
Customer Centric-
“The customers point of view is central to our organizational process, and with a
proactive focus on his/her changing needs, coupled with consistently excellent
service, at VECV we aim to create a mutually beneficial long-term relationship
with our customers.”
Passion-
“At VECV we revel in our work and strongly believe in making a difference to our
customers by walking the extra mile. This passion inspires us to demonstrate
constant enthusiasm and unlimited drive to deliver beyond our stakeholder’s
expectations.

Objectives
We are committed to manufacture the market products which meet or exceeds the
requirements agreed with our customers and to the continual improvement of our
process through involvement of our employees, customers and associates.
 Enhancing customer satisfaction
 Achieving total employee involvement
 Reduction of waste
 Maintaining recognized Quality Management System

History

In October 1982, a collaboration agreement with Mitsubishi for the light

commercial vehicles was signed in Tokyo and in the same period the incorporation
of Eicher Motors Ltd. also took place. In February 1990, Eicher Good earth bought
26% stake in Enfield India Ltd. and by 1993 Eicher acquired a majority stake (60%
equity shareholding) in Enfield India.
In July 2008, EML and Volvo Group’s 50:50 joint venture VE Commercial
Vehicles Ltd. (VECV) designs, manufactures and markets commercial vehicles,
engineering components and provide engineering designs.
In July 2012, EML and Polaris Industries Inc, USA announced a 50:50 joint venture
to design, develop, manufacture and sell a full new range of personal vehicles.

Group Structure

The Eicher Group has diversified business interests in design and development,
manufacturing, and local and international marketing of trucks, buses, motorcycles,
automotive gears and components. Eicher has invested in the potential growth areas
of management consultancy services, customized engineering, and maps and travel
guides.

VE Commercial Vehicles (VECV) Ltd. is a 50:50 joint venture between Volvo

Group (Volvo) and Eicher Motors Limited (EML).
VECV is divided into six business units:
 Eicher Trucks and Buses – The E series
 Volvo Trucks India – The VE series
 Eicher Engineering Components
 Eicher Engineering Solutions
 VE Powertrain
 Royal Enfield (India)
Highlights of Eicher Trucks and buses-
  50:50 joint venture between Eicher and Volvo
 Turnover of over US$ 1 Billion
 Present in more than 22 countries across the world
 More than 300 customer touch points within India
 Employee base of over 4000 people
 Comprehensive product range with latest technology
 Dominant market share in LMD segment in India

Milestones-

 1964 – Ramon and Demm set up a plant in Thane, the first commercial vehicle gear
manufacturing facility in India, in collaboration with Fratelli Daldi and Mattuecci.
 1992 – Eicher takes over Ramon and Demm.
 2004 – Started outsourcing of components.
 2006 – Take over the Dewas plant from the BMC company.
 2008 – 50:50 JV between Volvo and Eicher Motors Ltd.
 2009 – SEZ Pithampur plant set up for gearbox assemblies.
 2010 – First phase of expansion and CWS line set up at Dewas.
 2011 – Gear grinding and shaving cutter re-sharpening facility installed at Dewas
 2012 – Bhoomi poojan of Dewas plant-2
Location
Address: VE POWERTRAIN
VE Commercial Vehicles Ltd
(A Volvo Group and Eicher Motors joint venture)
105, 107, 109, Sector I
Pithampur - 454775, Dist. Dhar, Madhya Pradesh, India
Tel. No.: +91-7292-426500
Fax No.: +91-7292-426524

Production Capacity: 1,00,000 per annum

Established in: 2013
 Company Insight

VE Commercial Vehicals is a joint venture between Volvo group and

Eicher group started back in 2012 and since then it is known for producing
Euro 3 and 4 engines for national and international market.. The Euro-6
compliant diesel engines are being supplied to Volvo Group plant in
Venissieux, France where these engines are getting assembled for the
Volvo Group Euro 6 requirements. The same platform is adapted to Euro
3 and Euro 4 (BS 3/BS 4) technologies to meet the VE commercial
vehicles requirements and other Volvo Group requirements.

LOGISTICS MACHINING ASSEMBLY TESTING

Fig. Work flow diagram.

 PLANT LAYOUT
THE PLANT HAS FIVE LINES:
 Piston line.
 Block line.
 Head line.
 Timing gear assembly line.
 Final assembly line.

TIMING GEAR ASSEMBLY LINE

HEAD
LINE

BLOCK FINAL
LINE ASSEMBLY
LINE
PISTON
LINE
 PISTON LINE
Station Operations

Station 1 Connecting rod and Cap is separated.

Station 2 Piston is mounted on connecting rod and gudgeon pin

lubricated and fitted inside the connecting rod.

Station 3 Snap ring is fitted on both the ends of gudgeon pin.

Station 4 Piston rings are placed in piston.

 BLOCK LINE
STATION OPERATION
Station 1 The pallet keeps on the line Then Block is lifted and placed
on pallet. Water nipple is fitted in four cylinder engine.
Station 2 Engine number is punched on the block and lubrication is
done on the block and camera check is done.
Station 3 Piston is inserted in the cylinder. Connecting rod cap is
placed on pallet.
Station 4 The block is turned at 180 degree.
Station Oil plug is fitted, and main bearing cap is loosed.
5
Station 6 Piston cooling jet is inserted. Main bearing cap is further
loosed by puller.

Station 7 Cell bearing is inserted and Lubrication is done in cell

bearing.
Station 8 Crankshaft is inserted in the crank bore and then crankshaft
is lubricated. Thrust washer is placed with main bearing cap
and main bearing is placed inside in block.
Station 9 Pre torquing of main bearing cap and connecting rod cap
Station 10 Final torquing of main bearing cap is done and position of
thrust washer is checked and end play is checked.
Station 11 Final torquing of connecting rod cap is done.
Station 12 Block is again turned to its original position.

Station 13 Head is mounted on block.

Station 14 Cylinder head bolts are tighten.
Station 15 Valve bridge is placed on head and fuel pump is mounted on
socket. Water nipple screwed in six cylinder engine.
Station 16 Valve timing is set for inlet and exhaust valve.
Station 17 Leak test of oil gallery is done.
Station 18 Quality check is done.
Station 19 Position of engine is changed.

HEAD LINE

Station Operation
Station 1 Head is placed on pallet and rocker arms are loosed
from head.
Station 2 Fuel injector valve is lubricated and o-ring is mounted
on injector then it is inserted.
Station 3 Injector yoke is inserted and Sleeve tube is inserted.
Pre torquing of injector yoke is done.
Station 4 Sleeve nut is inserted. Final torquing of injector yoke is
done.
Station 5 Checking the leakage test by using H2 and N2 gases.

Station 6 Child parts are arranged on pallet manually.

Station 7 Cottar is fitted on the valve spring washer (upper).
Station 8 Child parts are checked by camera.

Station 9 Child parts are assembled with the help of fully

automatic machine on the head.
Station 10 Assembled head is placed on pallet.
Station 11 Parts of rocker arms are attached on rocker arm and
snap ring are fitted with them.
Station 12 Cell bearings are mounted on head and lubrication of
cell bearing is done.
Camshaft is lubricated and inserted on head and pre
torquing of rocker arm is done.
 TIMING GEAR ASSEMBLEY

Station Operations
Station 1 Position of engine is changed.

Station 2 Timing gears are mounted and pulsar plate is mounted on

gear. Torqueing of 2 gears are done.
Station 3 Remaining Timing gears are tighten.

Station 4 Sealant is applied on an engine surface and leakage tested and

positions of all gear is checked by laser.
Station 5 Flywheel housing and power steering pump is mounted on
the rear side of engine.
Station 6 (Tock light gas) liquid is applied on the crankshaft and then
flywheel is mounted.
Station 7 Here, the engine is lifted at a height from the line.
Station 8 Here, the engine is loaded and the position of engine is
turned.
 FINAL ASSEMBLEY

STATION OPERATION
2Station 1 Front cover is mounted on block and then front oil
seal is placed and damper pulley is attached.
Station 2 Oil pump, oil pipe and oil strainer are attached.
Station 3 Oil pan is installed and steppers are installed.
Station 4 Exhaust manifold is placed and common rail is
installed.
Station 5 Lower cover bolted over the engine head, engine
sensors and turbo charger, intake manifold are
installed.
Station 6 Water pump, idler pulley, injector harness and
solenoid are installed.
Station 7 Power cable and starter are installed.
Station 8 Compressor and thermostat are installed.
Station 9 Alternator is fixed.
Station 10 Electronic control unit bracket is installed.

Station 11 Fuel supply support bracket and mount bracket are

installed.
Station 12 Oil cooler unit is installed.
Station 13 Fuel pump pipes are fitted and oil pressure sensor
is installed.
Station 14 Breather pipe fitted and ECU is installed.
Station 15 Wire harness is installed.
Station 16 Air charger and oil filler pipe is fitted. ECU
software installation is done.
Station 17 Leak test (oil pump, water pump, turbocharger) of
engine is done.
Station 18 Quality check of engine accessories is done.