IN-PLANT TRAINING REPORT

SUBMITTED BY

S.SUBASH

N.GURUSUBRAMANI

D.K.JAYANTH NAIDU

BACHELOR OF ENGINEERING
in

MECHANICAL ENGINEERING

from

SRI SAIRAM ENGINEERING COLLEGE

West Tambaram, Chennai-600044.

Duration: 26/12/2017 – 30/12/2017

MANAGER SENIOR AGM. DEPUTY MANAGER

MANUFACTURING ENGINEERING MANUFACTURING ENGINEERING HUMAN RESOURCE

& PLANT ENGINEERING

 ACKNOWLEDGEMENT

The In-plant training opportunity we had with “KOMATSU INDIA

PVT.LTD” was a great chance to acquire the basic knowledge of how a
manufacturing unit works with the help of some assisting departments.

We are so grateful that we had a chance to meet so many skilled

labors and the way they showed their passion towards their work made
us to inspire them. We thank them to share their experience with us
apart from their hectic schedule.

We would like to thank Mr. S. Srikrishna -director, Sr. VP HRD for

offering us this opportunity and we also thank Mr.G.Prakash-Human
resource Department, Mr. P. Paari Sridattan-Sr.AGM Manufacturing
engineering, Mr.G.Prabhakaran – Manager, Manufacturing Engineering
for supporting us and our extended thanks to Mr.T.Karthick – Engineer,
Manufacturing Engineering and Mr.S.Saravanan – Manufacturing
Engineering for guiding us throughout.

At last, We would like to thank all the staffs for providing a

comfortable training without any hesitation and “quality through work
is what we found out the way the company is working”.
 1. HISTORY OF KOMATSU:

Komatsu Iron Works was started as a subsidiary to make industrial

tools. Komatsu eventually became large enough to sell to the public,
and was established on May 13, 1921 as Komatsu Ltd.

Komatsu produced its first agricultural tractor prototype in 1931.and it

supplies tanks, buldozers during world war-2 .then after new president
Yoshinari Kawai decided to add non-military bulldozers and forklifts line
of equipment. In 1949 it began production of its first diesel engine. Its
growth as a company was aided by the strong demand for its bulldozers
.By 1957 the company had advanced technologically to the point that
all its models were using Komatsu engines.

In July 1967, it entered the U.S. market, taking on caterpillar, the

largest bulldozer maker, in its home market. This was done under the
company slogan of "Maru-C", translating into English as "encircle
Caterpillar"

1.1 STEPPING INTO OVERSEAS

Komatsu America Corporation being established in February 1970 in

the UNITED STATES. A year later, in January 1971, Komatsu Singapore
Pte. Ltd. in April 1975 was the founding Komatsu do Brasil Ltda. In
BRAZIL. This company produced the bulldozer, marking Komatsu's first
offshore production of construction equipment. Komatsu Australia Pty.,
Ltd. in AUSTRALIA was established in Feb. 1979. Komatsu Industries
Europe GmbH was set up in 1986 in GERMANY.

Komatsu owns the former DEMAG range of mining machines, which

have been upgrades but are basically the same, with the pc-3000being
the old DEMAGH185, of which over 200 have been built under both
brands/model numbers.
Additional overseas expansion, primarily in ASIA was accomplished in
the 1990s. Komatsu Vietnam Co., Ltd. in VIETNAM.

The KOMATSU has been widely spreads all over the world and its
establishment is not only in manufacturing unit, but also founded
several service centers (Nagpur in India) .the map shown above
precisely describes the various locations of komatsu and their roles.

1.2 PRODUCTS OF KOMATSU

 BULLDOZERS MOTOR GRADERS DUMP TRUCKS

HYDRAULIC EXCAVATORS MOBILE CRUSHERS WHEEL EXCAVATORS

BACKHOE LOADERS WHEEL LOADERS

1.3 KOMATSU INDIA PRIVATE LIMITED - CHENNAI PLANT

1998; L&T KOMATSU PVT.LTD in INDIA in 1998 (shares sold in

2013), which then named as “KIPL”. The main plant is located in
Chennai at Oragadam. This plant initially produces DUMP TRUCK from
beginning and during the expansion of the plant in 2010 a REMAN plant
has been setup.

During Feb-2015, the company initiated in establishing the

HYDRAULIC EXCAVATOR plant and production started from May-2016.
The production rate grows higher at this plant and they celebrated their
th
1000 product in may-2017.the sales is completely done in Bengaluru
branch and a service center at Nagpur.

The Chennai plant is only the manufacturing plant in INDIA as Bengaluru

&Nagpur deals only with the sales & servicing.
The major products manufactured here are –
 1) DUMP TRUCKS
2) HYDRAULIC EXCAVATORS

1.3.1 DUMP TRUCKS

HD-785 HD-465

1.3.2 HYDRAULIC EXCAVATORS

PC-71 PC-130
 PC-210 PC-300

PC-350 PC-450

Apart from the above specified plant, this plant also has a REMAN
plant, which established in 2010 for the purpose of remanufacturing
the engine which have been used by the customers.
 2. KIPL ORGANIZATION STRUCTURE:

Various departments involving in the industry for providing better

products are;

FINANCE AND ACCOUNTING – Key department for providing and
maintaining the funds.

HUMAN RESOURCE - Acquiring man power & providing labor law
complaince.

MANUFACTURING ENGINEERING - Assisting and supporting the
production unit in an industry.

QUALITY AUDIT – Checking, measuring & testing of one or more
parts.

PLANT ENGINEERING AND MAINTENANCE – Applying engineering
concepts for optimising equipments, procedure & dept. budgets.

DESIGN - Activities involving styling, look & products mechanical
architecture.

PLANNING AND COORDINATION DEPARTMENT- Responsible for
engineering change implementation.

LOGISTICS – Integrating several aspects such as handling,
warehousing, transportation, packaging & inventory.

PRODUCTION- Process in which inputs & immaterial inputs in order
to make something for consumption.

PURCHASE – This department buys Raw Materials Spare parts,
services etc. as required by the company.

INTERNAL AUDIT AND COMPLIANCE-It is an independent, objective
assurance & consulting activity designed to add value & to improve
an organization’s operations.

ICT – Information of Communication Technology plays an important
role in achieving communications across the globe.

2.1 MANAGEMENT POLICIES

2.1.1 SAFETY FACTORS:

The company follows the safety factors while entering into the
plant by providing the helmet, goggles and earplugs and most
importantly is to wear safety shoes.
2.1.2 5S:
(1) Sorting (Seiri)
(2) Stabilizing (Seikon)
(3) Shine (Seisou)
(4) Standardize (Seiketsu)
(5) Sustain (Sitsuke)
2.1.3 KOMATSU Priority:
S- Safety
L- Legal
Q- Quality
D- Delivery
C- Cost
3 GENS:

Gemba- Real place

Gembutsu- See

Genjitsu- Reality

5 Time ask why-

In order to solve the main root cause ask 5 times “why”.

 3. KOMATSU INDIA PVT.LTD
In-plant training: from 26/12/2017-30/12/2017

REPORT

As we got a chance to undergone implant training in the KOMATSU

which considered as one of the esteemed company across globe
regarding the production based on heavy mining equipments, I hereby
stated the observation based on day basis.
 4. DUMP TRUCKS

The next day of our training starts with the dump truck. We undergone
the process in which both the dump trucks (HD-465 and HD-780) are
manufactured and we had a clear vision till the shipment of the trucks.

The dump truck manufacturing plant has a linear process which slightly
differs from HE manufacturing. The process of making the humongous
profiled truck begun with the preparation of chassis. The plant has
three lines or tracks on which the process takes place.

SS -SUB WELDING --SUB-ASSEMBLIES -DOJO

-MAIN WELDING - MAIN ASSEMBLY

4.1 FABRICATION

1) SIDE MEMBER :
The side member can also called as a sub-assembly, in which
initial stage of chassis preparation takes place by the “tack welding” of
the hoist cross and rear cross. Then bottom flange is welded to above
parts through semi-automatic welding and a clear inspection had done
by “co-ordinate measuring machine”. Then the welded part has been
sent to the main line.

2) MAIN LINE:
The part from the side member is then tack welded so that
partial profile of chassis is obtained and then it is welded by robot-
automatic welding process and ULTRASONIC TESTER is used for
inspecting. Then it is again welded manually and then sent to paint
booth in between the process, vertical frame is welded to the hoist and
rear cross.

4.2 ASSEMBLY
The process of assembly starts after the chassis passes over the paint
booth. The process followed is shown below;

4.2.1 SUB-ASSEMBLIES

The sub-assemblies are the key part of the plant, which

reduces the tedious process by doing process parallel to the main line.

The sub-assemblies are;

  Hydraulic Sub-Assembly: This station helps in assembling the
“hoist valve, demand valve, transmission filter, hydraulic air filter
and breather”.
 Radiator Sub-Assembly: This station assembles the radiator parts
like” hydraulic air cooler, ac condenser, oil condenser, Inner and
outer water coolant “.
 Cabin Sub-Assembly: This cabin sub-assembly assembles the
inner and outer cabin parts like “monitor, steering, brake pedal,
and some technological additions like VHMS,ATC,RHC AND
AUTOTRIP SENSOR”
 Transmission and engine: this station assembles the engine and
transmission to the chassis by including the “torque converter,
hoist pump, brake cooling pump, controller lubrication pump, v-
type engine, damper cover “.
 Rear axle (rear axle small sub assembly ,axle final, main and
test):
Axle plays a vital role in controlling the truck .the axle used here
is differential and since it is rear axle, It controls the vehicle
during the turning by slows the speed of respective wheel. The
station has features of testing the axle after the completion of
fixing the parts and then moved to the chassis for fitting.

4.2.2 SUB-ASSEMBLIES (after welding dojo):

The sub-assembly on the other side of the main

line, supplies quite a few needy and important parts. The parts
assembled are,

 Outer platform: this station fixes the outer platform which includes
the “mirror and air-filter”, which then fixed to the body.
  Inner platform: this station fixes the air filter to the inner side of
the cabin.
 Accumulator: this station fixes the accumulator which acts as an
energy reservoir or a storage device which stores a desired
pressure and then sends to the respective parts through the
hydraulics.
 Front support: this station assembles the hoses and the valves to
the machine.

4.3 MAIN LINE:

The main line is the heart of the manufacturing unit in this process
and this line has 5 stations which is also parallel to the sub-assemblies,
so that the complexity in assembling each parts can be reduced.

 STATION-1(MO1)

The station initially starts after the completion of the chassis

painting. The chassis is then assembled by several bushes and also front
axle, tubes and hydraulic tank is mounted.

The battery box is also fitted, which has 4 batteries so that the
emergency driving during brake down can be done by charging the
steering for 90 seconds.

 STATION-2(MO2)

The second station assembles the transmission, engine, tube

connection, accumulator and battery box are fitted. In this station more
care has taken since the engine is mounted in this station.
  STATION-3(MO3)

Cabin, rear axle, radiator, hoses and tubes are assembled in this station.

 STATION-4(MO4)

In this station the outer and inner platforms are assembled. The truck is
70% completed and then exhaust systems and oil filling are done.

 STATION-5(MO5)

This station fixes the balance parts which includes the tyres,
and then the truck is sent into the paint booth for further finished and
then the truck is tested in the track. Then it is dismantled for the
shipment.
 5. REMAN PLANT

As earlier, we finished our observation at the two plants. On

our third day, we further visited the dump trucks and HE assembly to
process the layout of the respective plants.

Then we moved into the REMAN plant. this plant is

established in the year 2010 and the motive of initiating this plant is to
Remanufacture the engine which used over the period of 18,000 hours
run (specified by komatsu).then the customers who handover the
engine will be provided with a temporary engine which they can use till
their engine remanufactured(45 days for the reman process).

NORTH
5.1 REMAN PROCESS:

The term Reman itself denotes Re-manufacturing. The

Remanufacturing process is only done for the Dump Truck & dozer
engines.

STAGE-1 DIS-ASSEMBLING

 The whole engine is kept on a stand with the help of EOT Crane &
is dismantled. In this station, the engine which arrives will be
completely disassembled and then move on to the sub-assembly.
Even if a simple part is failure, then a new part is provided by
informing the “PART RECOMMEND SYSTEM”.
STAGE-2 WASHING

 The whole engine block & all the engine components such as
piston, piston cylinder, crankshafts etc. are washed & cleaned
thoroughly.
STAGE-3 INSPECTION

 The engine is inspected thoroughly, so that the damaged parts

can be repaired & re-placed if necessary.
STAGE-4 SUB ASSEMBLY

 In this section the parts which are disassembled are again

assembled by using various techniques.

STAGE-5 SHORT BLOCK ASSEMBLY

 It is an engine sub assembly in which the portion of cylinder

block below head gasket has been fixed.
STAGE-6 MAIN ASSEMBLY
 All the engine parts such as pistons, cranks etc. are re fixed again.

STAGE-7 PERFORMANCE TEST

 The engine which is refixed is tested by using dynamometer which

can be viewed in performance test room.

The engine is repainted & finally shipment.

 6. HE - PLANT

We started from the HE fabrication and assembly section

where the excavators ranges from PC-71 to PC-450 (Power
Crawler).Their manufacturing begins with the raw materials which are
imported from their suppliers. The power crawlers began their process
from their initial stage from the fabrication unit and finished after the
assembly.

HE FABRICATION LAYOUT
Fabrication has following line:

1) TRACK FRAME LINE

2) REVO FRAME LINE (REVOLVING FRAME)

3) BOOM LINE

6.1. Fabrication Process-

The fabrication process includes the assembling of raw materials

such as track frames etc. In the First Stage, the frames are assembled &
tack welding is done so that the movement of frames & components
gets arrested. This process is followed by Robot welding, the robot does
the remaining welding & the welding which are complicated are done
by Semi-Automatic Welding (SAW).

After this the welded part is inspected & is sent to the shot
blasting machine. In this machine the welded component is forcefully
hit with metal balls, sometimes the blasting is done using sand, so that
the surface of the component will become little rough so that the
application of paint becomes easy. This processes are common for all
the three rows of the Fabrication Plant.
 6.2 HE ASSEMBLY LAYOUT

SUB-ASSEMBLY TRACK LINE WORK EQUIPMENT

REVO LINE MAIN LINE
6.3 Assembly Unit-
The assembly consists of many sub-assemblies & major assemblies.

TRACK LINE

First of all the finished track frame is transported to assembly unit

using Forklifts. The frame is then again fixed fixture in the Track line,
this includes the following process-

 T01- The track rollers & roller guard are assembled here
using nut runner system.
 T02- The swing circle is fixed & grease bath is done.
 T03- Sub-Assembly of Swivel Joint.
 T04- Swivel joint main assembly.

REVO LINE
 R01-This includes the fixing of horns, No. punching, wiring etc.
 R02- Fixing of cabins, cabin rooting, fixing of control valve.
 R03- The fuel tank is mounted & main valve is fixed.
 R04-The fuel tank & other oil-tanks are assembled with nuts.
 R05- The engine is lifted & is fixed inside the machine.
 R06-After the engine, the radiator is fixed.
 R07-The tank cover is placed & for PC71 model FRP ( Fiber -
Reinforced Polymer) cover is used.
 R08-The R/H door, Air Filter, Ducts are fixed.
 R09- Boom cylinder is fixed (Double Acting Type).
 R10- The cover is fitted under the machine.

The assembly of Revo-Frame & Track-Frame are finally assembled

together known as docking. This process is done in Main Line which
includes the following process-
  ML01- Marriage Section- The cabin/revolving part & track-frame is
fixed Together.
 ML02-Swing Machinery assembly & hose connections.
 ML03-The hand rails, lamps, Mirrors are fixed.
 ML04-The seat & A/C related components are fixed inside the
cabin.
 ML05-This stage includes the oil filling, fuel filling, coolant filling
etc.

Some of the Sub-Assembly lines are described as follows-


WORK EQUIPMENT LINE
 Includes fitting of tubes & nipples.
 Bucket cylinder is fixed & the bucket is finally fixed.

ENGINE SUB-ASSEMBLY
 The clamper disc, muffler, starter motor, alternators, oil filters are
fixed.
 Earth connection is given

CABIN SUB-ASSEMBLY
 Seat adjuster, Travel lever, Foot pedal & some wirings are done.
 Console fittings & R/H & L/H parts are fixed.
 The floor frame hose is connected by applying torque.
 The KOMTRAX is fixed. This is a GPRS controlled device which
shows the fuel, oil levelings, service schedule, place of the
equipment throughout the globe.
 A/C vents, monitor, cabin wirings are done


SMALL SUB-ASSEMBLY
 Pressure valves are placed & fixed.

ACCUMULATOR SUB-ASSEMBLY
 The air filter, radiator are assembled.
 Suction hoses are fixed.

RADIATOR SUB-ASSEMBLY
 The stay rod is fixed.
 A/C, condensers are fixed.

FINAL INSPECTION
 The hydraulic excavator which crosses all the modifications &
testing will be painted & decaling is done.
 The final inspection will be made & then sent to the storage yard.

Finally, The Hydraulic excavator is shipped.