FOUR WEEKS INDUSTRIAL TRAINING REPORT

On

“IMPLEMENTATION OF SONALIKA PRODUCTION SYSTEM”

AT
INTERNATIONAL TRACTORS LIMITED, HOSHIARPUR

VIKAS SINGH
(2323274)

DEPARTMENT OF MECHANICAL ENGINEERING,

IK GUJRAL PUNJAB TECHNICAL UNIVERSITY,

HOSHIARPUR “JUNE 2024”

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 CANDIDATE DECLARATION
I VIKAS SINGH hereby declare that I have undertaken
four weeks of industrial training at “INTERNATIONAL
TRACTORS LIMITED, HOSHIARPUR”during
period from 10/06/2024 to 20/07/2024 in partial
fulfillment of the requirements the award of degree of
B. Tech (Mechanical Engineering) AT IK GUJRAL
PUNJAB TECHNICAL UNIVERSITY.
The work which is being presented in the training
report submitted to Department of Mechanical
Engineering, IK GUJRAL PUNJAB TECHNICAL
UNIVERSITY HOSHIARPUR.
An authentic record of training work.

SIGNATURE OF STUDENT

2
 CERTIFICATE OF
TRAINING
ABSTRACT
The Sonalika production system is a comprehensive
and integrated approach to manufacturing that
focuses on
producing high-quality agricultural machinery,
particularly tractors, to meet diverse customer
needs. It encompasses the entire production
process from design and development to assembly
and quality control. The system is characterized by
the use of advanced technologies, lean
manufacturing principles, and stringent quality
assurance measures.
Emphasis is placed on innovation, efficiency, and
sustainability, ensuring that products are not only
reliable and durable but also environmentally
friendly. The Sonalika production system aims to
optimize resource utilization, minimize waste, and
continuously improve processes to maintain
competitive advantage and customer satisfaction
in the global market.

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 ACKNOWLEDGEMENT

We extend our deepest gratitude to everyone involved

in the successful implementation of the Sonalika
production
system. This achievement would not have been
possible without the unwavering support and
dedication of our
executive leadership, who provided strategic
guidance and resources throughout the project. We
also recognize the
invaluable contributions of our engineering and
technical teams, whose expertise and commitment
to excellence drove the meticulous planning, design,
and execution phases.

Special thanks go to our production staff for their

adaptability and hard work in adopting new
processes and technologies, ensuring a seamless
transition. We are grateful to our quality assurance
and continuous
improvement teams for their relentless pursuit of
excellence, ensuring that every product meets
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our high standards. Finally, we appreciate the
feedback and
cooperation from our customers and partners,
whose

5
insights have been instrumental in refining our
system. This collaborative effort has been
fundamental in establishing a robust, efficient, and
sustainable production system that will propel
Sonalika to new heights of success.

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 TABLEOFCONTENT

CHAPTERNO. TITLE. PAGENO.

CANDIDATE’S
DECLARATION CERTIFICATE
OF TRAINING
ABSTRACT
ACKNOWLEDGMENT
LIST OF TABLES

Introduction
1.1 History of Sonalika. 9-13

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1.2 Various department. 13-14
1.3 Rear cover assembly 15-16
1.4 Differential assembly 16-18
1 .5 Gear box assembly 18-20
1.6 Engine loop 20-24
1.7 Front axle 24-28
1.8 Main loop. 28-32
1.9 DWM boards 32-33

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CH-1

INTRODUCTION OF COMPANY

1.1HISTORY OF SONALIKA GROUP

The founder of Sonalika group is Sh. LAKSHMAN DAS

MITTAL
. SONALIKA group is one of the top automobile and
agriculture machinery manufactures in India. Apart
from Tractors its product line includes multi-utility
vehicles, three
wheeler,engines and various farm equipment and
implements. Established in 1969, sonalika Group
since the inspection theinspection tried to
understand customer need to be
Facilitating them with its value formoney products.
The
company has a state of art Manufacturing
facilities, spread in areas,located in the free shrubs
of Punjab and Himachal Pradesh. Sonalika is the
one of the top 3 tractors manufacturing companies
in India, other Product include of multi utility
vehicles, engines and various farm equipment.
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Today the Group stand tall with an approximate
turnover of 5000 Crore INR. An average growth of
30% makes it one of

1
fastest growing corporate in India. It is the one of
the few debts Few companies. Group has
strength of about 2000 employee technocrats.
The company Workson the maxims low
production cost and clean and safe
environment.
Such efforts Have fetched the company the
accreditation like ISO 9001 and ISO 14001. History
reveals Thatinnovative is the key to continued
progress and when applied to
technology.Touch human life,itc an unfold a whole
new economi c phenomenon that has the power
tochange the World. With unique initiative like the
thought leadership forum,
leadership forum, wehave Been able to create
a unique platform for learning through success
stories of
Industry leaders.The success saga of sonalika
group a business conglomerate Having prime
interest in agricultural & automachin ery goes back
to nearly 5 decades.The corporate philosophy
embedded in trust, quality and commitment has
helped the group of carve Out a niche for itself in
the highly competitive world of machinery.
Sonalika is the fastest Growing tractors company
registering growth over growth since its inception
Has crossed 1.80 lac merely in 10 years & has
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attained one of the position in top three in
india.SonalikA groups products exist in various
international markets. Company product exported
to Algeria, ANgola, Armenia, Australia, Bangladesh,
Cameroon, Ethiopia
, Ghana, Ivorycoast, Malawi, MalaYsia, Mauritius,
Mozambique, Nepal, Oman, Republic of

Benin,senegal,SouthAfrica,Srilanka.

Sonalika Tractors is an agricultural machinery

company based in India. The company Was
established in Punjab,
India, in 1995. It is India’s third-largest tractor
producer, with Aproduction capacity of 300,000
tractors per year. It makes tractors with engines
Ranging from 20 to 120 horsepower.
International Tractors Limited, a company founded in
1995,owns and operates the Sonalika Tractors
brand.Lachhma n Das Mittal created the
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company.In 1996, it sold its first
tractor in Hoshiarpur, Punjab, and Sonalika
possesses the
World’s largest tractor manufacturing facility. It
covers 85 acres o f land and comprises all
manufacTuring facilities, from the
engine to the final assembly. The factory has a
potential of 300,000 tractors per year. It has a 60%
market share in Algeria, a 22% market

1
inNepal, and a 20% market share in
Bangladesh.Thecompany is one of India’s biggest
tractor exporters, with operations in over 120
countries. Sonalika Tractors has a market share of
11.7 percent in India’s tractor sector. Sonalika owns
70% of the company, while Yanmar, a Japanese
diesel engine maker, owns 30%. In India, farm
equipment has about 80% marketshare. The total
revenue of the company is 220 million dollars (INR1000
Crores). One of India’s Top five tractor producers is
the Sonalika Group. Apart from tractors, it also
manufactures
Multi-purpose vehicles, three-wheelers, engines,
hydraulic systems, casting,forging, brake Systems,
automotive
components, and various farm equipment and
tools.Since its start, The Sonalika Group has
attempted to analyze
consumers’ needs in order tobe able to assist
Them with its cost-effective products. The
company boasts state-of-
The art production facilities spanning across acres
in Punjab and Himachal Pradesh’s pollution free
suburbs.It also appear stobe among the world’s few
debt free businesses. It employs about 25 00
individuals, including several industries most well
known figures. Low price and agood and hygienic
1
environment are the company’s Guiding principles.
These efforts have resulted in ISO 9001:2000 and ISO
14001

1
Certifications for the organization The Sonalika
Group now comprises of two businesses: (JOINT
VENTURE WITH RENAULT FROMFRANCE) International
Tractors Limited.
Sonalika Group owns 80% of the
company’sshares.20
percent for Renault Agriculture. Yearly Profit of the
company is Approximately Rs.2098 million.

2 VARIOUS DEPARTMENTS

The Sonalika heavy duty tractor line is manufactured

at the plant,which spread Over many acres and
contains ten various m anufacturing
departments.The overall quality is due to The highly
qualified and experienced people, with their core
being most effective. As a result, the
manufacturing facility offers a complete ”Total
Customer Satisfaction” solution.
⮚ RESEARCH AND DEVELOPMENT CENTER
⮚ HEAVY MACHINARY PLANT
⮚ AUTOMATED ENGINE PLANT
⮚ PRESS PLANT
⮚ ROBOTIC PTCED PAINT SHOP
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⮚ TRANSMISSION ASSEMBLY PLANT

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⮚ ROBOTIC GEAR SHOP
⮚ LIGHT MACHINE SHOP
⮚ EXPORT TRACTOR MANUFACTURING PLANT
⮚ NEW FINAL PLANT ASSEMBLY

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REAR COVER ASSEMBLY

The term “rear cover assembly” typically refers to a

component in various devices or machines. Could
you
specify what type of equipment or device you’re
referring to? For example:

1.Automobile: The rear cover assembly could

refer to parts of the vehicle’s rear, such as the
trunk lid, bumper, or other related components.
2.Electronic Device: For smartphones or
tablets, it could refer to the back cover that
protects the internal
components.
3.Machinery: In industrial or mechanical
contexts, it might refer to a protective cover at the
rear of a machine.

If you provide more details, I can give you more

specific information.

1
10

DIFFERENTIAL ASSEMBLY
A differential assembly is a crucial component in
vehicles, particularly in the drivetrain of
automobiles. It allows the
wheels to rotate at different speeds, which is
essential when a vehicle turns, as the outer wheels
need to cover more
distance than the inner wheels. Here’s a breakdown
of the differential assembly:

Main Components:
1. Differential Case: Houses the internal
components and is connected to the drive shaft.
2. Ring Gear: Attached to the differential case
and driven by the pinion gear.
3. Pinion Gear: Engages with the ring gear and is
driven by the drive shaft.
4. Spider Gears (or Planetary Gears): Small gears
that rotate on their own axes and allow the wheels
to rotate at different speeds.

1
5. Side Gears (or Sun Gears): Mesh with the
spider gears and are connected to the axle
shafts.
6. Axle Shafts: Transmit power from the
differential to the wheels.

Functions:
- Speed Differentiation: Allows wheels to rotate
at different speeds, which is crucial when
turning.
- Torque Distribution: Distributes engine power to
the wheels, allowing for smooth acceleration
and handling.

Types of Differentials:
1.Open Differential: Standard type that allows
wheels to rotate at different speeds but can be
less effective in low traction situations.
2.Limited Slip Differential (LSD): Provides better
traction by limiting the difference in speed
between the two wheels.
3.Locking Differential: Can lock the wheels
together, forcing them to rotate at the same
speed, useful in off-road conditions.
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4.Torque-Vectoring Differential: Uses electronic
controls to distribute torque to individual wheels,
enhancing handling and stability.

GEAR BOX ASSEMBLY

A gearbox assembly, also known as a transmission,
is a
complex mechanical system that transfers power
from an
engine to the wheels of a vehicle. It typically involves
several key components, including gears, shafts,
bearings, and a casing. Here’s an overview of the
main parts and their
functions:

1. Gears: These are the primary components of

the gearbox. They mesh together to change the
speed and torque of the vehicle. There are
several types of gears
used, such as spur gears, helical gears, bevel
gears, and planetary gears.

2. Shafts: Shafts hold the gears in place and allow

them to rotate. The main shafts in a gearbox are
the input shaft, countershaft (or layshaft), and

1
output shaft.

1
3. Bearings: Bearings support the shafts and
reduce friction between moving parts. This
ensures smooth operation and longevity of the
gearbox components.

4. Synchronizers: These are used in manual

transmissions to match the speed of the gears
before they are engaged, allowing for smooth gear
shifts.

5. Clutch: In manual transmissions, the clutch is

used to disengage the engine from the gearbox to
change gears.

6. Casing: The outer shell that houses all the

internal components and protects them from
dirt, debris, and other contaminants.

The assembly process involves precisely aligning

and fitting these components together to ensure
optimal performance and durability. Each gearbox
is designed to meet specific
requirements based on the vehicle’s power,
1
speed, and intended use.

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ENGINE LOOP
An engine loop, also known as a closed-loop system,
typically refers to the control system used in
modern internal combustion engines to regulate
various parameters for
optimal performance and efficiency. Here’s an
overview of the key components and their roles in
an engine loop:

1. Engine Control Unit (ECU): This is the brain

of the engine loop. It receives input from
various sensors and adjusts the engine’s
operation to maintain optimal
performance.

2. Sensors: Various sensors provide real-time

data to the ECU. Key sensors include:
- Oxygen (O2) Sensor: Measures the amount of
oxygen in the exhaust gases to monitor the air-fuel
ratio.
- Mass Air Flow (MAF) Sensor: Measures the amount
2
of air entering the engine.

2
 - Throttle Position Sensor (TPS): Monitors the
position of the throttle valve.
- Coolant Temperature Sensor: Measures the
engine’s coolant temperature.
- Crankshaft Position Sensor: Monitors the
position and rotational speed of the crankshaft.

3. Actuators: These are devices controlled by the

ECU to adjust various engine parameters.
Common actuators
include:
- Fuel Injectors: Control the amount of fuel delivered
to the engine.
- Ignition Coils: Provide the spark for combustion.
- Idle Air Control Valve: Regulates the engine’s
idle speed.

4. Closed-Loop Control: In this mode, the ECU

continuously adjusts the engine parameters
based on feedback from the sensors to
maintain optimal
performance. For example, the ECU adjusts the air-
fuel ratio based on input from the O2 sensor to
ensure efficient
2
combustion and low emissions.

2
5. Open-Loop Control: In certain conditions (such as
during engine startup or heavy acceleration), the
ECU may operate in open-loop mode, where it
uses predefined
settings instead of sensor feedback to control the
engine.

Key Processes in the Engine Loop:

- Air-Fuel Mixture Control: The ECU adjusts the

air- fuel ratio to ensure efficient combustion.
This involves monitoring the MAF sensor and
O2 sensor, and
adjusting the fuel injectors accordingly.

- Ignition Timing: The ECU controls the timing of

the spark provided by the ignition coils to
optimize
combustion and performance.

- Emissions Control: The ECU manages various

systems, such as the exhaust gas

2
recirculation (EGR) and catalytic converter,
to reduce emissions.

2
 - Idle Speed Control: The ECU regulates the idle
air control valve to maintain a stable idle
speed.

Benefits of the Engine Loop:

- Improved Fuel Efficiency: By continuously adjusting

the air-fuel mixture and ignition timing, the engine
loop helps maximize fuel efficiency.
- Reduced Emissions: Accurate control of
combustion parameters leads to lower emissions.
- Enhanced Performance: Optimized engine
parameters result in smoother and more
responsive performance.
- Adaptability: The system can adapt to changing
conditions, such as variations in fuel quality and
ambient temperature.

Would you like more detailed information on any

specific part of the engine loop?

2
FRONT AXLE
.Afront axle is a crucial component of a vehicle’s
suspension and steering systems. It serves
multiple functions, including supporting the
weight of the vehicle, enabling steering, and
allowing for the movement of the wheels. Here’s an
overview of the main components and their roles:

Main Components of a Front Axle:

1.Axle Beam: This is the central part of the front

axle, typically made from high-strength steel. It
provides
structural support and connects the
wheels to the vehicle’s frame.

2.Steering Knuckle: Attached to the ends of the

axle beam, the steering knuckle supports the
wheel hub and allows the wheels to pivot for
steering. It is the pivot
point of the steering mechanism.

2
3.Wheel Hub: Mounted on the steering knuckle,
the wheel hub holds the wheel and allows it to
rotate. It usually contains the wheel bearings
and is where the brake rotor or drum is
mounted.

4.Wheel Bearings: These are placed between

the wheel hub and the axle to reduce
friction and allow smooth rotation of the
wheels.

5.Tie Rods: Connected to the steering knuckle,

tie rods transmit the force from the steering
rack or box to the wheels, facilitating the
turning of the vehicle.

6.Control Arms: These connect the axle or knuckle

to the vehicle’s frame and allow for vertical
motion of the wheels, aiding in suspension.

7.Shock Absorbers and Springs: Part of the

suspension system, these components absorb
and dampen shocks and vibrations from the
2
road, providing a smoother ride.

2
 8.CV Joints (Constant Velocity Joints): Found in
front-wheel-drive and all-wheel-drive
vehicles, these
joints allow for a smooth transfer of power to the
wheels while accommodating the up and down
motion of the
suspension and the turning motion of the
wheels.

Functions of the Front Axle:

- Weight Support: The front axle bears the load

of the front part of the vehicle, including the
engine, transmission, and other components.

- Steering Mechanism: The front axle components,

like the steering knuckle and tie rods, play a
critical role in the vehicle’s ability to steer.

- Suspension Integration: It works in conjunction

with the suspension system to absorb road

2
shocks and provide a stable and comfortable
ride.

2
 - Wheel Alignment: Ensures the wheels are
aligned correctly for optimal handling, tire
wear, and vehicle
stability.

Types of Front Axles:

1.Dead Front Axle: This type of axle does not

rotate with the wheels. It is mainly used in
vehicles where the front wheels are not driven
by the engine, like in
traditional rear-wheel-drive vehicles.

2.Live Front Axle: This axle rotates with the wheels

and is used in vehicles where the front wheels
are also driven, such as in front-wheel-drive and
all-wheel-drive vehicles.

Maintenance of the Front Axle:

2
Regular inspection and maintenance of the front
axle and its components are essential for safe and
efficient vehicle
operation. This includes checking and replacing
worn-out bearings, ensuring proper lubrication of
joints, and
inspecting the suspension and steering
components for wear and damage.

Would you like more detailed information on a

specific part of the front axle or its maintenance?

MAIN LOOP
In the context of an assembly plant in an automobile
factory, the “main loop” refers to the core process
flow that governs the assembly line operations. This
loop ensures that all
steps in the manufacturing process are carried out
efficiently and in sequence. Here’s an overview of
the main components and the general workflow of
an automobile assembly plant:

Key Components of an Assembly Plant:

2
1. Conveyor System: Transports vehicle
components through various stages of the
assembly process.
2. Robotic Arms: Perform tasks such as
welding, painting, and component
installation.
3. Workstations: Specific areas where human
workers and robots carry out particular tasks.
4. Ǫuality Control Stations: Checkpoints to
ensure each component and the final product
meet quality
standards.
5. Control Systems: Computerized systems
that manage and monitor the entire
assembly process.

General Workflow of an Automobile Assembly Plant

Main Loop:

1. Frame Assembly:
- The main body frame of the vehicle is
constructed using robotic welding systems.
- Robotic arms and workstations assemble the
chassis and attach the frame components.
2
2. Painting:
- The vehicle frame is moved to a painting station
where it is cleaned, primed, painted, and baked.
- This process ensures a smooth, durable finish.

3. Drivetrain Installation:
- Engines, transmissions, and other drivetrain
components are installed onto the vehicle frame.
- Robotic systems and workers align and
secure these components.

4. Interior Assembly:
- Seats, dashboards, and other interior
components are installed.
- Workstations equipped with tools and robotic
arms carry out these tasks.

5. Electrical System Installation:

- Wiring harnesses, battery, and electronic
modules are installed.

3
 - Ǫuality control checks ensure all electrical
connections are secure.

6. Final Assembly:
- Doors, windows, and other exterior
components are attached.
- Tires and wheels are mounted.

7. Quality Control:
- Multiple quality control stations inspect and
test the vehicle for defects.
- Any issues are rectified before the vehicle
proceeds to the next stage.

8. Final Inspection and Testing:

- The completed vehicle undergoes a final
inspection.
- Functional tests (e.g., engine start, lights,
brakes) are performed to ensure everything is
working correctly.

9. Delivery Preparation:

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 - The vehicle is prepared for shipping, including
cleaning and documentation.
- It is then moved to the storage area or
directly to transportation units.

DWM BOARDS
(BEFORE AND
AFTER)
A daily work management board, also known as
a production board or visual management
board, is an essential tool used in
manufacturing plants, including
automobile factories, to track and manage daily
tasks and workflows. Before the painting process,
this board helps ensure that all necessary
preparations and checks are
completed to maintain efficiency and quality. Here’s
an
overview of how such a board might be structured
and used in the context of the pre-painting stage:
Key Components of a Daily Work Management Board:
1. Task List: Lists all the tasks that need to
3
be completed before the painting process.

3
2. Responsibility: Assigns tasks to specific workers
or
teams.

3. Status Indicators: Shows the current status of

each task (e.g., Not Started, In Progress,
3
Completed).

3
4. Time Schedule: Provides deadlines or time slots
for each task.
5. Ǫuality Checks: Includes checkpoints for
quality assurance.
6. Materials and Tools: Lists the materials and
tools needed for each task.
7. Issues/Concerns: A section to note any issues
or concerns that arise.
8. Safety. Use personal protective equipment
(PPE) such as gloves, safety glasses, and arc-flash
clothing when working with or near the DGM
board.
9. Productivity.Define and track KPIs relevant to your
team’s objectives. Regularly review these metrics to
gauge productivity and make data-driven decisions.
10. Morale.Boosting morale in a daily work
management board involves fostering a positive
work environment,
recognizing achievements, and ensuring team
members feel valued and supported.