SML 6 week TRAINING

7/21/2019 SML 6 week TRAINING

http://slidepdf.com/reader/full/sml-6-week-training 1/28

TRAINING REPORTOF

SIX WEEK INDUSTRIAL TRAINING, UNDERTAKEN

AT

“SML ISUZU LIMITED”

IN

“TOOL DEPARTMENT”

SUBMITTED IN PARTIAL FULFILLMENT OF THE SIX WEEK

INDUSTRIAL TRAINING

IN

MECHANICAL BRANCH

Under te G!"d#n$e %& S!'("tted ')*

N#(e* Mr+ M#n% K!(#r N#(e* Dee-#. K!(#r

De/"0n#t"%n* M#n#0er C%11e0e R%11 N%* 2345362

De-#rt(ent* T%%1 De-#rt(ent

RAYAT INSTITUTE OF ENGINEERING AND INFORMATION

TECHNOLOGY RAILMAJRASBS NAGAR NAWANSHAHR P!n#'



ACKNOWLEDGEMENT

I am highly grateful t the R#)#t In/t"t!te %& En0"neer"n0 7 In&%r(#t"%n Te$n%1%0) fr

!r"i#i$g thi% !!rtu$ity t &arry ut the %i' (ee) i$#u%trial trai$i$g at SML ISUZU LTD+ROPAR+

Thi% Trai$i$g !rgram ha% *ee$ a &lle&ti"e effrt f %e"eral i$#i"i#ual%+ It i% therefre my

frem%t #uty t a&)$(le#ge their effrt% that hel!e# me t &m!lete my trai$i$g+

I e'!re%% my heartfelt gratitu#e t(ar#% Mr+ M#n% K!(#r 8Sen"%r M#n#0er, T%%1

De-#rt(ent9 , fr gui#i$g me thrugh my trai$i$g !rgram+

Hi% e$thu%ia%m a$# !timi%m ma#e thi% trai$i$g e$-ya*le a$# re(ar#i$g+ M%t f $"el i#ea%

a$# %luti$ i$ thi% (r) are a re%ult f ur $umeru% %timulati$g #i%&u%%i$%+ Their fee#*a&)

a$# e#itrial &mme$t% (ere i$"alua*le+

I e'!re%% gratitu#e t ther fa&ulty mem*er% f Me&ha$i&al E$gi$eeri$g #e!artme$t f IET fr

their i$telle&tual %u!!rt thrughut the &ur%e f thi% (r)+

Dee-#. K!(#r

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PREFACE

I$#u%trial trai$i$g i% the *ri#ge t the %tu#e$t that ta)e% him frm the (r#% f thereti&al

)$(le#ge t the (rl# f !ra&ti&al )$(le#ge+ 1y u$#ergi$g trai$i$g i$ the i$#u%try2 a

%tu#e$t &a$ $arr( #($ the ga! *et(ee$ the i$%titute2 (r)%h! , i$#u%try+

The mai$ !ur!%e f i$#u%trial trai$i$g i% t e'!%e ur%el"e% t the i$#u%trial e$"ir$me$t

(hi&h &a$$t *e !%%i*le i$ the &la%%rm+ 3ee!i$g i$ "ie( thi% thi$g2 %tu#e$t% are %e$t t the

"ariu% rga$i4ati$% fr getti$g the !ra&ti&al trai$i$g+ The !re%e$t re!rt i% a re!rt that ha%

*ee$ #$e a% a$ i$#u%trial trai$i$g !r-e&t "er a trai$i$g !eri# f %i' (ee)% f 15Te&h+

6Me&ha$i&al E$gi$eeri$g7 at SML ISU8U LTD+ RO.AR+

Duri$g thi% trai$i$g2 I gt e'!%ure t "ariu% e9ui!me$t% , ma&hi$e%2 their mai$te$a$&e ,

te&h$lgie%2 relate# t ma$ufa&turi$g f tru&)%+

He$&e2 i$#u%trial trai$i$g (a% a%%i%te# i$ #e"el!i$g %elf5&$fi#e$&e+ The trai$i$g hel!e# me

i$ ha"i$g "ie( f im!leme$ti$g my thereti&al )$(le#ge t the a&tual i$#u%trial

e$"ir$me$t+ The trai$i$g at SML ISUZU LTD+ i% #efi$itely gi$g t !lay a$ im!rta$t rle

i$ #e"el!i$g a$ a!titu#e fr har# (r) a$# %elf &$fi#e$&e $e&e%%ary fr my %u&&e%%ful

future+

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OB:ECTI;ES OF TRAINING*<

The ma-r *-e&ti"e% f trai$i$g are a% fll(%;

<+ T im!art )$(le#ge t $e( re&ruit%+

0+ T im!art %)ill% t the $e( em!lyee% (hi&h are $ee#e# *y the rga$i4ati$+

:+ I$ #e"el!i$g *etter *eha"ir !atter$% (hi&h are a!!r!riate t their -*% a$#

re%!$%i*ilitie%+

=+ T i$&rea%e effi&ie$&y a$# mrale+

>+ Fr !rmti$2 t !r"i#e %u&&e%%r%+

?+ T i$&rea%e !te$tial+

TRAINING (e#n/ *<

T@ t *e i$ time $ yur %eat+

R@ remai$ atte$ti"e all the time+

A@ a&ti"ely !arti&i!ate+

I@ i$tera&t fr &larity

N@ $te !i$t% #iffi&ult t memrie%+

I@ im!r"e li%te$i$g ha*it+

N@ $e"er $egle&t the !rgram+

G@gai$ a% mu&h a% yu &a$+

Trai$i$g %hul# *e &$ti$uu% a$# !rgre%%i"e #e%ig$e# t i$&rea%e the i$#i"i#ual !te$tial f

mai$te$a$&e %taff mem*er% a$# t frm them i$t a te&h$i&ally 9ualifie# a$# (ell5rga$i4e#

effi&ie$t team+

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TABLE OF CONTENTS

SERIAL NO+ .ARTICULARS .AGE NO+

<+ Cr!rate .rfile >5

0+ E"l"i$g Jur$ey Of SML ISU8U <B5<<

:+ Share hl#i$g !atter$ !re%e$t <0

=+ >S A&ti"ity i$ SML ISU8U limite# <:

>+ Orga$i4ati$al %et u! f SML ISU8U LTD+

<=

ariu% De!artme$t% f SML ISU8U LTD+ <>

Fl( #iagram f the SML ISU8U !la$t

<?

Tl De!artme$t <50B

<< uality E$gi$eeri$g De!artme$t 0<

<0 Metrlgy la* 00

<: Sta$#ar# Rm 0:50?

<= &$&lu%i$ 0

<> 1i*ligra!hy 0

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SML ISUZU LIMITED

C%r-%r#te Pr%&"1e

SML ISU8U limite# (a% !rmte# i$ >th O&t*er <= i$ te&h$i&al a$# fi$a$&ial

&lla*rati$ (ith .u$-a* tra&tr% limite#2 Ma4#a mtr% &r!rati$ a$# Sumitm mtr%

&r!rati$2 Ja!a$2 fr ma$ufa&turi$g f light &mmer&ial "ehi&le% 6LC%7+ SML ISU8U

limite# re!re%e$t% t( !(erful *ra$#%; SML5 %ym*li4i$g *e%t I$#ia$ te&h$lgy a$#

e$gi$eeri$g a$# ISU8U5 a$ i$ter$ati$al !layer+ Ma4#a Mtr% Cr!rati$ f Ja!a$2

e%ta*li%he# i$ <0B2 i% a$ e$ter!ri%e f i$ter$ati$al re!ute+ Ma4#a %tarte# ma$ufa&turi$g

tru&)% a% *a&) i$<:<+ T#ay thi% e$ter!ri%e ha% the #i%ti$&ti$ i$ *ei$g the $ly &m!a$y i$

the (rl# !r#u&i$g !etrl a$# #ie%el e$gi$e a% (ell a% the re"luti$ary rtary e$gi$e%+

ISU8U i% e"er %eei$g the $e( area% f !r#u&t e'&elle$&e a$# i$$"ati$+ It a#here%

au#a&iu%ly t 0BBB &he&) !i$t *efre #e&lari$g a$y "ehi&le ra# (rthy+ The u%e f r*t%2

late%t te&h$lgy a$# (rl# &la%% !r#u&ti$ e$a*le% I%u4u t !r#u&e "ehi&le% f ut%ta$#i$g

9uality a$# !erfrma$&e+ N ($#er Sml i%u4u limite# ha% ($ a!!re&iati$% all "er the

(rl# fr the 9uality !r#u&t% that are rlli$g ut it% !la$t+

The a%%em*ly u$it f Sml i%u4u limtie# i% l&ate# at "illage A%r$ #i%tri&t Na(a$%hahar

6.u$-a*7 $ear the &ity f R!ar a$# at a #i%ta$&e f =B)m% frm the &a!ital &ity f Cha$#igarh

the !la$t ha% a &a!ti"ati$g %ite+ It i% %!rea# "er a 9uai$t2 %!ra(li$g <BB a&re% f la$# ri$ge# *y %hi(ali) hill% $ the three f it% %i#e% a$# ri"er Satlu- $ the ther+

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About ISUZU

I%u4u Mtr% Lt#+2 i% a Ja!a$e%e &ar2 &mmer&ial "ehi&le a$# hea"y tru&) ma$ufa&turi$g

&m!a$y2 hea#9uartere# i$ T)y+ I$ 0BB>2 I%u4u *e&ame the (rl#% large%t ma$ufa&turer f

me#ium t hea"y #uty tru&)%+ It ha% a%%em*ly a$# ma$ufa&turi$g !la$t% i$ the Ja!a$e%e &ity f Fu-i%a(a2 a% (ell a% i$ the !refe&ture% T&higi a$# H))ai#+ I%u4u i% famu% fr !r#u&i$g

&mmer&ial "ehi&le% a$# Die%el e$gi$e%+ 1y 0BB2 I%u4u ha# !r#u&e# "er 0< milli$ #ie%el

e$gi$e%2 (hi&h &a$ *e fu$# i$ "ehi&le% all "er the (rl# I%u4u #ie%el e$gi$e% are u%e# *y

Re$ault2O!el a$# Ge$eral Mtr%+

I$ m%t f A%ia2 Afri&a a$# Eur!e2 I%u4u i% m%tly )$($ fr tru&)% f all %i4e%2 after I%u4u

%mall autm*ile %ale% #ra%ti&ally !lummete# a$# I%u4u ha# t #r! all %ale% f %e#a$% a$#

&m!a&t &ar% i$ the late <B%+ I$ 0BB2 I%u4u a*a$#$e# the U$ite# State% &$%umer mar)et

#ue t la&) f %ale%I%u4u ha% a &$tra&t (ith 1u#get Tru&) Re$tal t ma$ufa&ture their re$tal

tru&)%+ Thi% &$tra&t i% al% %hare# (ith Fr#2GMC2 a$# Na"i%tar I$ter$ati$al+

O$ N"em*er 2 0BB?2 TOYOTA a&9uire# >+ f I%u4u2 ma)i$g them the thir# large%t

%harehl#er *ehi$# ITOCHU a$# MITSU1ISHI COR.ORATION+

Di%&i!li$e a$# it% right e$fr&eme$t i% a$ im!rta$t hallmar) f the Sml I%u4u+ It i% a great

%ig$ifi&a$&e i$ e"l"i$g (r) &ulture+ All the em!lyee%2 irre%!e&ti"e f their !%iti$ r

%tatu%2 ha"e t !u$&h their !%iti$ r %tatu%2 (he$ they re!rt fr #uty+ A% a re%ult %tri&t

!u$&tuality ha% *e&me a (ay f life a$# (r) (ith them+

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T e$%ure i$#u%trial !ea&e i+e+ a*%e$&e f the %tri)e% a$# l&)ut%2 Sml i%u4u limite# *elie"e%

i$ &reati$g a &$te$te# la*ur fr&e (ith a "ery l( rate f a*%e$teei%m a$# tur$ "er+

Rea%$a*ly fair (age% a$# "ariu% !er)% li)e %u*%i#i4e# u$ifrm a$# tra$%!rt2 me%% fa&ilitie%

g a l$g (ay i$ &reati$g i#e$tifi&ati$ (ith the -*+ Ear$e%t$e%%2 %i$&erity a$# %!irit f &5

!erati$ !er"a#e the e$tire atm%!here f the &m!a$y+

N !liti&% f &$fr$tati$ i% fu$# i$ Sml I%u4u+ .r*lem% if a$y are %rte# ut thrugh

mutual $egtiati$% i$ a$ amia*le atm%!here f gi"e a$# ta)e+ The%e !%iti"e %te!% ha"e *ee$

i$%trume$tal i$ e"l"i$g (r) eth%+ The ha!!y a*%e$&e f i$#u%trial #i%!ute% i$ the e$ter!ri%e

%!ea)% "lume% fr the %u&&e%% f the%e a$# &ulti"ati$ f (r) &ulture+ r) &ulture f (r)

eth% i% gi"e$ high !ririty+ It i% fully re&g$i4e# that the *-e&ti"e f the e$ter!ri%e K higher

a$# higher !r#u&ti$2 !r#u&ti"ity a$# i$#ige$i4ati$ &a$ *e attai$te# thrugh &mmitme$t i$

t &mm$$e%% f gal i$ ea&h a$# e"ery mem*er f Sml i%u4u family+ The e$tire !la$$i$g i%

u$#erta)e$ i$ %u&h a (ay a% t i$&ul&ate the %!irit f #e#i&ati$ i$ ea&h mem*er (hether he i%

a %emi5%)ille# (r)er r *el$g% t the ma$agerial &a#re+ Ma$y effe&ti"e %te!% are ta)e$ t

*ri$g thi% a*ut a$# im!rta$t am$g them are;

Cmm$ &a$tee$ a$# me%% fr all+ Same meal% are %er"e# t all a$# i$ i#e$ti&al ute$%il%+

E"ery*#y ha% t %ta$# i$ a 9ueue t get hi% r her meal%+

Cmm$ u$ifrm i% there fr all $e( mem*er% irre%!e&ti"e f their %tatu%+

N %e!arate &a*i$% fr the mem*er% f a higher hierar&hy+ All the mem*er% f a #e!artme$t r

a %e&ti$ there f %it a$# (r) i$ $e hall (ith the ma$ager+

The LC% are ma$ufa&ture# i$ fi"e &lur%5 Sa$t% re#2 Nile *lue2 Light 1eige2 hite a$#

Gl#e$ Yell(+ I$ a##iti$ t thi% ther &lur% &a$ *e ma#e $ #ema$#+ The m%t #i%ti$gui%h

feature f the%e "ehi&le i% that *e$eath the #e%ig$ a$# %lee) l)% are the %tu#y *' %e&ti$

tu*ular &r%%e# *ra&e# &ha%%i%+ The &ha%%i% are mre tha$ three time% %tr$ger tha$ ther

"ehi&le $ the ra#+ Sml i%u4u "ehi&le% are $t $ly %tr$ger $ the ra# *ut al% fuel effi&ie$t+

Fully la#e# they gi"e a$ a"erage f <:+> 3ml at => 3mhr+ A hy#rauli& a%%i%te# #ia!hragm

re#u&e% the &lut&h !re%%ure *y : !er&e$t+ A l( R.M high tr9ue e$gi$e a%%ure% l$g life a$#

ha$gi$g %!ee# fr u!hill #ri"i$g+ A %!a&iu% three %eater &a* (ith three le"el air "e$t% ma)e

the &a* e'tremely &mfrta*le a$# #ri"i$g a treat

.rmi$e$t am$g the la# &arrier% Sml i%u4u limite# i% al% ma$ufa&turi$g;

= (heel #ri"e%

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E'te$#e# (heel *a%e l$g &ha%%i% mi$i *u%e% (hi&h &arry u! t == !a%%e$ger%+

Delu'e *u%e% &arry u! t =B !a%%e$ger%+

Am*ula$&e #e"el!e# (ith a&ti"e i$"l"eme$t f %e$ir %!e&iali%t frm !%t gra#uate i$%titute

f me#i&al %&ie$&e a$# re%ear&h2 Cha$#igarh+

Hy#rauli& !erate# #um!er%+

Dual &a*i$ la# &arrier%+

I$tegrate# gar*age &lle&ti$ a$# #i%!%al %y%tem fr ur*a$ &e$ter%+

Sml i%u4u limite# "ehi&le% !!ulati$ t#ay %ta$#% "er B2BBB+ Sml i%u4u limite# gi"e% #ue

atte$ti$ t the mar)eti$g !art a$# the em!lyee% are highly 9ualifie# a$# trai$e# t fit the -*+

Sml i%u4u limite# ha% a "a%t $et(r) f "er <0 #ealer% %!rea# thrughut the &u$try

i$&lu#i$g the A , N I%la$#+ 8$al ffi&e !e$e# i$ Cha$#igarh2 Lu&)$(2 Cal&utta2

Ahem#a*a#2 Mum*ai2 a$# Che$$ai+ Thi% hel!% %u*%ta$tially i$ %ale% !rmti$2 e%!e&ially fr

hi5te&h !r#u&t%2 i% al% *ei$g em!ha%i4e#+Di%&i!li$e a$# rigi# e$fr&eme$t (ithut

#i%&rimi$ati$ are im!rta$t hallmar) f Sml I%u4u+ It i% f great %ig$ifi&a$&e i$ i$"l"i$g

(r) &ulture+ All the em!lyee%2 irre%!e&ti"e f their !%iti$ a$# %tatu%2 ha"e t !u$&h their

&ar#% (he$ they re!rt fr #uty a% a re%ult2 %tri&t !u$&tuality ha% *e&me a (ay f life a$#

(r) (ith them+ T i$%ure i$#u%trial !ea&e2 i+e+ a*%e$&e f %tri)e a$# l&)ut% Sml i%u4u

limite# *elie"e% i$ ma)i$g a &$te$#e# la*ur fr&e (ith a "ery %l( rate f a*%e$teei%m+

Rea%$a*ly fair (age% a$# "ariu% !er)% li)e %u*%i#i4e# u$ifrm a$# tra$%!rt2 me%% fa&ilitie%

g a l$g (ay i$ &reati$g i#e$tifi&ati$ (ith the -*The e$tire !la$$i$g i% u$#erta)i$g i$ %u&h

a (ay % a% t i$&ul&ate the %!irit f #e#i&ati$ i$ ea&h mem*er2 (hether he i% a %)ille# r

%emi5%)ille# (r)er r *el$g% t the ma$agerial &a#re+ The &r!rate !rfile f SML ISU8U

LTD+ !r-e&t% a *right future fr the &m!a$y+ It i% a##i$g it% %hare t the real a%%et% a$# -*

!!rtu$itie% i$ the area% thu% *ri$gi$g %&i5e&$mi& refrm% i$ (hle f .u$-a*+

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E=%1="n0 :%!rne) %& S(1 I/!>! 1"("ted

<:; SML "ehi&le% limite# 6SL7 i$ &r!rate i$ July+

<=; -i$t "e$ture a$# te&h$i&al a%%i%ta$&e &$&lu#e# *et(ee$ .u$-a* tra&tr% limite#2 I%u4u

mtr% &r!rati$ a$# Sumit &r!rati$ Ja!a$+

<>; .r-e&t %et u! (ith the &a!a&ity f >2BBB LC% at a &a!ital utlay f 0BB milli$%+

<>; Trail !r#u&ti$ a$# te%t mar)eti$g f SML tru&) T5= T5 = T5>B LC%

&mme$&e#+

<?; &mmer&ial !erati$ %tarte#+

<; I$tr#u&ti$ f i$#ige$u%ly #e"el!e# *u%+

<; I$5hu%e tli$g f l&al !r#u&ti$ f &ha%%i% l$g mem*er+

<B; I$5hu%e #e"el!e# %e&$# tru&) m#el 6SARAJ MA8DA Su!er7 lau$&he#+

<<; Tra$%mi%%i$ &m!$e$t% i$#ige$i4e#+

<0; Cm!$e$t% f tru&)% %u!!lie# t mi$i%try f #efe$%e 6MOD7+ >BB "ehi&le% %u!!lie# t

#efe$%e+

<:; Thir# tru&) m#el 6SARAJ MA8DA .REMIUM7 lau$&he#+

<=; De&lare# a %i&) &m!a$y u$#er SICA 6#ue t ru!ee #e"aluati$ f <<5:7

<>; 1IFR a!!r"e% reha*ilitati$+

<?; =5 (heel tru&) #e"el!e#+

<; Cm!a$y &ea%e% t *e a %i&) i$#u%trial &m!a$y $ the *a%i% f !%iti"e $et (rth+ =5

year% f 1IFR %&heme !r-e&ti$+

<; &m!lete (i!e f a&&umulate# l%%e%+

<; 1harat Stage5< emi%%i$ $rm% &m!ile#+

0BBB; Mai#e$ #i"i#e$# #e&lare# <B te&h$i&al a%%i%ta$&e agreeme$t (ith I%u4u e'te$#e#

u! t O&t*er 0BB=+

0BBB; Cumulati"e %ale% &r%%e% >B+BBB "ehi&le%2 =5 (heel #ri"e% am*ula$&e lau$&he# i$

Mar&h2 e&$my tru&) SARTAJP lau$&he# i$ Augu%t2 a$# CNG *u% fr NCR Delhi lau$&he#

i$ O&t*er2 a$# 1harat Stage 0 emi%%i$ $rm% &m!ile#+

0BB0; .rfit *efre ta' fr FY50BB0 &r%%e% R%<BB milli$ a$# #i"i#e$# rai%e# t 0>+

0BB:; Cumulati"e "ehi&le% %ale% rea&he# ?2BBB2 !rfit *efre ta' fr

FY50BB: gr(% <<> t R% 00> milli$%2 #i"i#e$# e$ha$&e# t =>+

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S#re H%1d"n0 P#ttern Pre/ent

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6S A$t"="t) "n S(1 I/!>! 1"("ted

I$ r#er t a&hie"e the gal% %et u! *y the &$&er$% effe&ti"ely a$# effi&ie$tly the rga$i4ati$

fll(% the >S a&ti"ity that i%;

SIEIRI* Cla%%ify the thi$g% i$t $e&e%%ary $e% a$# u$$e&e%%ary $e%+ Di%&ar# the

u$$e&e%%ary $e%+

SEITION* .ut the thi$g% i$ r#er % that they are a"aila*le (he$ $ee#e#+

SEISO* 3ee! the (r) area a$# the ma&hi$e tl &lea$ % that a*$rmal &$#iti$% are

#ete&te#+

SEIKETSU* )ee! the (r) area &lea$ a% (ell a% the !er%$al &lea$li$e%%+ The &$#iti$% f

the &m!a$y %hul# *e hygie$i&+

SHITSUKE* There %hul# *e all aru$# #i%&i!li$e+ The (r)er% %hul# *e taught t (r) i$ a#i%&i!li$e# ma$$er+

The re%ult f all thi% ha% *ee$ ra!i# i$&rea%e i$ ut!ut f "ehi&le% a$# %har! re#u&ti$ i$ &a%h

l%e%+ The tur$ "er fr 0BB50BB e'&ee#% R%+ :BB &rre%+ T#ay the &m!a$y ma$ufa&ture%

light &mmer&ial "ehi&le% li)e tru&)%2 *u%e%2 !li&e "a$%2 (ater ta$)er%2 am*ula$&e2 a$#

%!e&ial "ehi&le% a$# al% e'!rt% t the &u$trie% li)e Ne!al2 8am*ia2 1a$gla#e%h2 3e$ya2 Sri5

La$)a a$# Jr#a$+

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ORGANIZATIONAL SET UP OF SML ISUZU LIMITED

MANAGING DIRECTOR

EXECUTI;E DIRECTOR

;ICE PRESIDENT ASSOCIATI;E

;ICE

PRESIDENT

GENERAL MANAGER DEPUT?

GENERAL MANAGER

SENIOR MANAGER CHIEF MANAGER

MANAGER

ASST MANAGER

ENGINEER SENIOR ENGINEER ASST ENGINEER

:UNIOR ENGINEER

.age / <=



;#r"%!/ De-#rt(ent/ %& SML ISUZU L"("ted

• .er%$$el De!artme$t

• Re%ear&h a$# De"el!me$t

• uality E$gi$eeri$g De!artme$t

• Te&h$lgy De!artme$t

• Tl De!artme$t

• A&&u$t% De!artme$t

• .ur&ha%e De!artme$t

• Mai$te$a$&e De!artme$t

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.age / <?

ENGINE COM.ONENTS

FROM ASHING

MACHINE

ENGINE ASSEM1LY

AND TESTING

TRANSMISSION

COM.ONENTS FROM

ASHING MACHINE

TRANSMISSION

ASSEM1LY AND

TESTING

FRONTREAR AQLE ,

DIFFERENTIAL ASSY+

AQLE COM.ONENTS

FROM ASHING

MACHINE

LONG MEM1ER

STORAGE

TEM.ORARY .ART

SETTING

TAC3FULL

ELDING

STRAIN RELIEING

CHASSIS .AINTING

;EHICLE

ASSEMBL?

LINE

.RE DELIERY

INS.ECTION

ROADSHOER

TEST

CARGO 1OQ

MOUNTING

RUST .REENTIEA..LICATION

;EHICLE TO

STOCK ?ARD

.ARTS FROM

STORE

FLOOR

ASSEM1LY+

CA1IN

ASSEM1LY

DOOR ELDING

, ASSEM1LY

FINAL FITTING

AND FINISHING

TO .AINT SHO.

CA1IN .RE

TREATMENT

, 1LAC3

DI..ING

1A3ING

SEALANT AND

.RIMER

A..LICATION

1A3ING

FINAL

.AINTING

1A3ING

INS.ECTION

.AINTED

CA1IN TO

ECH+ ASSY+

CA1IN

DRESSING

ITH SU1

ASSEM1LY

CARGO 1OQ

FROM STORE

CARGO 1OQ

ASSEM1LY

SLEE.ER

ASSEM1LY

CARGO 1OQ

ELDING

CARGO

ASHING

SEALANT

A..LICATION

1A3ING

FINAL

.AINTING

1A3ING

INS.ECTION

BOD? SHOP

ENGINE

ASSEMBL?

CABIN

WELDIN

G

CABIN 7 CARGO

ASS? 7 PAINTING

T@M ASS?

LINE

AXLE

ASS? LINE

Flow Diagram of the Sml Isuzu Plant



TOOL DEPARTMENT

Thi% #e!artme$t i% $e f the m%t im!rta$t a$# &ru&ial #e!artme$t+ The re%!$%i*ility f thi%

#e!artme$t i% t !re!are a tl a&&r#i$g t the #ema$# fr #iffere$t (r) a$# the 9uality f

i$&mi$g a$# utgi$g &m!$e$t%+ There i% a tl rm+ The l#e%t a$# m%t &$&rete %e$%e f

the (r# tlrm i% %im!ly a rm (here tl% are %tre#+ The e"luti$ f IT a$# it%

i$tegrati$ i$t ma$ufa&turi$g i% &ha$gi$g the 9ue%ti$% a$# e9uati$% %till further+ Fr

e'am!le2 CNC a$# r*ti&% ha"e le# the (ay t ra!i# !rtty!i$g a$# i$%ta$t ma$ufa&turi$g2

(hi&h %hift the tlrm5!r#u&ti$ #i"i%i$ *y gi"i$g a$ u!5fr$t tlrm i$"e%tme$t the

fle'i*ility t *e 9ui&)ly a$# ea%ily u%e# fr a$y !r#u&t #e%ig$2 (ith *at&h %i4e irrele"a$t+

ariu% ma&hi$e% are u%e# fr tl a$# #ie (r) %u&h a% #rilli$g ma&hi$e%2 %ha!er2

lathe%ma&hi$e et&+

Tl a$# #ie ma)er% are %!e&iali4e# ma&hi$i%t% i$ the ma$ufa&turi$g i$#u%try (h ma)e

#ie%2 ma&hi$e tl%2 &utti$g tl% a$# frm tl% 2 gauge%2 a$# ther tl% u%e# i$ ma$ufa&turi$g

!r&e%%e%+ De!e$#i$g $ (hi&h area f &$&e$trati$ a !arti&ular !er%$ (r)% i$2 he r %he may

*e &alle# *y "ariati$% $ the $ame2 i$&lu#i$g tli$g %!e&iali%t2 tl #e%ig$er%2 ml# #e%ig$er%2

tl #e%ig$er r tl a$# #ie %!e&iali%t%+ Tl a$# #ie ma)er% (r) (ith e$gi$eeri$g a$# (r)

!rimarily i$ tl rm% e$"ir$me$t%2 %metime% literally i$ $e rm *ut mre fte$ i$ a$e$"ir$me$t (ith fle'i*le2 %emi!ermea*le *u$#arie% frm !r#u&ti$ (r)+ They are

%)ille# arti%a$% 6&raft%!e!le7 (h ty!i&ally lear$ their tra#e thrugh a &m*i$ati$ f a&a#emi&

&ur%e(r) a$# ha$#%5$ i$%tru&ti$2 (ith a %u*%ta$tial !eri# f $5the5-* trai$i$g that i%

fu$&ti$ally a$ a!!re$ti&e%hi! 6althugh u%ually $t $mi$ally t#ay7+

.age / <

http://en.wikipedia.org/wiki/Information_technology

http://en.wikipedia.org/wiki/CNC


http://en.wikipedia.org/wiki/Robotics


http://en.wikipedia.org/wiki/Rapid_prototyping


http://en.wikipedia.org/wiki/Instant_manufacturing

https://en.wikipedia.org/w/index.php?title=Fixtures_(tools),&action=edit&redlink=1

https://en.wikipedia.org/wiki/Machine_tool


https://en.wikipedia.org/wiki/Tool_bit

https://en.wikipedia.org/wiki/Gauge_(engineering)


https://en.wikipedia.org/w/index.php?title=Tool_rooms&action=edit&redlink=1


https://en.wikipedia.org/wiki/Artisan

https://en.wikipedia.org/wiki/Craft_production

https://en.wikipedia.org/wiki/Apprenticeship





http://en.wikipedia.org/wiki/Instant_manufacturing

https://en.wikipedia.org/w/index.php?title=Fixtures_(tools),&action=edit&redlink=1


https://en.wikipedia.org/wiki/Tool_bit



https://en.wikipedia.org/wiki/Artisan

https://en.wikipedia.org/wiki/Craft_production


http://en.wikipedia.org/wiki/Information_technology



T%%1 (#."n0

Tl ma)i$g ty!i&ally mea$% ma)i$g tli$g u%e# t !r#u&e !r#u&t%+ Cmm$ tl% i$&lu#e

metal frmi$g rll%2 lathe *it%2 milli$g &utter%2 a$# frm tl%+ Tl ma)i$g may al% i$&lu#e

!re&i%i$ fi'ture% r ma&hi$e tl% u%e# t ma$ufa&ture2 hl#2 r te%t !r#u&t% #uri$g their

fa*ri&ati$+ Due t the u$i9ue $ature f a tl ma)er% (r)2 it i% fte$ $e&e%%ary t fa*ri&ate

&u%tm tl% r m#ify %ta$#ar# tl%+

.age / <



D"e (#."n0

Die ma)i$g i% a %u*5ge$re f tl ma)i$g that f&u%e% $ ma)i$g a$# mai$tai$i$g #ie%+ Thi%

fte$ i$&lu#e% ma)i$g !u$&he%2 #ie%2 %teel rule #ie%2 a$# #ie %et%+ .re&i%i$ i% )ey i$ #ie ma)i$g

!u$&he% a$# #ie% mu%t mai$tai$ !r!er &leara$&e t !r#u&e !art% a&&urately2 a$# it i% fte$

$e&e%%ary t ha"e #ie %et% ma&hi$e# (ith tlera$&e% f le%% tha$ $e thu%a$#th f a$ i$&h+

.age / <

https://en.wikipedia.org/wiki/Die_(manufacturing)





:"0 (#.er

A -ig ma)er i% a fiel# u$#er tl a$# #ie ma)er2i$ (#(r)i$g r i$ the metal i$#u%trie%+ The

%ta$#ar# #iffere$tiati$ f -ig% frm fi'ture% i% that a -ig i% (hat mu$t% $t a (r)!ie&e2

(herea% a fi'ture ha% the (r)!ie&e !la&e# $ it2 i$t it2 r $e't t it+ A -ig ma)er $ee#% t )$(

h( t u%e a$ a%%rtme$t f ma&hi$e% t *uil# #e"i&e% u%e# i$ autmati$2 r*ti&%2 (el#i$g2

ta!!i$g2 a$# ma%% !r#u&ti$ !erati$%+

They are fte$ a#"i%e# *y a$ e$gi$eer t # the !er5!la$$e# (r) f ma)i$g the #e"i&e%+ I$ a

!r#u&ti$ %h! they $ee# t )$( a$ e'te$%i"e a%%rtme$t f ma&hi$e%2 tl%2 a$# material%2

a$# are fte$ the m%t e'!erie$&e# tlma)er% a$# (#(r)er%+ The rea%$ -ig ma)er% $ee# t

*e e'!erie$&e# i% % they &a$ ma)e effi&ie$t alterati$% a$# $ee#e# re!air%+ They %metime%

a%%i%t a$# m$itr the !rgre%% f the -ig r the fi'ture% gaugi$g2 l&ati$g2 a$# i$$"ati"e a*ility+

Th%e (h gra#uate t the le"el f -ig a$# fi'ture ma)er%+

The $gi$g e"luti$ f &m!uteri4e# #e%ig$ a$# &$trl te&h$lgie%2 %u&h

a% CADCAM2 CNC2 .LC2 a$# ther%2 ha% &ha$ge# the $ature f the re9uireme$t% fr -ig% i$

ma$ufa&turi$g2 i$ ma$y &a%e% re#u&i$g the $ee# fr -ig%+

.age / 0B

https://en.wikipedia.org/wiki/Robotics

https://en.wikipedia.org/wiki/Mass_production


https://en.wikipedia.org/wiki/CAD/CAM

https://en.wikipedia.org/wiki/CNC

https://en.wikipedia.org/wiki/PLC

https://en.wikipedia.org/wiki/Robotics


https://en.wikipedia.org/wiki/CAD/CAM

https://en.wikipedia.org/wiki/CNC

https://en.wikipedia.org/wiki/PLC



UALIT? ENGINEERING DEPARTMENT

Thi% #e!artme$t i% the m%t &ru&ial #e!artme$t+ The re%!$%i*ility f thi% #e!artme$t i% t e$%ure

the 9uality f i$&mi$g a$# utgi$g &m!$e$t%+ Stru&ture f 9uality e$gi$eeri$g #e!artme$t i%

a% %h($ i$ figure+ Thi% #e!artme$t i% t e$%ure that % ha% !a%%e# the "ariu% ma$ufa&turi$g2

&he&)e# a$# &$trlli$g fa&ilitie% fr 9uality !r#u&ti$+

<+ uality Ma$ufa&turi$g*A$ LC i$ *rief ha% t !a%% thrugh %tri&t te%t $um*eri$g a*ut 0>B+

Similarly2 at %u* a%%em*ly %tate% et&+ Li)e *#y %h!2 !ai$t %h!2 #ay t #ay re!rt f 9uality

ge% t #e!artme$t fr $e&e%%ary a&ti$+

0+ uality De"el!me$t;uality #e"el!me$t ha% gi"e$ mre %tre%% $ !re"e$ti$ f #efe&t%

rather tha$ %etti$g it right *y re&tifi&ati$+ I$ 9uality #e"el!me$t fr !r!er i$%ura$&e f

9uality2 relia*ility2 %er"i&e a$# ther a%!e&t% i$ ma$ufa&turi$g !r#u&t% thrugh a$# %&ie$tifi&

a&ti"itie%+ The -* f e"aluati$g the &m!a$ie% (ith re%!e&t t 9uality2 re!rti$g the re%ult f

e"aluati$ t all &$&er$e# #e!artme$t fr $e&e%%ary a&ti$ a$# i$frmati$+

uality E$gi$eeri$g 6re&ei!t7; It i% re%!$%i*le fr e"ery item that i% *ei$g re&ei"e# at the

re&ei!t %tre frm "ariu% "e$#r%+ Si$&e it i% $t !%%i*le t &he&) ea&h a$# e"ery item2

therefre ra$#m %am!li$g i% #$e+

.age / 0<

STRUCTURE OF UALIT? ENGINEERING DEPARTMENT



uality E$gi$eeri$g La*: Thi% #e!artme$t i% re%!$%i*le fr all ty!e f la* (r) i$ the

rga$i4ati$ her all the &riti&al #ime$%i$% are &he&)e# i$ the %ta$#ar# rm (ith %!hi%ti&ate#

ai#e%2 a$# !re&i%i$ i$%trume$t%+ ariu% gauge% li)e height gauge%2 #ial i$#i&atr%2 !rfile

!r-e&tr2 threa# gauge% are u%e#+ Har#$e%% te%t a$# te$%ile te%t% are &$#u&te# i$ thi% la*+ Al%

&hemi&al &m!%iti$% f "ariu% &m!$e$t% are &he&)e#+

Metr%1%0) L#'*

Metrlgy la* i% the !la&e (here all the material te%ti$g li)e har#$e%%2 &hemi&al &m!%iti$ f

the material% a$# mi&r%tru&ture f the material% i% #$e+ uality !arameter% (hi&h are te%te#

u$#er thi% la* are;

Har#$e%%* I$ the har#$e%% te%t mai$ly &m!$e$t% (hi&h are frge#2 &a%te#2 i$#u&ti$ har#e$e#

a$# &ar*uri4e# har#e$e# ha"e *ee$ &he&)e#+

a7 R&)(ell har#$e%% ma&hi$e* R&)(ell har#$e%% ma&hi$e i% u%e# fr har#er material%+ I$ thi%

ma&hi$e there are three %&ale R C %&ale2 R 1 %&ale a$# R A %&ale+ Thrugh thi% %&ale (e fi$# the

har#$e%% $um*er f the material+

<7 O$ R C %&ale the la# i% <>B )g a$# i$#e$ter i% f #iam$#

07 O$ R 1 %&ale la# i% <BB )g a$# i$#e$ter i% f %teel *all f #iameter <<? i$&h+

:7 O$ R A %&ale the la# i% ?B )g a$# i$#e$ter i% f #iam$#+

*7 1ri$ell har#$e%% te%ter 61HN7; Thi% ma&hi$e i% u%e# fr te%ti$g material (hi&h i% le%% har#er

tha$ (hi&h are te%te# u$#er R&)(ell har#$e%% ma&hi$e+ I$ thi% har#$e%% i% fi$#i$g a% 1ri$ell

har#$e%% $um*er 61HN7+ La# i% :BBB)g% a$# the i$#e$ter i% %teel *all f #iameter <B mm r

>mm+

&7 Mi&r har#$e%% te%ter * Thi% te%ter ma&hi$e i% u%e# fr &ar*uri4e# &m!$e$t% t &he&) the

&a%e #e!th f the &m!$e$t%+

.age / 00



St#nd#rd R%%(

A% the $ame i$#i&ate% %ta$#ar# rm it% the rm (here all the i$%trume$t% are %ta$#ar# a$# all

the i$%trume$t% (hi&h are u%e# fr mea%uri$g the #ime$%i$% f the !art% f the &m!$e$t% f

*#y !art% f tru&)% a%%em*ly are &ali*rate# (ith the%e i$%trume$t%+ There are %me %ta$#ar#%

i$%trume$t% (hi&h are u%e# fr mea%uri$g the #ime$%i$% f e$gi$e !art% a$# fr &ali*rati$ f

the ther i$%trume$t% (hi&h are a% fll(+

<+ PROFILE PRO:ECTOR* .rfile !r-e&tr i% the ma&hi$e (hi&h i% u%e# fr

!r-e&ti$g the !r-e&ti$ f "ery %mall !art% i$ the mag$ifie# (ay $ the !r-e&tr+ It ha% "erti&al

!ti&al a'i% a$# the image frme# i% i$"erte# a$# re"er%e#+ .r-e&ti$ le$%e% ha"e the

mag$ifi&ati$ f >Q2 <BQ2 0BQ2 >BQ2 a$# <BBQ+ It ha% the mag$ifi&ati$ a&&ura&y f u!t+B>f

&$tur illumi$ati$ a$# +B> f %urfa&e illumi$ati$+ It% (eight i% BB)g+it ha% : le$% f %&re(

0+ C%%rd"n#te (e#/!r"n0 MACHINE* AS (e )$( that mi&rmeter "er$ier

&ali!er a$# height gauge% are u%e# fr mea%uri$g $ly $e #ire&ti$ a$# !rfile !r-e&tr

.age / 0:



mea%ure t( #ime$%i$% i$ %!ite f the%e e$tire &r#i$ate mea%uri$g ma&hi$e% i% u%e# fr three

#ime$%i$% f the &m!$e$t% f e$gi$e i$ Q2 Y2 8 #ire&ti$+ Cr#i$ate mea%uri$g ma&hi$e i%

al% u%e# fr mea%uri$g the #ime$%i$ f a$y !art (ith re%!e&t t %me ther #ime$%i$+

Su!!%e (e ha"e t fi$# the !it&h &ir&le #iameter f the !art (ith re%!e&t t %me ther !i$t it

gi"e u% that #ime$%i$+ It al% hel!% t &al&ulate the #iameter f &ir&le a&&urately a% it i%

ele&tr$i&ally !erate#+

:+ UNI;ERSAL LINEAR MEASUREMENT MACHINE* thi% ma&hi$e i%

u%e# fr the &ali*rati$ f the ri$g gauge% a$# !lug gauge%+ It i% mai$ly u%e# fr the mea%uri$g

the !it&h f the gear%+ It i% al% )$($ a% light ma&hi$e a% it i% !ti&ally !erate#+

=+ TORUE WRENTCH TESTER * It i% the i$%trume$t (hi&h i% u%e# fr the

&ali*rati$ f the tr9ue (re$&h+ 6Tr9ue (re$&h i% the #e"i&e (hi&h i% !erate# u! t %!e&ify

tr9ue it mea$% that if tr9ue (re$&h ha% the %!e&ifi&ati$ f <B)gm the$ i$ tighte$i$g *lt after

<B)gm it *e&me% free+7It i% ele&tr$i&ally !erate#+

>+ AIR GAUGES AND BORE GAUGES* the%e are mai$ly u%e# fr mea%uri$g

the i$ter$al #iameter f a$y !art+ Air gauge are !erate# *y air *y air !re%%ure a$# *re gauge%

are !erate# me&ha$i&ally r *y ha$#%+ 1re gauge% ha% the ra$ge frm<0mm t :BBmm+

.age / 0=



?+ STANDARD PINS AND SLIP GAUGES* The%e are the %ta$#ar# $e% a$#

u%e# fr mea%uri$g the a&&urate #ime$%i$% f a$y !art% a$# u%e# r &ali*rate# ther

i$%trume$t%+ Sli! gauge% are u%e# fr mea%uri$g the (i#th f a$y !art% a$# ha% the ra$ge :BBmm+

a$# %ta$#ar# !i$% are u%e# fr mea%uri$g #iameter f a$y hle a$# it ha% the ra$ge frm+>mm t

:BBmm+

+ ELECTRONIC AND MECHANICAL HEIGHT GAUGES* The%e are

mai$ly u%e# fr the height f a$y !art +me&ha$i&al height gauge% ha% the ra$ge u! t :BBmm a$#

ele&tr$i& height gauge% ha% the ra$ge u! t ?BBmm+

.age / 0>



HEIGHT GAUGE

+ SUARNESS TESTER * It i% u%e# fr &he&)i$g the !er!e$#i&ularity f t(

%urfa&e% f the &m!$e$t%+

+ HEIGHT MASTER* It i% the ma%ter (hi&h i% u%e# fr the &ali*rati$ f the height

gauge%+ It ha% the lea%t &u$t f < mi&r$+

<B+ BARO PROTECTOR* It i% the a##iti$al a&&e%%ry (hi&h i% u%e# fr

mea%uri$g the heli' a$gle f the gear a$# threa#e# !art%

<<+ ;ERNIER AND MICROMETER * La%t *ut $t the lea%t "er$ier a$#

mi&rmeter are the i$%trume$t% (hi&h are u%e# fr mea%uri$g the #ime$%i$+

.age / 0?



CONCLUSION

After #i$g my trai$i$g at SML ISU8U LTD2RO.AR2 I felt the im!rta$&e f trai$i$g i$ the

i$#u%try a$# it% !ra&ti&al a!!li&ati$%2 (he$ I (a% %tu#yi$g the therie% f #iffere$t &$&e!t% I(a% thi$)i$g h( the%e all (ill *e im!leme$te#+ 1ut after the trai$i$g2 I lear$t h( all the%e

&ul# *e !ut i$ g# u%e+ It (a% the re%ult f trai$i$g $ly that I gt t %ee the *-e&t% i$ real a$#

!ra&ti&al u%e2 (hi&h I ha# $ly rea# a$# a*ut a$# %ee$ a% 0D *-e&t% i$ the *)+

Duri$g my trai$i$g at SML2 I gt &ha$&e t e'!%e t the i$#u%try &ulture a$#

(r) e$"ir$me$t+ I$ ther (r#%2 the%e #ay% f trai$i$g i$ SML (ere lear$i$g e'!erie$&e# all

the (ay+ The%e ha!!e$ $ly #ue t &5!erati$ f %taff a$# the ma$ageme$t (h hel!e# me i$

gai$i$g (hate"er )$(le#ge I ha"e t#ay a*ut the !r#u&ti$ a$# ma$ageme$t+

I$ the e$#2 I (ul# li)e t &$&lu#e that the trai$i$g i% a$ e%%e$tial !art f the

e#u&ati$ !rgramme+ e %hul# al(ay% !ur%ue fr the thereti&al a% (ell a% the !ra&ti&al

)$(le#ge2 *th f (hi&h are mu%t fr the !r#u&ti$ f high *uil#i$g+

.age / 0



BIBLIOGRAPH?

De-#rt(ent/ #t SML $%n/!1ted*<

<7 Te&h$lgy

07 uality

:7 .r#u&ti$=7 S!are .art% Di"i%i$

L"/t %& e'/"te/ $%n/!1ted*<

<7 (((+h(%tuff(r)%+&m07 (((+(i)i!e#ia+&m

:7 (((+ggle+&m

L"/t %& '%%./ $%n/!1ted*<

<7 Autm*ile E$gi$eeri$g5 3ir!al Si$gh07 Autmti"e E$gi$eeri$g5 Cru%e a$# A$gli$

:7 I$#u%trial .r#u&t Fi$#er

=7 I$#u%trial E$gi$eeri$g

http://www.howstuffworks.com/

http://www.wikipedia.com/

http://www.howstuffworks.com/

http://www.wikipedia.com/

Documents

SML 6 week TRAINING