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7/21/2019 SML 6 week TRAINING
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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$e %& S!'("tted ')*
N#(e* Mr+ M#n% K!(#r N#(e* Dee-#. K!(#r
De/"0n#t"%n* M#n#0er C%11e0e R%11 N%* 2345362
De-#rt(ent* T%%1 De-#rt(ent
RAYAT INSTITUTE OF ENGINEERING AND INFORMATION
TECHNOLOGY RAILMAJRASBS NAGAR NAWANSHAHR P!n#'
7/21/2019 SML 6 week TRAINING
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ACKNOWLEDGEMENT
I am highly grateful t the R#)#t In/t"t!te %& En0"neer"n0 7 In&%r(#t"%n Te$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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7/21/2019 SML 6 week TRAINING
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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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7/21/2019 SML 6 week TRAINING
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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$$er+
The re%ult f all thi% ha% *ee$ ra!i# i$&rea%e i$ ut!ut f "ehi&le% a$# %har! re#u&ti$ i$ &a%h
l%e%+ The tur$ "er fr 0BB50BB e'&ee#% R%+ :BB &rre%+ T#ay the &m!a$y ma$ufa&ture%
light &mmer&ial "ehi&le% li)e tru&)%2 *u%e%2 !li&e "a$%2 (ater ta$)er%2 am*ula$&e2 a$#
%!e&ial "ehi&le% a$# al% e'!rt% t the &u$trie% li)e Ne!al2 8am*ia2 1a$gla#e%h2 3e$ya2 Sri5
La$)a a$# Jr#a$+
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ORGANIZATIONAL SET UP OF SML ISUZU LIMITED
MANAGING DIRECTOR
EXECUTI;E DIRECTOR
;ICE PRESIDENT ASSOCIATI;E
;ICE
PRESIDENT
GENERAL MANAGER DEPUT?
GENERAL MANAGER
SENIOR MANAGER CHIEF MANAGER
MANAGER
ASST MANAGER
ENGINEER SENIOR ENGINEER ASST ENGINEER
:UNIOR ENGINEER
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;#r"%!/ De-#rt(ent/ %& SML ISUZU L"("ted
• .er%$$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$t
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ENGINE COM.ONENTS
FROM ASHING
MACHINE
ENGINE ASSEM1LY
AND TESTING
TRANSMISSION
COM.ONENTS FROM
ASHING MACHINE
TRANSMISSION
ASSEM1LY AND
TESTING
FRONTREAR AQLE ,
DIFFERENTIAL ASSY+
AQLE COM.ONENTS
FROM ASHING
MACHINE
LONG MEM1ER
STORAGE
TEM.ORARY .ART
SETTING
TAC3FULL
ELDING
STRAIN RELIEING
CHASSIS .AINTING
;EHICLE
ASSEMBL?
LINE
.RE DELIERY
INS.ECTION
ROADSHOER
TEST
CARGO 1OQ
MOUNTING
RUST .REENTIEA..LICATION
;EHICLE TO
STOCK ?ARD
.ARTS FROM
STORE
FLOOR
ASSEM1LY+
CA1IN
ASSEM1LY
DOOR ELDING
, ASSEM1LY
FINAL FITTING
AND FINISHING
TO .AINT SHO.
CA1IN .RE
TREATMENT
, 1LAC3
DI..ING
1A3ING
SEALANT AND
.RIMER
A..LICATION
1A3ING
FINAL
.AINTING
1A3ING
INS.ECTION
.AINTED
CA1IN TO
ECH+ ASSY+
CA1IN
DRESSING
ITH SU1
ASSEM1LY
CARGO 1OQ
FROM STORE
CARGO 1OQ
ASSEM1LY
SLEE.ER
ASSEM1LY
CARGO 1OQ
ELDING
CARGO
ASHING
SEALANT
A..LICATION
1A3ING
FINAL
.AINTING
1A3ING
INS.ECTION
BOD? SHOP
ENGINE
ASSEMBL?
CABIN
WELDIN
G
CABIN 7 CARGO
ASS? 7 PAINTING
T@M ASS?
LINE
AXLE
ASS? LINE
Flow Diagram of the Sml Isuzu Plant
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TOOL DEPARTMENT
Thi% #e!artme$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+
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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%+
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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$&h+
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:"0 (#.er
A -ig ma)er i% a fiel# u$#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 $ee# fr -ig%+
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UALIT? ENGINEERING DEPARTMENT
Thi% #e!artme$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% #$e+
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STRUCTURE OF UALIT? ENGINEERING DEPARTMENT
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uality E$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%+
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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$# !rfile !r-e&tr
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mea%ure t( #ime$%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+
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?+ 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$ge u! t ?BBmm+
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HEIGHT GAUGE
+ SUARNESS TESTER * It i% u%e# fr &he&)i$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$%i$+
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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+
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BIBLIOGRAPH?
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