AT

SONA KOYO STEERING SYSTEMS LTD

38/6, DELHI-JAIPUR ROAD, NH-8, GURGAON 122001, HARYANA (INDIA)

: SU MITTED Y :

R!"#$ G%&&
INSTITUTE ROLL NO' : 10/ME/6())

D!*#+,"!$, -. M!/0#$%/#& E$1%$!!+%$1

H%$23 4-&&!1! -. E$1%$!!+%$1 S-$!*#,

Projects Done:

U$2!+5,#$2%$1 ,0! #5%/5 -. 6#+%-35 S,!!+%$1 S75,!"5 8 D%..!+!$,%#& 9!%$1 %"*&!"!$,!2 %$ #3,-"-9%&! %$235,+7'

T- 5,327 #$2 %"*&!"!$, SP4'

R!"#$ G%&& 6())

PRE:A4E

Plant-1 Plant-2

A need to excel, which means to achieve is one of the most critical factor in development of a mechanical engineer. The changing Industrial scenario and environment needs trained and experienced Engineers who can effectively handle the man Power without much grievances and ensure the effective utilization of machines and materials to achieve the ob ectives laid down by the organization. Accordingly Engineers find placement in respective fields such as !esearch and "evelopment, "esigning, Production, Inspection, #uality control, $ar%eting, $aintenance etc. Practical Training is necessary part of engineering study, as we %now that no theoretical %nowledge is complete without practical %nowledge. It greatly enhances ones %nowledge and provides favorable opportunities to blend ones theoretical %nowledge with practical and also trainees get familiar with certain aspects of industry li%e shop floor management, industrial relation etc. I feel proud in getting training at &'(A )'*' &TEE!I(+ &*&TE$& ,T"., +urgaon, -aryana that is leading steering and automobile part manufacturer in India.

ACKNOWLWDGEMENT It brings me immense pleasure for an opportunity to have undergone training at Sona Koyo Steering System Limited . There is always a sense of gratitude which one expresses to others for their helpful and needy services, which they render during all phases of life. I too would like to do the same as I really wish to express my gratitude towards all those who have been helpful to me during different stages of my Industrial Training and encouraged me with their ideas and views, which were guiding and motivating factors in completion of mighty and tedious task of project report writing to be a success.

In presenting this !eport I would li%e to convey my deep and profound gratitude towards all Engineers and 'perators at &ona )oyo &teering &ystems ,imited for their co.operation and guidance.
Finally, I would also like to thank the entire Sona Family for helping and guiding me as and when re uired.

4ERTI:I4ATE
This is to certify that $r. &an eev /ose , student of /.Tech 0$echanical Engineering1 2rd year of 3areer Institute of Technology 4 $anagement has successfully completed training at S-$# K-7S,!!+%$1 S75,!"5 L,2', G3+1#-$, H#+7#$# for 5 wee%s from 67th 8une to 29th 8uly,:997. -is conduct through whole tenure of training was found to be excellent. ;e wish him all the best for his future. ;

T+#%$%$1 I$/0#+1!

Index
1. Company Profile 6.6 Introduction to &'(A 6.: Plant "etails 6.2 3ompany 'rganization 6.? ! 4 " "epartment 4 its 'rganization 6.7 &'(A )'*' wor%ing Philosophy 6.5 Professional Practices /eing followed in &)&&, 6.@ &'(A )'*' products 6.= Technical )nowledge of $ain Products 6.> 3ustomers of &)&&, 6.69 3ompetition of &)&&, 6.66 3ompany Performances, -istory 4 Plans 6.6: $ilestones 6.62 Auture Plans 6.6? (ew Products 6.67 8ournals 4 Trade $agazines 6.65 'ther 3ompanies of the +roup 2. Observational Training :.6 :.: :.2 :.? Introduction to Plant -eat Treatment Plant Paint &hop Testing ,ab < < < < 2? 27 2@ 2= < < < < < < < < < < < < < < < < = > 66 6: 6? 6> :: :? :7 :7 :5 :@ := :> 29 26

2. Project No.1

2.6 2.: 2.2 2.? 2.7

Aunction of &teering &teering 3olumn $anual &teering !P& Assembly Biew of !P& !/& wor%ing

< < < < < < < < < < < < < <

2> ?: ?? ?5 ?= 79 7: 72 77 75 7> 59 5? 5@

2.5 Assembly Biew of !/& 2.@ Power &teering 2.= ;or%ing of Power &teering 2.> Impact Absorbing $echanism 2.69 3ollapsible 3olumn 2.66 Cniversal 8oint 2.6: (eed of "ifferential 2.62 "ifferential 'peration 2.6? Ainal Inspection 3hec% of "ifferential ?. Project No.2 ?.6 ?.: ?.2 ;or% on Product 3atalogue Advantages of Product 3atalogue Barious Products being standardized

< < <

@9 @9 @6

7. Project No.3 7.6 7.: 7.2 7.? 7.7 7.5 7.@ Parametric Associativity End to End Associativity "esign $odes of Pro.E "atum, Axes 4 3oordinate &ystem "efining Parts in &%etcher Pro.E I(T!A,I() Barious Parts being modeled in Pro.E ;ildfire < < < < < < < < =9 =9 =6 =6 =: =2 =? =@

5. How this Training was helpf l

I$,+-23/,%-$ ,- SONA

;ith its beginning as a small company in 6>=@, now the D=9 million &'(A +roup comprises several companies each of which are in oint venture partnerships and technical and financial collaboration with global leaders in their specialist areas. S-$# K-7- S,!!+%$1 S75,!"5 L%"%,!2 (SKSSL) is a technical and financial oint venture company of K-7- S!%<- 4-"*#$7, J#*#$. ;ith a $ar%et share of 79E, the company is the largest manufacturer of steering gears in India and is the leading supplier ofF
-ydraulic $anual

Power &teering &ystems

!ac% 4 Pinion &teering &ystems Tilt and !igid &teering 3olumns for Passenger Bans and $CBs

3ollapsible,

PLANT LO4ATION 2=G5 "elhi H 8aipur !oad !urgaon "#aryana$ India

2= %ms from (ew "elhi :: %ms from "elhi Airport 69 %ms from $C,

Total site area I 75>@9 sJ Total floor area I 69=>9 sJ. mts.

PLANTS

. PLANT-1

P-=!+ S,!!+%$1 P&#$,

PLANT-2

$e!ei"t Store

Total Site -rea

1lant 2. 1lant3, 1lant 2/ #eat Treatment 0thers

Production Commenced - 1987 '()*+ m,

&'P Steerin" )e r Steerin" Column &%S Steerin" )e r *+le nd Pro$ S# ,t, -i,,. *ss. &'P Po(er Steerin" C r!urisin", Quenc#in", Tem$erin", Str i"#tenin", S#ot %l stin" Utilities, Stores etc., ,)// m, '/(/ m, .,(' m, %%( m, .//+ m,

Man"o#er Certi i!ation

%&'
QS 9000, ISO 14001,TS16949

7041-5; 907-TI05S

Sona e-Design L%M%TED&

SONA KO'O STEE$%NG S'STEMS LTD& ()AC%L%T'-1* SONA SOM%C LEM)O$DE$ COMPONENTS LTD& SONA COLD )O$G%NGS LTD& SONA OKEGAWA P$EC%S%ON )O$G%NGS LTD&

Ma.indra Sona Limited

MA+%ND$A SONA LTD&

DEL+%
Sona Koyo - G/rgaon

G,$GAON

M,M-A% NAS%K

Sona O0ina#a Pre!ision )orgings

> C+ENNA%

Sona Somi! Lem order Sona Cold )orgings

SONA KO'O STEE$%NG S'STEMS LTD& ()AC%L%T'- 2* 4-56F-7T68I5! F-7I9ITI:S 0FFI7:S

Sona Koyo - C.ennai

4OMPANY STRU4TURE AND LE?EL O: HIERAR4HY

Sona >oyo 0rganisation

Dr& S& Ka"/r !roup37.:.0 74 3 <

K&M& Des.m/0. 7.0.0

P&2& Parri0er Procurement Procurement

A& 2& Garde A&D& $ao 8=< A& Maity 4arketing '& A0iyama Plant PlantChief Chief -Gurgaon Gurgaon $&M& Lal Plant Chief - Chennai Finance

S& C.o"ra $&-& Sing. Quality System $&K& Gaind

Prodn. Planning & Control

S&C& G/"ta Mfg.Maint .

M&L& Goel P&A

Legal

M&S.arma Engineering

P&P& Ga1"al Quality Assurance

S-$# 0#5 ,0+!! 1+#2!5 -. !"*&-7!!5: 6. &enior $anagers 0&.$.1 . about 27 in number

:. 8unior $anagers 08.$.1 2. ;or%ers 0& grade1

. about 629 in number . about :79 in number

that ma%es a total wor%force of about )8@ employees.

8:S:-87# -5< <:?:9014:5T

The 8 = < department of S>SS9 is divided into two parts namely the product design group and the tool design group. @hile the former deals directly with the customer oriented products, the latter deals more with the toll that are used in carrying out the operations. Thus, while designing the rack bar or the pinion comes under the product design group, designing the heating inductor comes under the tool3designing group.

In addition to these two, there is one more section of the 8 = < that has been introduced recentlyA the :1S design group. The group aims at the development of the :1S technology that is bound to be in demand in the near future.

Though most of the designs come directly from >oyo, the department has the responsibility to modify them to meet the customer re uirements and carry out the tests on the products.

The department has the most dedicated engineers who work hard and stay till late to carry out the designs and to complete the projects at hand. The department also has done well in the TB4 and T14 aspects.

SONA KOYO AORKING PHILOSOPHY

SONA KOYO respects the dignity of human beings at all levels. In the matter of employment, it believes in the concept of eJuality in caste, religious, creed., race, sex and nationality. Employees selection shall be merit based and made on basis of proven ability of the incumbents0s1. SONA KOYO endeavors to provide eJual opportunity to all and one in the matter of internal promotion. 'nly the right person for the right ob however, shall be promoted. SONA KOYO is conscious of fact that the growth an d progress of its employees and the company is inter Hdependent, hence the concept of all round development of its team members shall be of prime importance. SONA KOYO encourages meaningful participation of its team members to achieve the organizational goals and ob ectives. SONA KOYO constantly endeavors to establish and promotes clean and safe wor%ing environment where it team members may wor% happily and drive oy and pleasure.

SONA KOYO shall encourage and promote sports and such other cultural activities, which may be useful in building the moral values and national character of honest, discipline and integrity among its team member.

SONA KOYO as a good cooperate citizen shall li%e to participate in the community development and welfare programs in its surroundings areas so as to develop understanding and generate goodwill amongst the inhabitancy of local society. SONA KOYO believes that the problems and difficulties emanating out of day today wor%ing be resolve satisfactorily. In this context, &'(A )'*' shall establish and promote direct contact with its team member and try to eliminate the problems from the grass root level. This handling approach shall directional be straightforward, devoid of any precedents customs and even popular views if any.

KAIBEN
)AIKE( means improvement and continuing improvement in personal life, social life, home life, and wor%ing life. ;hen applied to the wor%place )AIKE( means continuing improvement involving everyone H managers and wor%ers ali%e. )AIKE( is a 8apanese word meaning gradual and orderly, continuous improvement. The )AIKE( business strategy involves everyone in an organization wor%ing together to ma%e improvements Lwithout large capital investmentsM. )AIKE( is a culture of sustained continuous improvement focusing on eliminating waste in all systems and process of an organization. The )AIKE( strategy begins and ends with people. ;ith )AIKE(, an involved leadership guides people to continuously improve their ability to meet expectations of high Juality, low cost, and on time delivery. )AIKE( transforms companies into N&uperior +lobal 3ompetitorsO

T=- E&!"!$,5 -. KAIBEN

There are two elements that construct )AIKE(, improvementGchange for the better and ongoingGcontinuity. ,ac%ing one of these elements would not be considered )AIKE(.

Aor instance, the expression of Lbusiness as usualM contains the element of continuity without improvement. 'n the other hand, the expression of Lbrea%throughM contains the element of change or improvement without continuity. )AIKE( should contain both elements.

#5%/ :!#,3+!5 :-+ KAIBEN A/,%6%,%!5

"iscarding conventional fixed ideas. Thin%ing of how to do it, not why it cannot be done. (o place for excuses. &tarting by Juestioning current practices. ,ess emphasis on see%ing perfection. "oing things right away even if for achieving only 79E of target. 3orrecting it right away, if some mista%e is made. Csing wisdom, not money for )AIKE(. ;isdom is brought out when faced with hardship. As%ing L;-*PM five times and see%ing root causes. &ee%ing the wisdom of ten people rather than %nowledge of one. )AIKE( ideas are infinite.

KAN AN SYSTEM
$any people thin% the Toyota production system a )anban systemF this is incorrect. The Toyota production system is a way to ma%e products, whereas the )anban system is the way to manage the 8ustHinHtime production method. In short, the )anban system is an information system to harmoniously control the production Juantities in every process. It is a tool to achieve 8ust.in.time

production. In this system what %ind of units and how many units needed are written on a tag li%e card called )anban. The )anban is sent to the people of the preceding process from the subseJuent process. As a result, many processes in a plant are connected with each other. This connecting of processes in a factory allows for better control of necessary Juantities for various products.

The following supports the %anban systemF &moothing of production !eduction of set up time design of machine layout &tandardization of obs Improvement activities Automation A )anban is usually a card put in a rectangular vinyl envelope. Two %inds are mainly usedF ;ithdrawal )anban and Production.ordering )anban. A ;ithdrawal )anban details the %ind and Juantity of product, which the subseJuent process should withdraw from the preceding process, while a Production ordering )anban specifies the %ind and Juantity of the product, which the preceding process must produce.

PRO:ESSIONAL PRA4TI4ES EING :OLLOAED IN SKSSL

4LEANLINESS: A great emphasis is laid on the cleanliness of the plant so as to give the wor%ers a cleaner atmosphere to wor% in. There is hourly sweeping of the entire plant and all the wor%ers are provided with hand gloves and pollution mas%s, and although the latter is not used by many, the former goes a long way in helping the wor%ers maintain cleanliness. The operator at the end of his shift and each &aturday a half an hour cleaning program ta%es place in which everyone has to participate cleans each machine. PUN4TUALITY: The attendance is %ept trac% of using a punch card system which records the time of reporting as well as the time of departure. If a person is late by even a single minute, he has to sign on the late coming register. The system ensures timely arrival and departure of employees 0as well as trainees1. TEAMAORKF There is a great emphasis on teamwor% and total participation of all employees. To ensure this, there is a morning meeting

everyday in each department headed by the -ead if that particular department where daily plans are made and problems are discussed. In addition to the daily morning meeting there is a wee%ly +)A 0+roup )aizen Activity1 meeting in all the departments and also for all the operation lines. A problem is ta%en up and targets are set. Each group wor%s upon a problem, and in the process, there is a total employee participation in the improvement process. STRI4TNESS ON DEADLINESF The 3ompany is strict as far as deadlines are concerned. 3ommitments are respected and people often stay bac% till late in the evenings to complete the wor% at hand. This is being given more and more emphasis as the company focuses on higher customer satisfaction. CUALITY 4ONTROLF The freJuency of chec%ing different

components is predefined. There are some components that reJuire 699E chec%ing. These norms are followed rigorously with the help of Po%ayo%e, a foolproof system that doesnOt allow the next process in the line to ta%e place if the norm is not adhered to. EDU4ATED AORKERSF Cnli%e many factories and plants where there are huge numbers of illiterate wor%ers, every wor%er in &)&&, is educated and has gone through vocational training in ITI. All wor%ers are well trained on the line before they actually start wor%ing. DE4ORUMF The 3ompany has a smart uniform 0shoes included1 that helps in maintaining decorum. ;or%ers and the management wear the

same uniform. In fact even when $r. &urinder )apoor, the 3$" of the company, visits the plant he wears the same uniform that everyone else does. 4REDI LE EN?IRONMENT POLI4YF The 3ompany has a credible environment policy. A 3ross Aunctional Team 03AT1 core group has been formed by the $anagement !epresentatives for identification and evaluation of environment aspects and implementation of Environmental $anagement &ystem 0E$&1. STRESS ON THINKINGF The process of thin%ing is thought of highly by the management, which has put a note on each table and all the passages saying Thin%Q &uggestions from all the employees are ta%en seriously and the no. 'f suggestions from each department and the total no. 'f employees not contributing with their suggestions is %ept trac% of. Award is given to the best suggestions each Juarter. RE4OGNITIONF ,ast but not the least is the recognition that the management gives to the performing individuals and teams. /est suggestions and best )aizen groups are awarded and their photographs are put on the notice board along with their achievement. This ma%es the environment congenial for performing well.

SONA KOYO STEERING SYSTEM LTD' PRODU4TS P&#$, =%5! &%5, P&#$, 1
6. 6.!P& Assembly =99cc 0$C,1 :. !ac% /ar 2. Pinion ?. 3ase &teering +ear 7. 3ollapsible 3olumn &afari 0TE,3'1 5. 3ollapsible 3olumn $odel A 0$C,1 @. !igid 3olumn 0'$(I1

P&#$, 2
6.!/& Assembly 0+ypsy1 :.!/& Assembly 0'$(I1 2./all &crew Assembly 0+ypsy1 ?./all &crew Assembly 0'$(I1 7.&ector &haft 0+ypsy1 5.&ector &haft 0'$(I1 @.&lide yo%e &ub Assembly =.Alange yo%e &ub Assembly

>.Propeller &haft Assembly 0'$(I1 69.&haft 3omponent Propeller 66.Axle Assembly 0'$(I1 6:."ifferential Assembly 0'$(I1 62.3ase "ifferential Assembly 0TE,3'1 6?.3ase "ifferential Assembly 0*E.:1

P&#$, 3
6.Power &teering 0Toyota1 :.Power &teering 0Esteem1 2.Power &teering 0,ancer1
?.Power &teering 0&corpio1

T!/0$%/#& K$-=&!21! -. M#%$ P+-23/,5

R#/< #$2 *%$%-$ 1!#+ #557'( "#$3#&): It is a combination of rac% and pinion. !ac% is ust li%e a rod having teeth with left and right alignment. Pinion is small component having helical teeth .the pinion enhanced the movement of rac% in horizontal direction. :3$/,%-$: !otations of pinion translate as action axial movement of rac% bar. R#/< #$2 *%$%-$ 5,!!+%$1 1!#+ #557' (P-=!+): The only difference in movement is easier than above. ItOs basically for heavy vehicles. In it, there is power assist being provided either hydraulically, or electronically. :3$/,%-$: !otation of pinion translates action movement of rac% bar. R!/%+/3&#,%$1 9#&& 5/+!= 5,!!+%$1 1!#+ #557': Cnli%e the rac% and pinion gear assy. here is a screwball that is responsible for movement of sector shaft. &ector &haft is used in !/&. :3$/,%-$: its wor% li%e a rac% bar. 4-&3"$ #55!"9&7 +%1%2/0#$2&! D-%$,5/%$,!+"!2%#,! 50#., #557: Its helps to oin the steering to wheel. . -andle oints are universal oint 0u 1 And I&A is getting inserted into shaft of particular level. 4-&3"$ #55!"9&7 /-&&#*5%9&!/#55!"9&7 /-&&#*5%9&! #$2 ,%&,%$1: /asically there is no difference in it and above. (ow it is used in almost all the four vehicles. :3$/,%-$F prevention from in ury to driver because during column collapses.

P+-*!&&!+ 50#., #55!"9&7: Its oins the bac% wheels of vehicles to the front wheels. $ovement causes the running of vehicles. 4#5! 2%..!+!$,%#& #55!"9&7:
Its oins the bac% wheels of vehicles.

435,-"!+5
The main customer of the &)&&, is $C, !"ar ti #$yog %t$.&, which consumes about 79E of its total production. $a or customers of the company areF 6. $aruti. &uzu%i :. Toyota 0India1 2. -$. $itsubishi ?. Tata Engineering 7. $ahindra 4 $ahindra 5. &wara $azda @. +eneral $otors India =. -yundai $otors >. Eicher. $itsubishi 69. Aiat India 66. $aval $fg. 6:. )oyo &ei%o 62. ,otus

4-"*!,%,%-$
The company en oys a top position in its core competency, that is, steering systems. The competition is mainly from a 3hennai based company called !ane. The rival company is a TB& group company and is in collaboration with T!;.

4-"*#$7 *!+.-+"#$/!, 0%5,-+7 #$2 *&#$5

&ona )oyo &teering &ystems ,imited 0&)&&,1 is a technical and financial oint venture company of )oyo &ei%o 3ompany, 8apan' ;ith a $ar%et share of 79E, the company is the largest manufacturer of steering gears in India. The companyOs product range also extends to !ear Axle Assemblies and Propeller &hafts. The ;orld Economic Aorum named the company as a +lobal +rowth 3ompany in 6>>@. The company is paying a lot of attention to Total #uality $anagement 0T#$1. It is also developing its core competence and aligning ob ectives at all levels so as to realize synergy in operations. An initiative of improving the most important resources, the -uman !esource, as well as the plant eJuipment has been initiated. This techniJue, Total Productive $aintenance 0TP$1, has been adopted to improve performance through the philosophy of prevention. SKSSL aims to achieve Kero accidents Kero defects

Kero brea%downs

3ustomer &atisfaction continues to be of utmost importance to S-$# K-7S,!!+%$1 S75,!"5, as do consistent Juality, constant innovation, value engineering, process improvement and customer orientation. The companyOs Juality policy readsF E4-""%,"!$, ,- 2!.!/, *+!6!$,%-$ #$2 /-$,%$3-35 %"*+-6!"!$, =0%&! "!!,%$1 -+ !F/!!2%$1 /35,-"!+ +!G3%+!"!$,5 #, #&& ,%"!5'H

M%&!5,-$!5

Y!#+ 8an 6==7

M%&!5,-$! #/0%!6!2 Technical collaboration agreement with )'*' &EI)' 3'., ,T"., 8apan for manufacture ofF $anual &teering +ear Assemblies &teering 3olumn Assemblies

'ct 6>=@ 8ul 6>>: Aug 6>>? &ep 6>>? 8ul 6>>7 $ay6>>@ 'ct 6>>=

3ommencement of Production EJuity participation 0=E1 by )'*' )'*' certified &'(A as an approved vendor, exports of steering parts to 8apan started I&'. >99: 3ertification by TCB. 3E!T, +E!$A(* Technical collaboration agreement with )'*' for manufacture of Power &teering +ear Assemblies )'*' increased eJuity to :9.7E (ame of &'(A &TEE!I(+ &*&TE$& changed to &'(A )'*' &TEE!I(+ &*&TE$& ,T".

"ec 6>>= (ov :999 $ay :99: (ov :992

Established plant in 3hennai #&>999G I&' >996 3ertification by TCB.3E!T, +E!$A(* I&' 6?996 3ertification by TCB.3E!T, +E!$A(* "eming Prize

:3,3+! P&#$5 1'M#$#1!"!$,

The management of the company has chal%ed out a plan %nown as ?%5%-$ 2010. &alient features of the plan are as followsF a.3urrently &'(A en oys the (o.6 position as far as the number of products made per year is concerned. Bision :969 loo%s ahead to maintain this position in the long run. b.The present contribution of exports to the total turnover is a mere :E. The company plans to increase it to as high as ?7E of the total turnover by the year :969. c.Arom being a !s. :79 crore company presently, the management wants to ma%e it a !s. :999 crore by the end of the year :969. This year the company has started electronics ! 4 " department to develop the electronic components 0all of which are being imports currently1 in the plant itself. The ! 4 " is developing into a proactive department, and instead of waiting for the customer to come with the reJuirementsR the company plans to proactively gauge the customer reJuirements.

The company plans to develop its core competence and plans to withdraw its eJuity from rest operations.

N!= P+-23/,5
The company is also on its way to launch a number of new products. &ince there has been a change in govt. regulations recently, it is now mandatory for all cars to have collapsible columns. Till "ec. :99:, &'(A provided rigid columns for $aruti =99cc. /ut starting "ec. 67 th, the company has started providing collapsible columns for =99 cc car as well. The ongoing pro ects on which wor% is being going on areF a. Elimination of the plastic ball retainer from the column assembly to ma%e it cost effective. b. Electronic Power &teering. The launch of the EP& is going to be done in phases, with the company importing many basic components such as I.3.C.s and motors.

J-3+$#&5 #$2 T+#2! M#1#I%$!5 R!&#,!2 ,- /-"*#$7J5 &%$! -. =-+< 6. A number of popular Auto magazines and ournals such as Auto India, Automotive Engg. Automotive $anufacturing etc are available. 6.)oyo design ournalF This is a ournal that comes monthly from )oyo, the technical partner of the company. :.Automotive Engineering $agazineF This is a monthly magazine published by &AE. 2.+ear "esign magazine ?.&teering &ystems $anualF This is a manual to help new recruits and trainees understand steering systems. It discusses types of steering systems as well as the various parts they are made up of. 7./esides, the ! 4 " has a full.fledged library that has various boo%s related to manufacturing, heat treatment, various standards and industrial engineering. /oo%s on 8apanese systems of manufacturing are also available. 5.There is an online manual available on the intranet which is similar to the &teering &ystems $anual.

O,0!+ 4-"*#$%!5 -. ,0! G+-3*

SONA 1+-3* 0#5 ,0! .-&&-=%$1 "#D-+ /-"*#$%!5, #&-$1 =%,0 SKSSL (S-$# K-7- S,!!+%$1 S75,!"5 L%"%,!2) 3$2!+ %,5 3"9+!&&# F

S-$# S-"%/ L!".-+2!+ 4-"*-$!$,5 L%"%,!2 (SSL4L) : The

3ompany was initially set up as S-$# S-"%/ 4-"*-$!$,5 L%"%,!2, a oint venture with S-"%/ I50%<#=# of 8apan. In 6>>=, L!".-+2!+ M!,#,,=#+!$ pic%ed up an eJuity sta%e in this company and the company expanded into S-$# S-"%/ L!".-+2!+ 4-"*-$!$,5 L%"%,!2 (SSL4L) . This tie.up has expanded the product base of this company as it can now cater to both the 8apanese and European customers.

SSL4L is a lea$ing man fact rer of ball joints for steering systems an$ s spension components in the country. Its products are used in passenger cars, eeps and light commercial vehicles. The companyOs ma or customers are S-$# S,!!+%$1, M#+3,% U27-1 L%"%,!2 #$2 H-$2# S%!&.

S-$# 4-&2 :-+1%$15 L%"%,!2 (S4:L):

In automobiles, cold forged components are used in the gear box, engine, drive train, steering system, electrical system, seat belt mechanism, spiders for steering, drive shafts, inner and outer parts of constant velocity oints, bevel gears, valve tappets, pinions, fuel in ection systems and many other mechanical parts. $a or customers for S-$# 4-&2 :-+1%$15 L%"%,!2 are S-$# K-7- and S-$# S-"%/ and it is currently developing components for T?S S3I3<% and D!$5-.

S-$# O<!1#=# P+!/%5%-$ :-+1%$15 L%"%,!2 (SOPL):

The O<!1#=# *&#$, %$ J#*#$ was established under the aegis of M%,539%50% $aterials in 6>?? for manufacture of metal alloys. It started precision die forging in 6>57. Precision forging enables production on a mass scale, at lower costs, and expands the eJuipment manufacturerSs possibilities of designing. 'perations have, since the introduction of precision die forging, continued to expand through the introduction of new alloys such as nic%el, cobalt and titanium, and through the complete confidence and support of customers.

3 4 A**+-#/0!5
4-++!/, 4-$,#%$!+F 3ontainers are specified for all the components. The different types of containers are used for different items depending on the weights, sizes, usage etc. and to avoid confusion and chaos, it is best that the component is put into the container specified for it. It also controls damages and hence saves money and time. 4-++!/, C3#$,%,7: The Juantity of a particular component to be carried is fixed depending on the weight, size, utility and value. $oving only the specific Juantity of material saves us from the problem of physically counting the Juantity repeatedly and saves time. This is also aided by following the first approach 0that of correct container1 because many containers do not ta%e more than the Juantity specified for them. 4-++!/, L-/#,%-$ -. M#,!+%#&: ,ocations are specified for each and every component not only in the holding area, but also on assembly lines and wor%stations. This is done ta%ing in view the freJuency of usage, ease in handling and ease in moving the material to the place where it is reJuired. "oing this saves time because identification of the material is very easy in this case.

O SER?ATIONAL TRAINING I$,+-23/,%-$ ,- P&#$,5:

&)&&, has a total of three plants, each of which manufactures different products. Also %nown as the !P& Plant, Plant I manufactures !P& Assemblies, rigid columns collapsible columns and tilt steering assembly 0for Tata &afari1. Apart from the assemblies themselves, the various in.house parts that are used in the manufacturing of these assemblies are made in Plant I. !P& Assembly consists of various components li%e !ac%, Pinion, 3ase gear etc. that are produced in.house. Apart from this various other brought out parts 0/'P1 are used such as /ellow, !ac% cover, !ac% housing etc. that come from various vendors. The C.8. assembly is also made in this plant. In addition to the various assembly line and the lines for ma%ing the in.house components, the plant also accommodates tool room machines 0lathe, milling etc1. Plant II is slightly bigger and manufactures a larger number of items than Plant I. The most important of the products manufactured here are the !/& Assemblies for various models, Propeller &haft Assemblies and Axle Assemblies. In addition to these assemblies, the sector shaft assemblies that are used in the !/& Assemblies, the &lide *o%e and Alange *o%e Assemblies that are used in the Propeller &haft Assemblies and the "ifferential Assemblies that

are used in the Axle Assemblies are also made in this plant. Barious in.house products li%e the sector shaft, worm.shaft, bevel gear, spider and ball.nut are made in Plant II. Plant III is also %nown as the Power &teering Plant. The plant is the newest of the three, and started in 6>>=. The plant ma%es Power &teering Assemblies and has ust an assembly line currently. The layouts of the various lines in Plant 6 and Plant II are shown in the subseJuent figures. In addition to the three plants, there is a heat treatment plant, a paint shop 0in Plant II1 and an Engineering Testing ,ab 0in the basement of Plant II1 that are discussed separately1.

H!#, T+!#,"!$, P&#$,

#) C3!$/0%$1 The heat treatment plant in &)&&, has three &ealed #uench Aurnaces. Two of them are hot oil Juench furnaces while the third one is cold oil one. 6. &#A.I a. -ot oil Juench b. /ric% lining c. '(G'AA control :. &#A.II a. 3old oil Juench b. 3eramic lining c. '(G'AA control 2. &#A.III

a. -ot oil Juench b. 3eramic lining c. PI" control 9) T!"*!+%$1 The process of tempering that is nothing but heating the components to be Juenched at 659.6@9T3 precedes Juenching. The process softens the material a bit so that it does not crac% when used due to over hardness. /) S0-, &#5,%$1 &hot blasting is a process to improve the surface finish of the components after heat treatment. The components are %ept on a circular plate that revolves on its axis with steel shots hitting the components randomly. The optimum abrasive 0shot1 velocity is @7.mG sec. The impact depends on the mass 0and hence the radius1 and the velocity of the steel shots. The shots are hurled by a centrifugal force from a bladed wheel. 2) 4!$,+#& L#**%$1: This process is carried towards the end of the heat treatment cycle. -ere, the preexisting holes are cleaned and chamfered. !) S,+#%10,!$%$1: &traightness of each and every piece is chec%ed after heat treatment. There are two machines for straightening, one being manual while the other automatic. .) A$$!#&%$1 -. T0+!#25: The threaded parts of the components are annealed to remove the brittleness. The heat source here is an inductor coil.

1) ENDO G#5 E("' gas is produced in the plant itself by heating a mixture of propane and air 0typical ratio 6F691 at around 6699 T3 in the presence of (ic%el catalyst. The typical E("' +as composition is (: 3' -: 3-? ?7.2E :2.?E 26.6E 9.:E U6E

;ater Bapors

E("' +as is used in the conditioning of furnaces while propane is used for heating purposes. (: cylinders are %ept in the -T plant to ta%e the heat away in case of an emergency.

P#%$, S0-*
&)&&, has a paint shop for catering to its in.house demand of painting of various components. The shop is located in Plant II and paints about 699 pieces per hour, wor%ing one shift a day. The cycle time for painting each component is about : hours and ?7 minutes. The main components that are painted in the shop are propeller shaft, !/& Assy, I.&haft Assy, lower shaft and collapsible column. The main activities that are carried on in the paint shop in the order of ta%ing place areF 6. "egreasingF "egreasing is the process of removing rust, chemicals etc. from the surface of the component by washing it in al%aline powder solution 0p- 6:1 in the degreasing tan%. The solution is changed once a month.

:. ;ater rinsingF It is the process of washing off the degreasing solution from the surface of the component. This is basically washing the piece in water of p- between @ and =. This water is replaced daily. 2. ActivationF This is a prereJuisite to the phosphatising process. -ere the component is treated with a solution of Cltra Act.3 0of p- =.>1 ?. PhosphatisingF This process is important because it ma%es sure that the paint stic%s to the component and does not remove easily. -ere the component is sprayed with a solution of Cltra./ond 7P and accelerator. The solution is changed once a month. 7. ;ashingF -ere the component is washed in "$ water. 5. "ryingF After washing, the component passes through a furnace 0oven1 where the moisture and water on the surface is dried. @. PaintingF The components are spray painted one.by.one manually by the operator. =. "ryingF The paint is then dried by passing it again inside the oven. The time spent by the component in the oven this time is twice that of the time spent before painting. >. 'pen "ryingF After drying in the oven, it is desirable to leave the components in open air for about :? hours before dispatch.

E$1%$!!+%$1 T!5,%$1 L#9

The engineering testing lab is located in the basement of Plant II. The lab is operational round the cloc% and testing of various components is done here periodically to ma%e sure that the Juality of the products is of utmost Juality. The various tests carried out in the lab areF

6. /ellow "urability Test 0-ot and 3old1F To chec% for crac%s, abrasions and brea%age in the bellow while operating under very hot or very cold conditions1 :. 3olumn "urability TestingF -ere input is a rectangular wave form given from the handle side of the column1 2. /earing Endurance Test ?. &teering 3olumn Impact TestingF In this test, a body bloc% is attached to a linear actuator and through this systemR a thrust is given to the steering column. &ufficient thrust is given to cause brea%age of the column. 7. I/8 Endurance Testing Apart from the eJuipment to carry out the above tests, the lab also has a Cniversal Testing $achine and an Impact Testing !ig.

U$2!+5,#$2%$1 ,0! 9#5%/5 -. 6#+%-35 S,!!+%$1 S75,!"5 8 D%..!+!$,%#&'

A9-3, 5,!!+%$1 575,!"5

The purpose of the steering system is to allow the driver to control the direction of the vehicle by turning the front wheels. Together with the suspension system, it plays an important role in ensuring easy, comfortable driving all the way from the low speed range to the high.speed ranges. A good and efficient steering system has to ensure the followingF 6. EF/!&&!$, M#$!36!+#9%&%,7F ;hen the car is cornering on a narrow, twisting road, the steering system must be able to turn the front wheels sharply yet easily and smoothly.
:. P+-*!+ S,!!+%$1 E..-+,F If nothing is done to prevent it, steering effort

will be greater when the car is stopped and will decrease as the speed of the car increases. Therefore, in order to obtain easier steering and better feel of the road, the steering should be made lighter at low speeds and heavier at high speeds. 2. S"--,0 R!/-6!+7F ;hile the car is turning, the driver must hole the steering wheel firmly. After the turn is completed, however, recovery. that is, the return of the wheels to the straight.ahead position. should occur smoothly as the driver relaxes the force with which he is turning the steering wheel. ?. M%$%"3" ,+#$5"%55%-$ -. S0-/< .+-" R-#2 S3+.#/!F ,oss of steering wheel control and transmission of %ic%bac% due to road surface must not occur. The main components of a steering system are the 5,!!+%$1 =0!!&, a 5,!!+%$1 /-&3"$ which transmits the rotation of the steering wheel to the steering gears, the 5,!!+%$1 1!#+5 which increase the rotational force of the steering wheel in

order to transmit greater torJue to the steering lin%age, and the 5,!!+%$1 &%$<#1! which transmits the steering gear movement to the front wheels. 6. S,!!+%$1 4-&3"$F The steering column consists of the "#%$ 5,!!+%$1 50#.,, which transmits the steering wheel rotation to the steering gear, and the /-&3"$ ,39! that fixes the steering main shaft to body. The top end of the steering main shaft is tapered and serrated, and a nut fits the steering wheel to it. The bottom end of the steering main shaft is connected to the steering gear, generally by way of a universal oint to minimize the transmission of road shoc% from the steering gear to the steering wheel.

STEERING 4OLUMN ASSEM LY :. S,!!+%$1 G!#+F The gears in the steering gears in the steering gear

assembly not only steer the front wheels but, at the same time they act as reduction gears, reducing steering wheel turning effort by increasing the output torJue. The reduction ratio is called the steering gear ratio and is normally between 6= and :9F6. A larger ratio reduces the 2. &teering effort bur ma%es it necessary to turn the steering wheel more when going around a curve.

There are various types of steering gear systems, but the +#/<-#$2-*%$%-$ ,7*! (RPS) and the +!/%+/3&#,%$1-9#&& ,7*! (R S) are most commonly used on current vehicles. &'(A )'*' &TEE!I(+ &*&TE$& ,I$ITE" 0&)&&,1 produces both types of steering systems.
?. S,!!+%$1 L%$<#1!F A steering lin%age is a combination of the rods and

arms that transmit the movement of the steering gear to the left and right front wheels. The steering lin%age must accurately transmit the movement of the steering wheel to the front wheels as they move up and down while the car is in motion. ?ARIOUS TYPE O: STEERING LINKAGE 4OMPONENTS 6. P%,"#$ A+"F It transmits the movement of the steering gear to the relay rod or drag lin%. The large eng of the arm is taper.splinted to the sector shaft of the steering gear and fixed by a nut. The small end is connected to the relay rod or drag lin% by a ball oint. :. R!&#7 R-2F It is lin%ed to the pitman arm and the left and right tie rods. It transmits the motion of the pitman arm to the tie rods. It is also lin%ed to the idler arm. 2. T%! R-2F The tie rod end screws into the rac% end of rac%.and.pinion assembly, or into the ad usting tube on recirculating.ball steering, so that the distance between oints can be ad usted. ?. T%! R-2 E$2F Tie rod ends are mounted on the ends of tie rods to connect the tie rods with %nuc%le arms, relay rod etc. A tie rod incorporating a spring for preloading and wear compensation is also used. 7. K$3/<&! A+"5F They transmit the movement of the tie rods to the front wheels via the steering %nuc%les.

5. S,!!+%$1 K$3/<&!F &teering %nuc%les support the load applied to the front wheel, and also function as the rotational axes of the wheels. @. I2&!+ A+"F The pivot of the arm is installed to the body, and the other end of is connected to the relay rod by a swivel oint. This arm supports one end of the relay rod, and restricts the motion of the relay rod to the proper range. =. D+#1 L%$<F The drag lin% connects the pitman arm to the %nuc%le arm, acting as a lin% that transmits the forward and bac%ward, and left and right movements of the pitman arm.

M#$3#& S,!!+%$1 S75,!"5

RA4K-AND-PINION STEERING:

R#/<-#$2-*%$%-$ 5,!!+%$1 is Juic%ly becoming the most common type of steering on cars, small truc%s and &CBs. It is actually a pretty simple mechanism. A rac%.and.pinion gear set is enclosed in a metal tube, with each end of the rac% protruding from the tube. A rod, called a ,%! +-2, connects to each end of the rac%.

<ust Coot 8ack Cushing Steering 1inion Inner Tie 8od

Tie 8od 9ock 5ut

Steering 8ack

ASSEM-L' 2%EW O) $ACK AND P%N%ON STEE$%NG The *%$%-$ 1!#+ is attached to the 5,!!+%$1 50#.,. ;hen you turn the steering wheel, the gear spins, moving the rac%. The tie rod at each end of the rac% connects to the 5,!!+%$1 #+" on the 5*%$2&! 0see diagram above1. The rac%.and.pinion gear set does two thingsF It converts the rotational motion of the steering wheel into the linear motion needed to turn the wheels. It provides a gear reduction, ma%ing it easier to turn the wheels. 'n most cars, it ta%es three to four complete revolutions of the steering wheel to ma%e the wheels turn from loc% to loc% 0from far left to far right1. The 5,!!+%$1 +#,%- is the ratio of how far you turn the steering wheel to how far the wheels turn. Aor instance, if one complete revolution 0259 degrees1 of the steering wheel results in the wheels of the car turning :9 degrees, then the steering ratio is 259 divided by :9, or 6=F6. A higher ratio means that you have to turn the steering wheel more to get the wheels to turn a given distance. -owever, less effort is reJuired because of the higher gear ratio. +enerally, lighter, sportier cars have lower steering ratios than larger cars and truc%s. The lower ratio gives the steering a Juic%er response .. you donSt have to turn the steering wheel as much to get the wheels to turn a given distance .. which is a desirable trait in sports cars. These smaller cars are light enough that even with the lower ratio, the effort reJuired to turn the steering wheel is not excessive. &ome cars have 6#+%#9&!-+#,%- 5,!!+%$1, which uses a rac%.and.pinion gear set that has a different tooth pitch 0number of teeth per inch1 in the center than it has on the outside. This ma%es the car respond Juic%ly when starting a turn 0the rac% is near the center1, and also reduces effort near the wheelSs turning limits.

S*!/%#& .!#,3+!5
061 I$!F*!$5%6! +enerally when rac% and pinion steering is used the gearbox is fitted into the steering lin% structure. The ,in%ages are very much reduced because the !P& is complete in itself. Therefore the cost is much cheaper with respect to other types. 0:1 L%10, %$ =!%10, As a steering gear assembly the no. of lin%ages are less. Arom the angle of strength the material of gearbox is aluminum die cast compared to !/&, it is light in weight. 021 A S0#+* S,!!+%$1 .!!&%$1 /#$ 9! 0#2 In the case of !/& type steering the torJue applied to main shaft goes through the /all &crew to /all (ut and then to &ector +ear. Bis a Bis the !P& where !ac% and Pinion are in direct contact therefore, the feeling is sharper in response. At high speed driving there is a direction in the handle is steady and a sharp response can be need where the steering handle is turned. 0?1 S,+!$1,0 %5 0%10 In the !P& type the meshing force between the teeth of the gears is lower in comparison to the !/& type, therefore the impact strength can be higher. 071 N-%5! #$2 $%,+#,%-$ /-3$,!+"!#53+! The gear portion and the rac% bush in the !P& steering are the negative points of the !P& steering as compared to the !/& type, the noise through their interference and the vibration arising due to type and the steering line portion and rac% bush. /y the usage of anti vibration ball oints a satisfactory fitting can be had.

M!+%,5 -. ,0! R#/<-#$2-P%$%-$ 5,!!+%$1 1!#+F

6. 3onstruction is simple, compact and lightweight. &ince the gear box is small, and the rac% itself acts as the steering lin%age, the relay rods used in the !ecirculating.ball type are not necessary. :. +ear meshing is direct, so steering response is very sharp.

2. There is little sliding and rotational resistance and the torJue transmission is better, so the steering is light. ?. The steering gear assembly is completely sealed so it is maintenance free.

RE4IR4ULATING- ALL STEERING R!/%+/3&#,%$1-9#&& 5,!!+%$1 is used on many truc%s and &CBs today. The lin%age that turns the wheels is slightly different than on a rac%.and.pinion system.

The re.circulating.ball steering gear contains a worn gear you can image the gear in two parts. The first part is a bloc% of metal with a threaded hole in it. This bloc% has gear teeth cut into the outside of it, which engage a gear that moves the *%,"#$ #+" 0see diagram above1.

The steering wheel connects to a threaded rod, similar to a bolt, that stic%s into

8eturn Tube @orm Shaft

Call 5ut

Sector gear

the hole in the bloc%. ;hen the steering wheel turns, it turns the bolt. Instead of twisting further into the bloc% the way a regular bolt would, this bolt is held fixed so that when it spins, it moves the bloc%, which moves the gear that turns the wheels. Instead of the bolt directly engaging the threads in the bloc%, all of the threads are filled with ball bearing that re.circulates through the gear as it turns. The balls actually serve two purposesF Airst, they reduce friction and wear in the gearR second, they reduce 5&-* in the gear. &lop would be felt when you change the direction of the steering wheel .. without the balls in the steering gear, the teeth would come out of contact with each other for a moment, ma%ing the steering wheel feel loose.

7ross Shaft Call 5ut 4ain Shaft

Call Tubes Calls #ousing

4OMPLETE 8 EKPLODED ?IEA O: R S

S*!/%#& .!#,3+!5:
061 H#$2&! %5 &%10, -ighly efficient 0about =7E1, very light, very little fatigue even in long distance driving. Especially our patented product of variable ratio steering. Even when full rotation of the steering wheel is reJuired the handle is still light. In the neutral position the steering has a very sharp response, the steering feeling at low speed and high speed is extremely good. 0:1 S,#9%&%,7 %5 1--2 Appropriate gear ratio has been achieved through research in design and along with the guarantee of a comfortable driving and exceptional stability at high speeds can be achieved with the employment of variable ratio gear. 021 D!*!$2#9%&%,7 Turning of the handle is very smooth, especially at high speeds the dependability and certainty of turning is very high. 0?1 H%10 E$23+#$/! -. S#.!,7 The critical parts have been selected through extensive tests and are of high Jualities carburised steel and with the help of highly balanced design. The parts

are exceptional in anti impact Jualities and the wear is very little even in long term use.

M!+%,5 -. ,0! R!/%+/3&#,%$1- #&& T7*! 5,!!+%$1 1!#+:

6. Efficiency is high 0about =7E1, ma%ing it light and causing a very little fatigue, even in long distance travel. :. It is more stable at higher speeds. 2. It has high endurance ma%ing the wear low even in long.term use. ?. Turning of the handle is very smooth, thus the dependability and certainty of turning is very high.

POAER STEERING
NE4ESSITY: To improve the driving comfort, most modern automobiles have wide, low.pressure tires that increase the tire.to.road surface contact area. As a result, more steering effort is reJuired. Even though the steering effort can be decreased by increasing the gear ratio of the steering gear, this will ma%e sharp turns impossible. Thus, a steering assist is reJuired in the passenger cars as well.

POAER RA4K AND PINION STEERING

;hen the rac%.and.pinion is in a power.steering system, the rac% has a slightly different design.

Part of the rac% contains a cylinder with a piston in the middle. The piston is connected to the rac%. There are two fluid ports, one on either side of the piston. &upplying higher.pressure fluid to one side of the piston forces the piston to move, which in turn moves the rac%, providing the power assist.

A-+<%$1 -. P-=!+ S,!!+%$1 M!/0#$%5":

Power &teering is an assist device that helps %eep the steering agile and at the same %eeps the steering effort small. &'(A manufactures the rac% and pinion type power steering mechanism, which is primarily used in passenger cars. Power rac% and pinion steering assemblies are hydraulicGmechanical unit with an integral piston and rac% assembly. An internal rotary valve directs power steering fluid flow and controls pressure to reduce steering effort. The rac% and pinion is used to steer the car in the event of power steering failure, or if the engine 0that drives the pump1 stalls. ;hen the steering wheel is turned, resistance is created by the weight of the car and tire.to.road friction, causing a

torsion bar in the rotary valve to deflect. This changes the position of the valve spool and sleeve, thereby directing fluid under pressure to the proper end of the attached to the rac%1 helps move the rac% to reduce turning effort. The fluid in the other end of the power cylinder is forced to the control valve and bac% to the pump reservoir. ;hen the steering effort stops, the control valve is centered by

DE:INATION O: POAER STEERING:

A means of hydraulically assisted steering. A belt.driven power steering pump creates system pressure. The pressurized fluid is then routed into a cylinder that helps push the wheels one.way or the other when the steering wheel is turned. The two most common power steering complaints are noise and lea%s. A slipping drive.belt on the power steering pump can produce a loud sJueal, especially when turning sharply. A bad valve or bearings in the pump itself can ma%e a growling noise. ,ea%s most often occur at hose couplings or on the power cylinder seals. In power rac% 4 pinion steering units, internal lea%s can be a ma or problem 0which reJuire replacing the entire unit with a new or rebuilt assembly1. The only reJuired maintenance for this system is to chec% the level of the power steering fluid periodically. If low, chec% for possible lea%s, and then add fresh fluid to the pump reservoir. !unning the system low can ruin the pump. Part of the rac% contains a cylinder with a piston in the middle. The piston is connected to the rac%. There are two fluid ports, one on either side of the piston. &upplying higher. pressure fluid to one side of the piston forces the piston to move, which in turn moves the rac%, providing the power assist. the twisting force of the torsion bar, pressure is eJualized on both sides of the

S,!!+%$1 4-&3"$ I"*#/, A95-+9%$1 M!/0#$%5"

;hen a car is involved in a collision, this mechanism helps prevent the main shaft from during the driver in two waysF by the brea%ing at the time of the collision 0*+%"#+7 50-/<1R and by reducing the 5!/-$2#+7 50-/< imposed upon the driverOs body when it hits the steering wheel due to inertia. In &'(A, the manufacture of !$2%$1 +#/<!, T7*! impact absorbing and #&& T7*! impact absorbing columns is ta%ing place. The steering main shaft is divided into upper and lower sections, which are connected by plastic pins. The steering column 9+!#<#=#7 9+#/<!, is bolted to the vehicle via two /#*53&!5. The capsules are installed onto the column upper brac%et with four plastic pins. ;hen the vehicle collides with an obstacle and a sufficiently strong thrust force is applied by the steering gear to the main shaft, the shoc% 0primary1 brea%s the plastic pins of the main shaft. The lower main shaft slides upward into the upper main shaft to prevent the steering wheel as a whole from moving and in uring the driver. If the body of the driver hits the steering wheel 0secondary shoc%, the brea%away brac%et comes off from the capsules, shearing off the plastic pins. In the bending brac%et mechanism, the column is supported at the lower end by another brac%et, called the bending brac%et. The entire steering column moves, with the bending brac%et bending and deforming, thus absorbing the force. In the ball type impact absorption mechanism, the column itself is divided into two parts, which have balls between them. In case of an impact, with the shearing of the plastic pins oining brea%away brac%et to the body of the vehicle, upper part of the column slides over the lower one and the balls between them absorb the impact energy in the process.

4OLLAPSI LE 4OLUMN

I((E! 8A3)ET

'CTE! 8A3)ET

!ETAI(E!

In recent times with increase in automobile accidents, the progress of research into how far the life of the driver can be protected has resulted in the development of a new product called collapsible column 0Impact absorbing type column1, In case of an automobile accident where the chart of the driver stri%e the handle and due to the collapsing nature of the handle the shoc% of the impact is reduced thereby preventing a death in the accident. In our country from 6st 'ctO6>@2 a rule was implemented which specifies that all the automobiles sold in the domestic mar%et must have the above mentioned impact absorbing handle. In other words itOs a contraption, which has been made as a product because of safety regulations. 'ur company developed a product, which matched well with the impact features of the vehicle under special license from +.$. for the 6st ma%ers of the automobile in the ;orld. 'ur company started using it on 6:99cc -onda in 6>@: and as such the history of the product is very. /ut our companyOs !4" has brought up the product as a high technology, high safety and presently due to the independent development of collapsible column by our company, it is being used in $itsubishi "ebonair, "iamate, &herio, +T' and &uzu%i Alto. 1':3$/,%-$5, =0%/0 # /-&&#*5%9&! /-&3"$ "35, 0#6! In case of an accident a collapsible column must have the ability to abort the shoc% due to the impact on the handle when the driver stri%es. Along side being a product when protects the drivers it must have the function of normal steering. ,egally it should satisfy safety regulations 0A$B&&.:921. In the experimentation rooms the column must satisfy and collapse at force of 6627 )gf due to the burst portion of the dummy body stri%e. 2'S,+3/,3+!

The collapsible column is an apparatus, which absorbs the impact to the body from the handle at the time of collision and the structural parts, are column, 8ac%et, steering shaft column brac%et etc. 2'1 4-&3"$ J#/<!, 3olumn 8ac%et is that part which is the extreme outer side of the collapsible column and which covers the steering chart. The structure is made up of two points outer and inner ac%et where lots of steel balls are press fitted. Their balls are located with retainers of resin, and are press fitted with a slightly higher dimension about 9.6mm over the I", '" of the 8ac%et. The size of the balls decides the interference load between the outer and inner 8ac%ets and thus the collapsing load of the 8ac%et. (ormally about :99 V 279 )gf is the load at which it collapses. &teering &haft The steering shaft is that part that is connected to the handle and steering gear and is made up of upper shaft, shaft tube and lower shaft. ;elding oins upper shaft and tube. The shaft tube has holes of W : 4 W 2. The upper shaft and upper shaft tube are oined by a resin which is inspection molded. 'n impact the resin pin brea%s down and the shaft enter into the shaft tube thereby absorbing the impact 0normally 679 V 299 )gf1. 2'2 4-&3"$ +#/<!, The column brac%et is that part which is used for fitting the 3olumn 8ac%et to the body of the car, and it is made up of brac%et main body and capsule. The capsule is hale to the main body of the car and the brac%et is fixed to the column ac%et. The capsule and the brac%et both have small holes. The polyethenal resin is in ect through the holes and is connected by a pin of resin. It is possible to change the resistance by change the resistance by changing the dia of resin pin by changing the hole dia. (ormally at a load of 699V:99 )gf this pin brea%s and along with the absorption of the impact the column brac%et and capsule get separated.

S,+3/,3+! -. %"*#/, #95-+*,%-$ #, ,0! ,%"! -. /-&&%5%-$

061 At the time of collision the shaft tend to enter the chamber because of the force it removes, but due to the structure of the brac%et being such it does not slide into the chamber. 0:1 ;hen the driver is thrown to the chamber and he stri%es the steering wheel and the process of energy absorption starts because of the resin pin when the load comes on to the shaft and if the load cross a particular limit the pin brea%s and the collapsing of the shaft t the front starts. 021 "ue to the handle wheel stri%ing the column ac%ets upper portion the column ac%et gets pushed and the load comes on to the column brac%et which fixes the column ac%et to the body of the car and the process of energy absorption starts by the resin pin which is in ection moulded between capsule and column brac%ets and if the load crosses a particular limit the pin brea%s and the column upper brac%et and capsule separates. 0?1 Aurther when the column 8ac%et is pushed the load comes on to the press fitted balls between outer and inner ac%et. The energy absorption starts simultaneously due to the ball press fit portion the outer ac%et collapses when sliding.

T0! U$%6!+5#& J-%$, (U-D-%$,):

The Cniversal oint 0C. oint1 is used to connect the drive shaft to the transmission output shaft and the "ifferential

pinion gear shaft. This oint must be flexible enough to allow changes in the driving angle 0road incline1 and the drive shaft. This way, the torJue is constantly transmitted when the rear axle is moving up and down. &maller C. oints are used to route the turning motion of the steering wheel through the steering column to the steering box. There are two types of C. oints, the cross and roller type and the ball and trunnion type. The cross and roller type is used the mostR it allows the drive shaft to bend. The ball and trunnion type less freJuently usedR it allows the drive shaft to bend and also permits bac%ward and forward motion of the drive shaft.

A07 A! N!!2 # D%..!+!$,%#&

3ar wheels spin at different speeds, especially when turning. ;e can see from the picture below that each wheel travels a different distance through the turn, and that the inside wheels travel a shorter distance than the outside wheels. &ince speed is eJual to the distance traveled divided by the time it ta%es to go

that distance, the wheels that travel a shorter distance travel at a lower speed. Also note that the front wheels travel a different distance than the rear wheels. Aor the $-$-2+%6!$ =0!!&5 on a car .. the front wheels on a rear.wheel drive car, the bac% wheels on a front.wheel drive car .. this is not an issue. There is no connection between them, so they spin independently. /ut the driven wheels are lin%ed together so that a single engine and transmission can turn both wheels. If our car did not have a differential, the wheels would have to be loc%ed together, forced to spin at the same speed. This would ma%e turning difficult and hard on your carF Aor the car to be able to turn, one tire would have to slip. ;ith modern tires and concrete roads, a great deal of force is reJuired to ma%e a tire slip. That force would have to be transmitted through the axle from one wheel to another, putting a heavy strain on the axle components. The differential is a device that splits the engine torJue two ways, allowing each output to spin at a different speed. The differential is found on all modern cars and truc%s, and also in many all. wheel.drive 0full.time four.wheel.drive1 vehicles. These all.wheel.drive vehicles need a differential between each set of drive wheels, and they need one between the front and the bac% wheels as well, because the front wheels travel a different distance through a turn than the rear wheels The differential has three obsF To aim the engine power at the wheels To act as the final gear reduction in the vehicle, slowing the rotational speed of the transmission one final time before it hits the wheels To transmit the power to the wheels while allowing them to rotate at different speeds 0This is the one that earned the differential its name.1

Part.time four.wheel.drive systems donSt have a differential between the front and rear wheelsR instead, they are loc%ed together so that the front and rear wheels have to turn at the same average speed. This is why these vehicles are hard to turn on concrete when the four.wheel. drive system is engaged.

S*%$$%$1 #, D%..!+!$, S*!!25 ;hen a car is driving straight down the road, both drive wheels are spinning at the same speed. The %$*3, *%$%-$ is turning the ring gear and cage, and none of the pinions within the cage are rotating .. both side gears are effectively loc%ed to the cage. The input pinion is a smaller gear than the ring gearR this is the last gear reduction in the car. The terms li%e +!#+ #F&! +#,%- or .%$#& 2+%6! +#,%- refer to the gear ratio in the differential. If the final drive ratio is ?.69, then the ring gear has ?.69 times as many teeth as the input pinion gear. ;hen a car ma%es a turn, the wheels must spin at different speeds. The pinions in the cage start to spin as the car begins to turn, allowing the wheels to move at different speeds. The inside wheel spins slower than the cage, while the outside wheel spins faster.

P+-9&!" =%,0 O*!$ D%..!+!$,%#&5 The open differential #&=#75 #**&%!5 ,0! 5#"! #"-3$, -. ,-+G3! ,- !#/0 =0!!&. There are two factors that determine how much torJue can be applied to the wheelsF eJuipment and traction. In dry conditions, when there is plenty of traction, the amount of torJue applied to the wheels is limited by the engine and gearingR in a low traction situation, such as when driving on ice, the amount of torJue is limited to the greatest amount that will not cause a wheel to slip under those conditions. &o, even though a car may be able to produce more torJue, there needs to be enough traction to transmit that torJue to the ground. If the car is given more gas after the wheels start to slip, the wheels will ust spin faster. If a car is driven on ice, then there is a tric% that ma%es acceleration easierF If started out in second gear, or even third gear, instead of first, because of the gearing in the transmission you will have less torJue available to the wheels. This will ma%e it easier to accelerate without spinning the wheels. (ow what happens if one of the drive wheels has good traction, and the other one is on iceP This is where the problem with open differentials comes in. !emember that the open differential always applies the same torJue to both wheels, and the maximum amount of torJue is limited to the greatest amount that will not ma%e the wheels slip. It doesnSt ta%e much torJue to ma%e a tire slip on ice. And when the wheel with good traction is only getting the very small amount of torJue that can be applied to the wheel with less traction, your car isnSt going to move very much. Another time open differentials might get you into trouble is when you are driving off.road. If you have a four.wheel drive truc%, or an &CB, with an open differential on both the front and the bac%, you could get stuc%. If one of the front tires and one of the bac% tires comes off the ground, they will ust spin helplessly in the air, and you wonSt be able to move at all. The solution to these problems is the &%"%,!2 5&%* 2%..!+!$,%#& 0,&"1, sometimes called *-5%,+#/,%-$. ,imited slip differentials use various mechanisms to allow normal differential action when going around turns. ;hen a wheel slips, they allow more torJue to be transferred to the non.slipping wheel.

The next few sections will detail some of the different types of limited slip differentials, including the clutch.type ,&", the viscous coupling, loc%ing differential and Torsen differential. The gearing of an automobile differential is illustrated as following in final form. ;ithout the XsJuareX set of four gears in the middle of the above diagram which yields to the figure below, both wheels turn at the same angular velocity. This leads to problems when the car negotiates a turn.

A3,-"-9%&! A0!!& D+%6! =%,0-3, D%..!+!$,%#&

DI::ERENTIAL OPERATION: The differential is the thing that wor%s both drive axles at the same time, but lets them rotate at different speeds so that the car can ma%e turns. ;hen a car ma%es a turn, the outer wheel has to turn faster than the inner wheel, due to the

difference in the length of the paths they ta%e. The differential is located between the two wheels, and is attached to each wheel by a half.shaft rotated through a bevel gear. Aour.wheel drive cars have a separate differential for each pair of wheels.

0"ifferential Assembly1 A grooved, or splined, axle side gear is positioned on the splined end of each axle. The side gears are driven by XspiderX gears, which are little gears mounted on a shaft attached to the differential case. As it is supported by the differential case, the side gear can turn inside the case. The differential case can be turned, revolving around the axle gears. The differential pinion 0a pinion is a small gear that either drives a larger gear or is driven by one1 shaft turns the ring gear, which is fastened to the differential case. The propeller shaft 0drive shaft1 connects the transmission output shaft to the differential pinion shaft. The turning differential case is mounted on two large bearing holders. These bearings are called carrier bearings.

(A-+<%$1 -. D%..!+!$,%#& U$%,) The propeller shaft rotates the ring gear pinion, and the pinion turns the ring gear. The ring gear then turns the differential case and pinion shaft, but the axle side gears will not turn. /y passing the differential pinion shaft through two

differential pinion gears that mesh with the side gears, the case will turn and the axle side gears will turn with it. "uring turns, the side gears turn at rates dictated by the radius of the turns, and the spider gears then turn to allow the outer wheel to turn faster than the inner one. 4ASE DI::ERENTIAL

AKLE ASSEM LY

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The drive shaft, or propeller shaft, connects the transmission output shaft to the differential pinion shaft. &ince all roads are not perfectly smooth, and the transmission is fixed, the drive shaft has to be flexible to absorb the shoc% of bumps in the road. Cniversal, or XC. ointsX allow the drive shaft to flex 0and stop it from brea%ing1 when the drive angle changes. "rive shafts are usually hollow in order to weigh less, but of a large diameter so that they are strong. -igh Juality steel, and sometimes aluminum are used in the manufacture of the drive shaft. The shaft must be Juite straight and balanced to avoid vibrating. &ince it usually turns at engine speeds, a lot of damage can be caused if the shaft is unbalanced, or bent. "amage can also be caused if the C. oints are worn out.

There are two types of drive shafts, the -otch%iss drive and the TorJue Tube "rive. The -otch%iss drive is made up of a drive shaft connected to the transmission output shaft and the differential pinion gear shaft. C. oints are used in the front and rear. The -otch%iss drive transfers the torJue of the output shaft to the differential. (o wheel drive thrust is sent to the drive shaft. &ometimes this drive comes in two pieces to reduce vibration and ma%e it easier to install 0in this case, three C. oints are needed1. The two.piece types need ball bearings in a dustproof housing as center support for the shafts. !ubber is added into this arrangement for noise and vibration reduction. The torJue tube drive shaft is used if the drive shaft has to carry the wheel drive thrust. It is a hollow steel tube that extends from the transmission to the rear axle housing. 'ne end is fastened to the axle housing by bolts. The transmission end is fastened with a torJue ball. The drive shaft fits into the torJue tube. A C. oint is located in the torJue ball, and the axle.housing end is splined to the pinion gear shaft. "rive thrust is sent through the torJue tube to the torJue ball, to transmission, to engine and finally, to the frame through the engine mounts. That is, the torJue tube pressing on the engine pushes the car forward.

:%$#& I$5*!/,%-$ 40!/< -. D%..!+!$,%#& 9!.-+! D%5*#,/0%$1 (21/06/200@) "ifferential of Telco S'N' 6. 40!/< I,!" Tapping L-/#,%-$ Alange -oles 069 nos.1 M!,0-2 Bisual

:. 2. ?. 7. 5. @. =. >. 69. 66.

3rown ;heel "ia &haft -ole "iameter 3irclip /earing "ia &erration of gears +ear $ovement "entGrustGdamage /low -oles Extra materials Assy. /atch code, card number

'n Alange &ide of 3ase "ifferential Inner "ia, /oth sides &pider &haft 'uter "ia, both sides +ear "ifferential +ear "iff. $achining Area All mGc areas 3asting Area Alange Aace

!ing +auge Plug +auge Bisual &nap +auge &erration $andrel -and feel Bisual Bisual Bisual $ar%ed by mar%er

A26#$,#1!5 -. :%$#& I$5*!/,%-$: To prevent defective product from reaching customer. To improve companyOs productivity and companyOs mar%et image. To prevent probability of accident, by preventing defective product dispatching. To %now and rectify the production method which may be leading to defective product being manufactured.

I. 2!.!/,%6! *+-23/, +!#/0!5 /35,-"!+ ,0#$, If shaft circlip absent than, than gears may get open, leading to accident. If tapping absent than the ring gear tightening will be a difficulty. If '"GI" not correct within tolerances, than shaft may not insert or will be loosely held. If holes are present in oil gallery, than there can be chances of lea%ages. Presence of !ust may lead to reducing of life of differential. Presence of chips etc. may interfere in wor%ing of gears of differential. 40!/<%$1 R-3,%$!: The whole lot being dispatched is chec%ed thoroughly with each and every piece being chec%ed properly in prescribed order being mentioned previously.

P+!*#+#,%-$ -. P+-23/, 4#,#&-13! .-+ S,#$2#+2%I#,%-$ -. S-$# K-7- P+-23/,5 USING AIND4HILL

P+!*#+#,%-$ -. P+-23/, 4#,#&-13! .-+ S,#$2#+2%I#,%-$ -. S-$# K-7- P+-23/,5: T0! *+!*#+#,%-$ -. /#,#&-13! %$/&32!2: &earching of various varieties of similar product using ;I("3-I,, in companyOs &erver. Identifying of various parameters common in various different varieties of similar product from drawing sheets

such as diameters, lengths, hardness, material type, hole diameters, pitch of threads, etc. After identifying them, than creating a database of all these parameters of similar %ind of product, which could be seen later on for %nowing the dimensions of various parts without even loo%ing into the drawing sheets. A26#$,#1!5 -. P+!*#+#,%-$ -. 4#,#&-13!: "esign Time !eduction 3ost !eduction &tandardization $inimum Inventory !eduction in "evelopment 3ost ,ess Bariety

Preparation of catalogue also helps in (ew Product development of the company. N!= P+-23/, D!5%1$ P+-/!55: "ecision to start $aster "evelopment &cheme Pro ect Assignment 3onsolidate "esign "eptt Propose Production "esign 4 "evelopment Plans 3oncept "esign 3oncept Ainalizations (ew Product &heet Evaluation A$EA 3onverting Inputs to 'utputs "esign !evision 6

Prototype "esign "esign Balidation "esign !evision : Prototype $anufacturing "esign !evision 2 3ost Approximation !edo Ainal drawings Prelaunch sample mGf "esign !evision ? "esign Ainalization 4 $anufacturing

The various products which were being standardized under this product are as followsF
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Part Name

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&uppose you want an extrusion centered on a rectangular surface. *ou could place the extrusion by measuring half the sides of the rectangle and using dimensions to locate its x.y position. /ut your design intent is to have the extrusion centered, even if the length or width of the surface changes. ProGE gives you the tools at every level to build in this %ind of information. In this instance, you could constrain the extrusion to be centered between the four referenced edges. The x. and y.coordinates of the extrusion will always eJual half of the length and width of the rectangular surface. This way ProGE does the wor% of calculating and updating the extrusionSs position no matter what the dimensions of the rectangle are. *ou can use these and other processes to define simple geometry, or you can use them with more complex calculations li%e mass, volume, or center of gravity. (eedless to say, establishing these parametric relationships between design entities can save an enormous amount of time and effort when engineering changes are reJuired. The more associative information that you build into the model, the more you can Juic%ly experiment with new solutions in the design as they occur to you.

E$2-,--E$2 A55-/%#,%6%,7:
ProGE not only lets you design individual parts Juic%ly, it also records their assembly relationships and produces finished mechanical drawings. Throughout the wor%flow, from any stage, ProGE ma%es it easy for you to access and edit the dimensions and parametric associations you established at any other stage. Even in the drawing stage, the dimensions that show on the plot are derived from the 2" model dimensions, and remain dynamically lin%ed to the source 2" files. The lin% is bidirectional, so you can edit the 2" part directly from the drawing to ma%e sure that the dimensions in the drawing and in the model are always in synch.

P+-/E #5%/ D!5%1$ M-2!5:

;hen you bring a design from conception to completion in ProGE, you pass the design information through three basic design stepsF Y 3reating the component parts of the design Y 8oining the parts in an assembly that records the relative positions of the parts Y 3reating mechanical drawings based on the information in the parts and the assembly ProGE considers these steps as separate modes, each with its own characteristics, file extensions, and relations with the other modes. As you build a design model it is important to remember that all informationHdimensions, tolerances, and relational formulasHare passed from one mode to the next bidirectionally. This means that if you change your design at any mode level, ProGE reflects it at all mode levels automatically. If you plan ahead and use the associative features correctly, you can save significant time in the design and engineering change order process.

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;hen you start a new part, three datum planes and a coordinate system are added for you. The datum planes are automatically named Aront, Top, and

!ight. The coordinate system indicates the x., y., and z.axes. The positive z.axis is perpendicular to the front datum plane. If you orient the datums so the Aront plane is flat to the screen, the z.axis is perpendicular to the screen. "atums are points of reference in space that ProGE uses to calculate distances. "atums can be actual points, planes, or curves, but they have no value for thic%ness. *ou will create and place them freJuently for a variety of uses in both Part and Assembly modes. ,i%e solid features, datums are added to the $odel Tree as you create them. They are named numerically by default, for example "T$6, "T$: 0for datum planes1 or P(T6, P(T:, 0for datum points1. *ou can rename them to better describe their purpose after they are added.

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The &%etcher is best described as a submode of Part mode. *ou could regard it as a :" drafting board within the 2" environment. *ou will use it to create most of the geometric shapes you use in a part. Associative details that you build into a s%etch, or section, such as geometric constraints or relations between dimensions act as a foundation for all other additions and edits to follow.

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In ProGE(+I(EE!, 2" ob ects begin as :" outlines. After the :" outline is defined with x and y dimensions, it is given a z dimension, or depth, that brings it to 2". The purpose of &%etcher is to let you literally Xs%etchX an imprecise or exaggerated :" profile of the part you want to create.

After you s%etch the lines, you enter the precise lengths, angles, and radii as needed. This saves you from having to laboriously count grid lines or use on. screen rulers, as you would with a simpler drafting program. &%etcher adds dimensions, complete with arrows and witness lines, as you draw. These are called wea% dimensions, they are XguessesX that &%etcher is ma%ing. +oing from &%etch to 2" ;hen a &%etcher section gains depth, or a z. dimension, it becomes a 2" geometric entity called an extrusion. The extrusion may add or remove material. In other words it may be a solid, or it may be a cut. Aor an example of a solid, imagine a :" circle extruding outward to create a cylinder. An extrusion created as a cut removes material from any solid it passes through. Aor example, a bolt hole through a plate may be a circular section placed on the surface of the plate as a cut, and extruded through the plate. *ou donSt have to define the extrusion as a cut or a solid when you create it, you can toggle the cut or solid property at any time. Extrusions may be defined in several ways. Aor example, both protrusions and cuts may be extruded, where depth is added directly to a section, or revolved, where the depth of the cut or solid is added in degrees around an axis.

Pro3%NT$AL%NK4
;hen multiple people wor% together on a product, providing access, managing everyoneOs data and integrating revisions is critical to delivering a product on time. Arom wor%groups to enterprise.wide deployments, PT3 enables engineers to focus on creating innovative designs and ma%ing 3A" data management a bac%ground process. PT3 offers three deployment options to choose fromF ProGI(T!A,I(), ;indchill, or layered together. A-+<1+-3* 2#,# "#$#1!"!$, ;ith production.proven ProGE(+I(EE! wor%group data management capabilities, ProGI(T!A,I() is the industry.standard solution to manage concurrent design teams and the power of ProGE(+I(EE! data associativity. Engineers easily perform data management tas%s, so they can concentrate on innovative product design. The resultF more control, higher Juality designs, and happier engineers. In ProGI(T!A,I() the tool used to search the 3ommon space is called ,ocate. 4#*#9%&%,%!5 8 !$!.%,5:

3ommon wor%ing environment and methodologies for ProGE(+I(EE! users that improve engineering efficiency 3entralized vaulting and revision control of ProGE(+I(EE! models, relationships, and functionality for improved information security and accuracy Individual and group level access control to control when changes are permitted, whom can ma%e them, and communicating changes broadly Powerful searching tools, product configuration reports, and easy copying G renaming of existing designs facilitates design reuse Intuitive user interface improves productivity simplifies data management activities.

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+o# t.is training #as .el" /l to me 5

I am than%ful to entire SONA family for providing me this golden opportunity, which made me to learn a lot of valuable things. In our college, we are taught theoretical %nowledge which is not sufficient to cope up in the industry. &o, here in SONA I learnt how production activities are carried and various activities are coordinated. -ere, I learnt the organizational behavior, which is a very important part of engineering education. I saw the various production activities, which were ust taught in the classroom to us. Practical %nowledge is entirely different from theoretical %nowledge , so it is very necessary to gain practical aspect of technical %nowledge. -ere in SONA I

learnt this thing i.e., practical %nowledge. -ere, I saw how ob ectives could be achieved by the hard wor% of a group. It is the hard wor% of the SONA family, which made them the mar%et leader in their field. It was a pleasure to see the SONA family members wor%ing with such devotion. &o, again, I than% the entire SONA group for ma%ing me familiar with the practical aspect of %nowledge.