Final Report Done1111

A
PROJECT REPORT
ON
Transmission and its maintenance

Submitted in partial fulfillment of the requirements of the award of the degree
of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
by
Shivam Anuj Agarwal

(PRN-13070121713)
UNDER THE GUIDANCE OF
Sir Nilesh Janpandit (External Guide)

Prof. Prabhakar Shinde (Internal Guide)
DEPARTMENT OF MECHANICAL ENGINEERING

SYMBIOSIS INSTITUTE OF TECHNOLOGY
(A CONSTITUENT OF SYMBIOSIS INTERNATIONAL UNIVERSITY)
PUNE-412115
(2016 - 2017)
Symbiosis Institute of Technology

(A Constituent of Symbiosis International University)
Symbiosis Knowledge of Village, Gram: Lavale, Tal. : Mulshi,
Pune-412115 , Maharashtra State, India
CERTIFICATE
The Project Report entitled Transmission system and its maintaince is delivered and
submitted by Mr. Shivam Agarwal (PRN -13070121713) of VI Semester for partial
fulfillment of requirement for the degree of B.Tech. in Mechanical Engineering of Symbiosis
International University during the academic year
Prof. Nitin Solke
2015-2016.
Prof. Prabhakar Shinde
(Head)
(Internal Guide)
Department of Mechanical Engineering
Department of Mechanical Engineering
EXAMINERS:
1) ---------------------------------------------2) ---------------------------------------------3) ----------------------------------------------
Date
Place :
ii
(Colour Photocopy/ Scan Copy of Company Certificate)

Certificate should be on letter head of company and its contents should at least specify
following:
1. Name of student
2. Name of project
3. Name of Industry Mentor as external guide
4. Duration of internship (Starting and completion date)
5. Company seal and signature.
iii
ACKNOWLEDGEMENT
I am thankful to Industry Mentor Shri. Nilesh Junpandit for giving me an opportunity to
work under him and allowing me to work on project related to Transmission and its
maintenance
I am thankful to Faculty Mentor Prof. Prabhakr Shinde for giving me time to time valuable
suggestions for completing monthly progress report , assignments and internship project.
I am thankful to Prof. Nitin sholke , Head of Department of Mechanical Engineering, for

his motivating and valuable support throughout the course.
I am also thankful to Shri. ________________ and Shri._________ for their guidance and
co-operation during completion of Seminar report.
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Mr. Shivam Agarwal

(PRN -14070121759)
iv
ABSTRACT
The engineering internship is about 180 days full time work placement with an industrial
partner conducted as an alternative pathway to an engineering thesis for third year
engineering student at Symbiosis Institute of Technology.
The purpose of internship is to provide engineering students with experience to the

world of engineering practice through a period of work place employment
This report details the work performed during an 180 days internship placement with
Pandit Automotive Pvt. Ltd. The report feature Transmission system and its
maintenance done during the period.
The future work required to be completed as the continuation of a work performed

during internship is presented.
CONTENTS
Chapter
Page
No.
No.
List of Figures
Viii
List of Tables
ix
List of Abbreviations
Introduction to Company
1.1
Introduction
1.2
Company Profile
1.2.1 Vision and mission
1.2.2 Brief History
1.2.4 Product and or Service Profile
1.2.5 Product range and profile
1.3
Organization structure
1.4
Achievements of the company
Introduction to Department
2.1
Introduction
2.2
Employees
2.3
Types of Machines present
1) Drilling machine
2) Lathe machine
3) Hydraulic press
4) Hydraulic press
5) Compressor
Process Chart
2.4
Study of transmission and differential

vi
11
3.1
Objectives of Project
11
3.3
Transmission
11
3.3.1 Methodology used
12
3.4
Differential
13
3.5
Function of transmission and differential
13
3.6
Types of transmission
14
3.6.1) Manual Transmission
14
3.6.2) Fully automatic
16
3.6.3) Semi automatic
18
3.6.4) CVT
20
Types of differential
22
3.7.1) open differential
22
3.7.2) Locking differential
23
3.7.3) Limited slip differential
24
3.7.4) Electronic Limited slip Differential
25
Types of transmission and differential in TATA motors
27
3.8
11
3.2
3.7
Introduction
Study of plant layout
28
4.1
Introduction
28
4.2
Definition
28
4.3
Determination of plant layout
28
4.4
Importance of plant layout
29
4.5
Objective of plant layout
29
4.6
Factor influencing plant layout
30
4.7
Dynamics of plant layout
30
4.8
Principle of plant layout
31
33
Types of layout
vii
5.1.
Process or Functional layout
33
5.2
Advantages
33
5.3
Disadvantages
34
5.4
Suitability of Process layout
34
5.5
Recent trends in plant layout
35
5.6
Factory building
36
5.7
Factors in designing factory building
38
5.8
Types of building
38
Plant layout and its implementation
39
6.1
Plant layout
39
6.2
Recommendation of plant layout
39
Introduction to industrial management
40
7.1
Introduction
40
7.2
Brief history
42
7.3
Significance of Industrial safety
43
7.4
Objective of industrial safety
44
7.5
Causes of industrial accident
44
7.6
Measures to ensure industrial safety
45
7.7
Four E' of safety
45
7.8
Recommendation of safety management
47
Introduction to inventory
49
8.1
Introduction
49
8.2
Inventory according to catalogue
49
8.3
Conclusions
summary
viii
List of Figures
Figure No.
Name of figure
Page No.
2.1
Drilling machine
2.2
Lathe machine
2.3
Hydraulic press
2.4
Hydraulic press
2.5
Compressor
3.1
Gear arrangement
15
3.2
Fully automatic transmission
17
3.3
Semi-automatic transmission
18
3.4
Paddle shift
18
3.5
CVT Transmission
20
3.6
Open differential
23
3.7
Locking differential
24
3.8
Limited slip differential
25
6.1
Plant layout
40
8.1
Gear shaft and gear
50
2.7
Gear shaft and gear
50
ix
List of Tables
Table
No.
2.1
Name of Table
Page No.
Processes
3.6
Types of transmission
14
3.7
Types of differential
22
List of Abbreviation
CVT
Continuously variable transmission
LSD
Limited slip differential
Auto LSD
Automatic Limited slip differential
HCV
Heavy commercial vehicle
SCV
Small commercial vehicle
xi
Chapter 1
INTRODUCTION TO COMPANY
1.1.
Introduction: -
Pandit Automotive is the authorized dealer and channel partner for Tata motors passenger
car and commercial vehicle business unit and for FIAT CHRYSLER India for Pune, Satara,
Sangli and Kolhapur districts in western Maharastra, India.
1.2.
Company Profile: -
Pandit Automotive Pvt. Ltd. Commercial workshop located at dange chowk road 49/2 B
Tathawade Taluka: mulshi district: Pune 411033.
Some basic information about the company is as follows:
Other plant location: Pune, satara, sangli and Kolhapur.
Activities carried out in different plants: Sales, Repair, Service of lights, Medium and
Heavy commercial vehicles and buses.
Total employees: 1200+ across functions.
Total employees in Tathwade: 125.
Market shares: 70% in Maharastra.
Annual turnover: 687 Cr.
Annual profit: ~10% of profit (approx).
Other plant location: Pune, satara, sangli and Kolhapur.
Activities carried out in different plants: Sales, Repair, Service of lights, Medium and
Heavy commercial vehicles and buses.
1.2.1. Vision and Mission of Company

Vision:
Pandit automotive envisions becoming a truly global automobile retail behemoth which will
impact our entire stakeholder in a positive way and which will give us the resources to give
back to the society.
Mission:
Pandit automotive aims to provide a world class automobile buying and ownership
experience to customers and also to ensure a conductive and convivial workplace for
employees.
1.2.2 Brief History

The Founder late Mr. R.H Pandit first started a small car repairing garage in Malabar Hill in
Mumbai under the name Malabar Motor in 1940. Thereafter with new opportunities
beckoning in Pune, a Caterpillar/Larsen and Turbo tractors spares shop called Ram agencies
was established in Pune in 1952. In 1956, the founder replied to an Ad in the newspaper
which declared the requirement of sub dealer for TATA MERCEDES trucks in Pune region.
The successful application resulted in Pandit Automotive being named as the sub dealer for
Bombay dealer DADAJI DHAKJEE and Co. for Pune region. In 1961, we successfully
graduated to being a full-fledge dealer for TELCO as it was then called, for Pune region.
Soon in the late 60s and early 70s the dealership started expanding to Satara and Sangli
regions of Maharastra. The impeccable service levels given to truck owners in those days led
to people from far flung places of Maharastra coming to Pandit Automotive to buy and
service their Tata trucks.
Thus brand Pandit started to symbolize trust, commitment to customers and highly
efficient service levels. Even the great J.R.D TATA was wholesome in his praise of our
commitment and social outlook. [1]
1.2.4 Product and service profile
Repair Quality: Each and every repair is carried out to strict quality standards, and
certified by a separate final quality check.
Time compliance: whenever a booking is made to repair or maintain a vehicle it is done

in a quoted delivery deadline.
Vehicle inspection: your car will be checked in your presence to verify its overall status
and no scheduled repair or additional work will be commenced without prior
explanation and consent.
Transparency of information: All work conducted are fully explained to ensure your
understanding and satisfaction.
Professionalism and Expertise: Technicians are trained and certified, and backed up by
the technical knowledge of the whole organizations.
Client Service: Detailed information regarding products and services, service network
and authorized service workshops can be accessed through website, email and phone
number.
1.2.5 Product Range and Profile
Spare parts
Maintenance
Repair works
Annual maintenance contacts
Washing
Greasing
Wheel alignment
1.3. Organization Structure
GM
AGM
WM1
S1
WM2
CRM
S2
SA1 SA2
G1
G1
S2
S1
G2
G2
SA3 SA4
G3
G4
G3
G4
SA1
SA2
G1
G1
G2
SA3 SA4
G2
G3
G3
G4
G4
1.4 Achievements of the company:

1. Western India Highest Sales for FIAT Vehicles.
2. All India 3rd Rank-Tata Motors Passenger Vehicle Sales.
3. All India 1st Rank-Tata Vista Sales.[2]
CHAPTER 2
INTRODUCTION TO DEPARTMENT
2.1 Introduction
Name of the department: Service department
Name of activity: Maintenance, servicing and retro-fitting of components in TATA

commercial vehicles
2.2 Employees
The company has a task force of 125 employees. The service department holds 110
technicians, the rest are office and customer relation staff.
2.3 Types of machines present:

Some of machines we came across are as follows
1. Drilling machine
Drilling machine is commonly found machine used to drill hole in metals and other hard
materials. This machine in the picture was kept at different machining room to drill hole in
certain parts or woods for other uses.
Fig. 2.1 drilling machine
2. Lathe machine
A lathe machine is used to rotate a work piece on its axis to perform various
operations such as cutting, sanding, knurling, drilling, or the deformation, facing,
turning. This machine in the picture is kept at the machine room. It is used for facing
or cutting of certain parts in the workshop.
Fig 2.2 lathe machine
3. Hydraulic press
A hydraulic press is a device using a hydraulic cylinder to generate a compressive
force.
Fig 2.3 lathe machine
4. Hydraulic press
This is another different type of hydraulic press machine that we came across in the
company.
Fig. 2.4 hydraulic press
5. Compressor
Fig 2.5 compressor
A gas compressor is a mechanical device that increases the pressure of a gas by

reducing its volume
2.4 Processes:
Processes that take place when a vehicle arrives till it is departed are as follows:
Vehicle approaches
workshop gates.
Guard addresses and takes

down vehicle details
Primary visual inspection of

vehicle to check for hazards
Customer is enquired about

nature of work
Vehicle is guided to
designated work area.
Works advisor consultant
Job card is prepared
Supervisor assigns jobs to

technicians
Material issued with

authorization from supervisor
Washing and greasing after

servicing of vehicle.
Job card reviewed and

checked.
Final bill prepared and

checked with customer.
Customer is issued gate

pass
Feedback from customer

after 3 days is recorded.
10
Chapter 3
Study of transmission and differential system

3.1 Introduction
My mini project in the service station was to study the transmission of different vehicles,
It was basically more of theoretical study of the transmissions and the understanding it
practically in the workshop with the help other colleagues.
3.2 Objective of the project :

"To understand the working of transmission and to counter the common problems easily
that is faced usually in the vehicles."
3.3Transmission:
A Transmission is a machine that consists of a power source and a power transmission
system. This provides controlled application of the power. Often the term transmission refers
simply to the gearbox that uses gears and gear trains to provide speed and torque conversion
from a rotating power sources to another device.
Furthermore, the engine provides its highest torque and power outputs unevenly across the
rev range resulting in a torque band and a power band. Often the greatest torque is required
when the vehicle is moving from rest or travelling slowly, while maximum power is needed
at high speed. Therefore, a system is required that transforms the engine's output so that it
can supply high torque at low speeds, but also operate at highway speeds with the motor still
operating within its limits. Transmissions perform this transformation.
A transmission has multiple gear ratios (or simply "gears") with the ability to switch between
them as speed varies. This switching may be done manually (by the operator) or
automatically. Directional (forward and reverse) control may also be provided. Single-ratio
transmissions also exist, which simply change the speed and torque (and sometimes
direction) of motor output.
11
In motor vehicles, the transmission generally is connected to the engine crankshaft via a
flywheel and/or clutch and/or fluid coupling, partly because internal combustion engines
cannot run below a particular speed. The output of the transmission is transmitted via
the driveshaft to one or more differentials, which drives the wheels. While a differential may
also provide gear reduction, its primary purpose is to permit the wheels at either end of an
axle to rotate at different speeds (essential to avoid wheel slippage on turns) as it changes the
direction of rotation.
Many transmissions and gears used in automotive and truck applications are contained in a
cast iron case, though more frequently aluminium is used for lower weight especially in cars.
There are usually three shafts: a main shaft, a countershaft, and an idler shaft.
The main shaft extends outside the case in both directions: the input shaft towards the
engine, and the output shaft towards the rear axle (on rear wheel drive cars. Front wheel
drives generally have the engine and transmission mounted transversely, the differential
being part of the transmission assembly.) The shaft is suspended by the main bearings, and is
split towards the input end. At the point of the split, a pilot bearing holds the shafts together.
The gears and clutches ride on the main shaft, the gears being free to turn relative to the main
shaft except when engaged by the clutches.[3]
12
3.3.1Methodology used:
Methodology used while doing this project is as follows:

Step 1- Studying about transmission and understanding it practically in the workshop
Step 2- Noting down all the types of vehicles available in the work shop
Step 3- checking which kind of transmission is present in the vehicle
Step 4- trying to understand more and ways to tackle the common problems associated
with it.
Step 5- research part- trying to find any possible way to make it more efficient and make
it better if possible in different aspect
3.4 Differential
A differential is a gear train with three shafts that has the property that the angular velocity
of one shaft is the average of the angular velocities of the others, or a fixed multiple of that
average. A differential consists of one input, the drive shaft, and two outputs which are the
two drive wheels.[4]
3.5 Functions of Transmission and Differential
1)
Transmission
The transmission adapts the output of the internal combustion engine to the drive wheels.
Such engines need to operate at a relatively high rotational speed, which is ina33.5ppropriate
for starting, stopping, and slower travel. The transmission reduces the higher engine speed to
the slower wheel speed, increasing torque in the process when vehicles move with less speed
and vice versa for when vehicle moves with a a higher speed or is starting or stopping the
vehicle.
13
2)
Differential
The differential allows the outer drive wheel to rotate faster than the inner drive wheel
during a turn. This is necessary when the vehicle turns, making the wheel that is travelling
around the outside of the turning curve roll farther and faster than the other. The average of
the rotational speed of the two driving wheels equals the input rotational speed of the drive
shaft. An increase in the speed of one wheel is balanced by a decrease in the speed of the
other.
14
3.6 Types of Transmission:

TYPES OF TRANSMISSION
MANUAL
AUTOMATIC SEMI AUTOMATIC
CVT
3.6.1 Manual Transmissions
As the name suggests, the selection of gear ratios on manual transmissions is accomplished
by manually shifting a gear selector mechanism that disengages one gear and selects another.
Most modern types of this transmissions have five or six forward (and one reverse) gears.
This type of transmission is connected to the engine via a clutch, which if disengaged (by
pressing the foot pedal or hand lever), removes torque from the system. With the clutch
engaged, power is delivered to the transmission through an input shaft that is separated from
the primary cluster, and which can rotate at a different speed to the cluster. The cluster is
comprised of gears that can be moved to either engage, or disengage from fixed gears on the
secondary shaft, which is normally located below the cluster gears, and supported by roller
bearings in its casing.
a) Gear Selection
The input shaft has only one gear that engages with a gear on the secondary shaft. When it is
running and the clutch engaged, the transmission is said to be in Neutral. No gears on the
primary are engaged with gears on the secondary shaft.
When shifting into first gear (for example), the gear on the primary shaft is slowed down by
a synchronisation mechanism, and aligned with a gear on the secondary shaft. The current
15
gear is always disengaged before the next one is engaged. When the clutch is re-engaged,
rotational energy is transferred from the transmission to the axle(s) by the drive train.
Fig: 1.1 gear arrangement
By using progressively smaller ratios, the speed of the vehicle can be maintained or
increased using less power from the engine.[5]
b) Advantages
Extremely robust, and can handle high torque loads.
Very reliable, and relatively easy to service, maintain, and repair.
The solid link between driving wheels and the engine provided by this transmission
provide a valuable driving aid to drivers in the off-road environment, by allowing the
use of engine braking while descending slippery slopes where the use of ABS brakes
could be dangerous.
Cheapest to repair
16
3.6.2 Fully Automatic Transmissions

In an automatic transmission, the hydraulically operated control systems are managed
electronically by the vehicles computer instead of the clutch and gear stick. All the driver
has to do is shift the selector from Park (P) or Neutral (N), into Drive (D), and the gear
shifting will take place automatically and smoothly, without any additional input from the
driver under normal driving conditions.[6]
a) Gear Selection
Gear selection in automatic transmissions depends on many operational conditions, such as
vehicle speed, engine speed, performance mode selected as well as driver assist systems such
as traction control, stability control, automatic/autonomous braking and cruise control.
Provided all necessary conditions are met, and there is agreement between the Engine
Management and Transmission Control systems, pressurized transmission fluid is
automatically channelled to mechanisms that drive sets of planetary gears and clutches,
which are roughly analogous to the gear ratios found in in this type of transmission.
Rotational energy is provided by a torque converter, a mechanism consisting of two freely
rotating parts. One half is attached to the engine and the other to the transmission input shaft.
The two halves of the converter are positioned very closely together. The fluid that circulates
between them is influenced by the rotational energy of the engine which in turn impacts the
transmission side of the converter. Torque is transferred from the engine to the transmission
with the help of shearing strength of fluid.
17
Fig: 1.2 fully automatic

In older automatic transmissions, the shifting action was accomplished by internal fluid
pressures overcoming spring tension closing one circuit before opening another. This
control system produced harsh, jerky shifting. Modern systems moderate the action of the
controlling valve shuttles, providing almost seamless shifting.
b) Advantages
Very easy to use
Provides a comfortable driving experience
Modern automatic transmissions match manual transmissions in terms of

performance and fuel economy
c) Disadvantages
Complex and prone to failures, malfunctions, and unsatisfactory performance due to

a variety of possible issues, some of which are unrelated to it itself
More expensive than a manual transmission to maintain over a vehicles lifetime
Expensive to repair. Replacement is often the more cost effective option
Unsuitable for use in off-road environments because it cannot provide engine braking
18
3.6.3 Semi-Automatic Transmissions
Fig: 1.3 Semi automatic transmission

Also known as an automatic manual or clutch less manual transmission, the simplest
way to describe this type is to call it a hybrid between a fully automatic and manual
transmission.
Similar to a manual transmission, gears are changed via a simple shifter or paddles located
behind the steering wheel. However, there is no need to operate a clutch pedal. Processors,
sensors, pneumatics and actuators are all used to automatically shift the gears once the
drive has signalled the change.[7]
Fig: 1.4 paddle shift

19
The basic principles of shifting mechanical gears in a semi-automatic fashion have been in
use on heavy commercial vehicles for many years. The latest and best designs provide
lightning-fast, almost undetectable gearshifts.
The design of these systems varies, but all semi-automatic transmissions rely on
microprocessors to control the changing of mechanical gear ratios with the help of
electrically operated actuators and servos. These transmissions were limited to high-end
supercars at first due to their high cost, but an increasing number of manufacturers are fitting
them to mid-range cars.
Dual clutch systems employ two clutches, one controlling gearshifts in the even numbered
gears and, anther that controls the odd numbered gears and reverse. This arrangement does
not interrupt the power flow from the engine. The driver still has to initiate a gearshift via a
shifter or paddles located behind the steering wheel, but there is no need for the driver to
operate a clutch.
a) Advantages
Smoother shifting/driving experience
No energy losses due to slippage in torque converters, or during the time lag of
manual shifts
b) Disadvantages
Complex and prone to failures, malfunctions, and unsatisfactory performance due to

a variety of possible issues, some of which are unrelated to the transmission itself
More expensive to maintain than a manual transmission
Very expensive to repair. Replacement is often the more cost effective option
20
3.6.4 Continuously Variable Transmissions (CVT)
Fig: 1.5 CVT transmissions

This transmission doesnt use gears as its means of producing various vehicle speeds at
different engine speeds. Instead of gears, the system relies on a rubber or metal belt running
over pulleys that can vary their effective diameters. To keep the belt at its optimum tension,
one pulley will increase its effective diameter, while the other decreases its effective
diameter by exactly the same amount. This action is exactly analogous to the effect produced
when gears of different diameters are engaged.[8]
a) Gear Selection
Since one pulley is driven by the engine and the other is connected to the drive shaft, an
infinite number of ratios can be produced. This enables it to always run at the most efficient
speed, regardless of the load placed on it. Microprocessor-controlled sensors quantify load
variations and by adjusting both pulleys, the optimum operating speed for the engine can be
maintained without any input from the driver.
21
b) Advantages
Constant, stepless acceleration throughout the engines optimum operating range
Provides a comfortable ride by eliminating shift shock
Better fuel efficiency
Faster response to changing driving conditions such as variations in throttle and

engine speed
Eliminates energy losses associated with torque converters. Bottom of Form
c) Disadvantages
Unsuitable for use in off-road environments because of limited torque-handling

ability.
Cannot provide engine braking
22
3.7 Types of differential:

TYPES OF DIFFERENTIAL
OPEN
LOCKING
LIMITED SLIP
AUTO LSD
3.7.1 Open Differential

Splits engine torque into two outputs, each of which is able to rotate at a different speed.
a) Shortcomings
When one tire loses traction, the opposing tire also experiences a torque reduction. In
the worst case, your car is stuck with one wheel freely spinning while the tire with
better traction cant deliver enough torque to budge the vehicle. Modern tractioncontrol systems compensate by applying the brakes (and thus a reaction torque) to the
slipping wheel. That said, a more sophisticated diff is generally quicker-acting and
more effective than this type.[9]
b) Found In
Anything without the pretence of performance or off-road abilityfamily sedans,
crossovers, minivans, economy cars, etc.
Fig: 1.6 image of a open differential
23
3.7.2 Locking Differential

With the diff locked, the connected wheels always spin at equal speeds. In sand, mud, and
snow, a locked differential ensures that torque continues to flow to the wheel with higher
traction.[10]
a) Shortcomings
Behaves like an open differential when not locked. Locking the diff on a high-grip
surface such as dry pavement makes it difficult to turn the vehicle and can grenade
the driveline.
b) Found In
Jeep Wrangler, Mercedes-Benz G-class, Ram 2500 Power Wagon; optional on most
full-size trucks.
Fig: 1.7 image of a locking differential
24
3.7.3 Limited-slip Differential

A limited-slip differential marries the concepts of open and locked differential, working like
an open differential the majority of the time, then automatically beginning to lock as slip
occurs. Lock-up can be achieved via a viscous fluid, a clutch pack, or a complex geartrain.[11]
a) Shortcomings
Purely mechanical limited-slip differential are reactive. That is, they dont begin to
lock up until after wheel-slip has occurred.
b) Found In
Nissan 370Z with Sport package (viscous), Mazda MX-5 Miata (clutch type), Scion FR.
Fig: 1.8 limited slip differential
25
3.7.4 Electronically Controlled Limited-slip Differential

An electronically controlled clutch pack offers rheostat like control between open and fully
locked behaviours, with adjustments made hundreds of times per second. For example, if the
computer determines theres too much over steer during cornering, it can dial in more
lockups to stabilize the car.
a) Shortcomings
As with a conventional limited-slip diff, torque is biased toward the slower wheel.
b) Found In
BMW M3 and M4, Cadillac ATS-V and CTS-V, Chevrolet Corvette with Z51
package, Ferrari 488GTB.
26
3.8 TYPE OF TRANSMISSION AND DIFFERENTIAL USED IN TATA

MOTORS HCV AND SCV
TATA MOTORS imports its different parts for different vehicles from different company;
some of the company that it imports its transmission parts are from ALLISON
TRANSMISSION, EATON COPERATION etc.
All most all of the TATA vehicles have manual transmission, whereas some buses like
TATA MARCOPOLO bus which is a joint venture of TATA MOTORS and MARCOPOLO
has automatic transmission. Whereas differential used is mostly open and locking
differential.
27
Chapter 4
STUDY OF PLANT LAYOUT

4.1INTRODUCTION
Plant layout refers to the arrangement of physical facilities such as machinery,
equipment, furniture etc. within the factory building in such a manner so as to have
quickest flow of material at the lowest cost and with the least amount of handling in
processing the product from the receipt of material to the shipment of the finished
product.[12]
4.2 DEFINITION
The overall objective of plant layout is to design a physical arrangement that most
economically meets the required output quantity and quality. Plant layout ideally
involves allocation of space and arrangement of equipment in such a manner that overall
operating costs are minimized.
4.3 DETERMINENTS OF PLANT LAYOUT
TYPE OF PRODUCT (size, shape and quality)
TYPE OF PROCESS (technology employed, sequencing etc)
VOLUME OF PRODUCTIONS- (INCREASE OR DECREASE)
28
4.4 IMPORTANCE OF PLANT LAYOUT

It is long-term commitment
It facilitates the production process, minimizes material handling, time and cost,
and allows flexibility of operations
It facilitates easy production flow, makes economic use of the building, promotes
effective utilization of manpower, and provides for employees convenience, safety,
comfort at work, maximum exposure to natural light and ventilation.
It affects the flow of material and processes, labour efficiency, supervision and control,
use of space and expansion possibilities.
4.5 OBJECTIVES OF PLANT LAYOUT

Proper and efficient utilization of available floor space
To ensure that work proceeds from one point to another point without any delay
Provide enough production capacity
Reduce material handling costs
Reduce hazards to personnel
Utilize labour efficiently
Increase employee morale
Reduce accidents
Provide ease of supervision and control
Provide employee safety and health
Allow ease of maintenance
Allow high machine or equipment utilization
Improve productivity
To minimize cost of productions
Better inter department relationship
29
4.6 FACTORS INFLUENCING PLANT LAYOUT
Factory building: - The nature and size of the building determines the floor space
available for layout. While designing the special requirements, e.g. air
conditioning, dust control, humidity control etc. must be kept in mind.
Nature of product: - Product layout is suitable for uniform products whereas

process layout is more appropriate for custom-made products.
Production process: - In assembly line industries, product layout is better. In job

order or intermittent manufacturing on the other hand, process layout is desirable.
Type of machinery: General purpose machines are often arranged as per process
layout while special purpose machines are arranged according to product layout.
Repairs and maintenance: - Machines should be so arranged that adequate space

is available between them for movement of equipment and people required for
repairing the machines.
Human needs: - Adequate arrangement should be made for cloakroom,

washroom, lockers, drinking water, toilets and other employee facilities, proper
provision should be made for disposal of effluents, if any.
Plant environment: - Heat, light, noise, ventilation and other aspects should be
duly considered, e.g. paint shops and plating section should be located in another
hall so that dangerous fumes can be removed through proper ventilation etc.
Adequate safety arrangement should also be made.
Management policies: - management policies regarding size, quality, employee

facilities and delivery schedules should be considered while deciding plant
layout.
4.7 DYNAMICS OF PLANT LAYOUT
Increase in the output of the existing product
Introduction of a new product and diversification
Technological advancements in machinery, material, processes, product design,

fuel etc.
Deficiencies in the layout unnoticed by the layout engineer in the beginning.
30
4.8 PRINCIPLES OF PLANT LAYOUT

PRINCIPLE OF MINIMUM MOVEMENT
PRINCIPLE OF FLOW
PRINCIPLE OF SPACE
PRINCIPLE OF SAFETY
PRINCIPLE OF FLEXIBILITY
PRINCIPLE OF INTERDEPENDENCE
PRINCIPLE OF OVERALL INTEGRATION
PRINCIPLE OF MINIMUM INVESTMENT
PRINCIPLE OF MINIMUM MOVEMENT

o As far as possible materials and labour should be moved over minimum
distances.
PRINCIPLE OF FLOW
o The work areas should be arranged according to the sequence of operations so
that there is continuous flow of materials without congestion. The layout
should allow for easy movement of materials without interruption or delay.
PRINCIPLE OF SPACE
o All available cubic space should be effectively used both vertically and
horizontally.
PRINCIPLE OF SAFETY
31
o There should be consideration for safety and convenience of workers. There

should be built in provision for the safety and comfort.
PRINCIPLE OF FLEXIBILITY
o Layout should be designed in the manner that production facilities can easily
be rearranged when it becomes necessary in future on account of expansion
and technological advancement.
PRINCIPLE OF INTERDEPENDENCE
o Interdependent operations and processes should be located in close proximity
to each other.
PRINCIPLE OF OVERALL INTEGRATION

o All the plant facilities and services should be fully integrated into a single
operating unit so as to maximize efficiency and minimize costs of production.
PRINCIPLE OF MINIMUM INVESTMENT

o
The layout should yield savings in fixed capital investment through optimum
utilization of available facilities
32
Chapter 5
TYPES OF LAYOUTS
1. PRODUCT OR LINE LAYOUT
2. PROCESS OR FUNCTIONAL LAYOUT
3. FIXED POSITION OR LOCATION LAYOUT
4. COMBINED OR GROUP LAYOUT [2]
5.1 PROCESS OR FUNCTIONAL LAYOUT

This is the type of layout used in Pandit Automotive. In this type of layout machines of a
similar type are arranged together at one place. E.g. Machines performing drilling
operations are arranged in the drilling department, machines performing casting
operations be grouped in the casting department. Therefore the machines are installed in
the plants, which follow the process layout. The work, which has to be done, is allocated
to the machines according to loading schedules with the object of ensuring that each
machine is fully loaded. Used when the operations system must handle a wide variety of
products in relatively small volumes (i.e., flexibility is necessary) The grouping of
machines according to the process has to be done keeping in mind the following
principles:
The distance between departments should be as short as possible for avoiding

long distance movement of materials.
The departments should be in sequence of operations
The arrangement should be convenient for inspection and supervision
33
5.2 ADVANTAGES OF PROCESS LAYOUT

1. Lower initial capital investment in machines and equipments. There is high degree of
machine utilization, as a machine is not blocked for a single product
2. The overhead costs are relatively low
3. Change in output design and volume can be more easily adapted to the output of
variety of products
4. Breakdown of one machine does not result in complete work stoppage
5. Supervision can be more effective and specialized
6. There is a greater flexibility of scope for expansion
5.3 DISADVANTAGES OF PROCESS LAYOUT
Material handling costs are high due to backtracking
More skilled labour is required resulting in higher cost.
Time gap or lag in production is higher
Work in progress inventory is high needing greater storage space
More frequent inspection is needed which results in costly supervision
5.4 SUITABILITY OF PROCESS LAYOUT
Products are not standardized
Quantity produced is small
There are frequent changes in design and style of product
Job shop type of work is done
Machines are very expensive Thus, process layout or functional layout is suitable
for job order production involving non-repetitive processes and customer
specifications and non-standardized products, e.g. tailoring, light and heavy
engineering products, made to order furniture industries, jewellery.
34
5.4 RECENT TRENDS IN PLANT LAYOUT

Plant layout is the art and science of bringing to gather men, materials, methods and
supporting facilities in the form of a given arrangements that suits individuals industrial
activity to have the benefits of profits maximizations through economy, efficiency,
effectiveness and productivity. The designing and instilling a layout is the responsibility
of Engineering and planning department. The process of preparing layout is an art and
well as science.
The recent trends in layout are as follows
1. The use of computerized facilities design: The various techniques have been
developed and used in layout engineering such as ALDEP (Automated layout design
program),
CORELAP
(Computerized
relationship
layout
planning),
CRAFT
(computerized related allocation of facilities technique), CALP (computer Aided layout

planning) etc. These and other programme can save time and effort in large and complex
layout problems.
2. The use of various tools and techniques for planning the layout
Templates: It is a pattern which consists of thin plate of wood or metal which

serves as gauge or guide in mechanical work. A plant layout template is a scaled
representation of physical object in a layout.
Model equipment: Model or three dimensional models represents machinery

installed in a factory. It is a replica or a miniature prototype of machine and
equipment. These show minor details and can be mounted on a thick plastic sheet.
Layout drawing: Layout drawings are the replica of a factory floor plan showing
the space management. It is blue print which indicates the total square feet where
all the equipment has to be arranged.
Plot plan: Is a miniature of the entire factory building including the facilities of
workers.
Line balance: is phase of assembly line study that equally divides then works to
be done among workers so that the total number of employees required is
minimum. OR concepts like linear programming, dynamic programming and
optimal methods are used to study line balance problem. [14]
35
5.5 FACTORY BUILDING

A ideal plant building is the one which is built to house the most efficient layout that can
be provided for the process involved, and artificially attractive and of such standard
shape and design which is flexible its use and expansive units construction. The building
ensures functional smoothness of the operation. It should be strong enough to withstand
damages, vibrations and heavy machines.
5.6 FACTORS IN DESIGNING IN FACTORY BUILDING
Adaptability
Expandability
Product and equipment
Employee facilities and services areas
Materials handling
Lighting, ventilation and air-conditioning
Fire protection
Security and services and maintenance
5.7 TYPES OF BUILDINGS

The decision on choosing a suitable type for a particular firm depends among other
things on the manufacturing process, the area of land, and the cost of construction. The
industrial building can be grouped under four types
1. Single storey building

2. High bay and monitor types
3. Multi-storey building
4. Special building
36
Single storey building:
The reduced cost of land and extensive transport facilities have encouraged single
storey buildings in sub-urban area.
High bay and monitor types:
It is a single storey structures with roof surrounded by a monitor, giving maximum

overhead space. The overhead space may be used to operate crane and other
overhead facilities. The monitor provides natural ventilation and side walls with
glass provide natural lighting.
Multi-storey building:
In big cities costs of land is high and has no much scope of horizontal expansion
which has given ways to multi-storey.
Special building:
These are needed for certain manufacturing processes. E.g. the aircraft
Industry needs a building with spans 300 to 500 feet in length
37
Chapter 6
Plant layout and its implementation

6.1 Plant layout:
Actual plant layout of Pandit Automotive Pvt. Ltd. is as shown in the figure. The figure is
made in Auto cad using the actual plat of the company and show location of different
departments.
Figure no. 6.1 plant layout
38
This is the actual layout of Pandit Automotive presently, it presently has 3 workshops
which includes shop floor for MCV,HCV and LCV, Bus service station and SCV and
utility workshop. This layout was created in AutoCAD.
6.2 Recommendation on plant layout

These recommendations are given by detailed study of plant layout and study of how
plant layout can be made more useful. These are as follows:
All 3 service bay can be shifted to end part of the company, and rest both customer
lounge should be shifted to front, this would help the new customer to not search for the
specific bay for their vehicle. This will also help minimize the distance from one to
another. Tracking vehicles would turn easy as all the vehicle will be in one place and not
divide into two spaces. All the customer lounge , inventory store and office can be
shifted in the starting of the company because they dont have many reason to visit the
workplace.
The big advantage of doing this is that the customer wont be able to visit the work floor.
In my 6 months internship I observed most of the time customer visit the workplace
where employees are working on their vehicles and sometimes they often lead to disputes
which is not only bad for the company reputation but also can lose valuable customer of
the company. Sometimes this can often lead to low morale of the employee. Putting all
the admin office will also benefits the customers as it would be easy for them to reach the
advisor without the need of going into department themselves to search for advisor to file
the complaints.
39
Chapter 7
INTRODUCION TO INDUSTRIAL SAFETY MANAGEMENT
7.1. INTRODUCTION
I chose to take up my next mini project as industrial safety management, I intend to learn
about industrial safety and how it can be implemented in industry like Pandit Automotive.
My objective for this report is to show industrial safety already present in Pandit Auto and
also how it could be further improved for the betterment of the company and for safety of the
employees in the company.
Measures or techniques implemented to reduce the risk of injury, loss & danger to persons,
property or the environment in any facility or place involving the manufacturing, producing
and processing of goods or merchandise is called as safety management. Today, industrial
safety is widely regarded as one of the most important factors that any business, large or
small, must consider in its operations. Employers are required to compensate employees for
work-related injuries or sickness by paying medical expenses, disability benefits, and
compensation for lost work time.
In the modern context, corporate management increasingly has viewed industrial safety
measures as an investment one that may save money in the long run by way of reducing
disability pay, improving productivity, and avoiding lawsuits. Rather than viewing an injury
as a fluke or a random mistake, management today is more likely to look for systemic
problems, such as: The way equipment is designed or used and the way workflow is
configured and how workers are trained.
40
7.2. BRIEF HISTORY

First comprehensive industrial safety legislation passed at the federal level was Occupational
Safety and Health Act of 1970 The Occupational Safety and Health Act (OSH Act) of 1970
was passed by Congress "to assure so far as possible every working man and woman in the
Nation safe and healthful working conditions and to preserve our human resources." OSHA
was established within the Department of Labour and was authorized to regulate health and
safety conditions for all employers with few exceptions. Includes safety standards are
designed to prevent accidents, and health standards, Also designed to protect against
exposure to toxins and to address the more long-term effects of occupational hazards.
Types Of Inspection carried by OSHA
Imminent Danger: Condition where there is reasonable certainty that a danger exists
that can be expected to cause death or serious physical harm immediately or before
the danger can be eliminated through normal enforcement procedures.
Employee Complaints: Each employee has the right to request an OSHA inspection
when the employee feels that he or she is in imminent danger from a hazard or when
he or she feels that there is a violation of an OSHA standard that threatens physical
harm Programmed
High Hazard Inspections: OSHA establishes programs of inspection aimed at specific

high hazard industries, occupations, or health hazards.
Re-inspections: Establishments cited for alleged serious violations may be reinspected to determine whether the hazards have been corrected.[15]
41
7.3. Significance of Industrial Safety
Industrial causes a great loss to both the Employer & Employee, thats it is
having importance
Cost of compensation
Cost of medical-aid
Cost of training a new worker
Cost of the lost time
Cost of investigation
Cost of supervision & inspections
Cost to the Govt. in terms of factory inspectors, & public health services
Cost of spoilage of materials
Cost of the damage of machinery
Cost of cost of wages payable during injury
Cost of loss of morale
Cost of loss to the worker and his family
7.4. Objective of industrial safety
To prevent accidents in the plant by reducing the hazard to minimum.
To eliminate accident caused work stoppage and lost production.
To achieve lower workmens compensation, insurance rates and reduce all other
direct and indirect costs of accidents.
To prevent loss of life, permanent disability and the loss of income of worker by
eliminating causes of accidents.
To evaluate employees morale by promoting safe work place and good working
condition
To educate all members of the organization in continuous state of safety mindless and
to make supervision competent and intensely safety minded.[16]
42
7.5. Causes of Industrial Accidents
Unsafe conditions
o The job itself
o Work schedules
o Psychological conditions
o Machinery & Equipment
Unsafe Acts
Miscellaneous Causes
7.6. Measures to ensure Industrial Safety
Safety Policy
Safety Committee
Safety Engineering
o Guarding of machinery
o Material handling equipment
o Safety devices
o Ergonomics
o Plan maintenance
o General house keeping
Safety Education & Training
Role of Government
43
7.7. Four Es of safety
Engineering: i.e. safety at the design, equipment installation stage.
Education: i.e. education of employees in safe practices.
Enlistment: i.e. it concerns the attitude of the employees and management

towards the programmed and its purpose. This necessary arose the interest
of employees in accident prevention and safety consciousness.
Encouragement: i.e. to enforce adherence to safe rules and practices.[17]
Safety inspection procedure
Safety audit A safety audit subjects each area of a companys activity to a

systematic critical examination with the object of minimizing loss.
Safety survey-A safety survey is a detailed examination in depth of a narrower field
of activity.
Safety inspection- A routine scheduled inspection of a unit or department, which
may be carried out by someone (may be a safety representative) from within the
unit, possibly accompanied by the safety advisor. The inspection would check
maintenance standards.
44
Safety measures
Fencing of machinery
Work on or near machinery in motion
Employment of young persons on dangerous machines.
Striking gear and devices for cutting off power
Self-acting machines
Casing of new machinery
Prohibition of employment of women and children near cotton-openers
Hoists and lifts
Lifting machines, chains, ropes and lifting tackles
Revolving machinery
Pressure plant
Floors, stairs and means of access
Pits, sumps openings in floors, etc
Excessive weights
Protection of eyes.
Precautions against dangerous fumes, gases
Precautions regarding the use of portable electric light.
Explosive or inflammable dust, gas, etc
Precautions in case of fire
Power to require specifications of defective parts or tests of stability
Safety of buildings and machinery
Maintenance of buildings
Safety Officers
Power to make rules to supplement this Chapter
45
7.8. Recommendation of safety measures

In this 6 months of internship I observed that not severe steps are taken to ensure the safety
of the employees, which is not only dangerous but can also lower their moral value and
could turn out to be very dangerous in the long run.
Some recommendations that can be taken into account by the company for their benefit are:
Introducing safety audit
Introducing specially made fit glove as per requirement for different field.
Giving away high grip boots to employees to ensure they dont slip in oily area
Putting up danger sign to wherever needed.
Putting up proper fencing to machines which can be dangerous when come near
Putting up fire extinguisher near every area.
46
CHAPTER 8
INTRODUCTION TO INVENTORY OF TRANSMISSION
8.1Introduction
Pandit Automotive uses a software for maintaining the records of the parts of each vehicles,
their software not only keeps the records parts but also keeps the information of number of
that part available in the workshop which not only helps them to be aware of the number of
parts available but also helps them be alert when parts are running low. By this method they
also can also calculate the approximate number of each part used and which part is most
frequently used by which they can get needed parts accordingly.
Luckily I could get my hands on one of those catalogues which shows parts of a truck LPK
909. It has all list of all the parts of the truck system wise (e.g gear box, brake, differential).
The list is too long to put up as whole so I chose to showcase my concerned system
transmission and differential picture trough actual pages of the catalogue as it also shows the
position of that very part in that system.
8.2 Inventory according to catalogue
47
Table: 3.1 gear shaft and gear
48
2505066026R.02
GEAR SHAFT AND GEAR
GROUP 26
CHASSIS TYPE: ALL

FIG.
NO.
1
PART NUMBER
250526257919
DESCRIPTION
DRIVE SHAFT
QTY
REMARKS
(NUP)(T=15)(497/310)287.4MM
2
3219931201
COMPRESSION SPRING
3212620073
CLAMPING PLATE
250526203129
CYLINDRICAL ROLLER BEARING
250526204302
SNAP RING 2.68 MM THICK
FOR SELECTION
250526204303
FOR SELECTION
250526204304
FOR SELECTION
250526204305
FOR SELECTION
250526204306
FOR SELECTION
250526204307
FOR SELECTION
250726258601
SPACER ON DRIVE SHAFT
250526258201
OIL SLINGER (FRONT SIDE)
3122621172
LOCK NUT LH THREAD
250526253118
ROLLER CAGE (LONGER) 28X48X30.8
269026208601
CIRCLIP (LAYSHAFT)
10
250526207903
MAIN SHAFT (LONGER PILOT BEARING)
250526203106
FOUR POINT BALL BEARING
52
0009811201
CYLINDRICAL ROLLER BEARING
11
3129931701
PRESSURE SPRING
12
3212620374
PIN ON MAIN SHAFT
13
250526208608
BUTTING RING 6.95 MM THICK
FOR SELECTION
13
3212622062
FOR SELECTION
13
250526208609
FOR SELECTION
13
250526208610
FOR SELECTION
13
250526208611
FOR SELECTION
13
3212621762
FOR SELECTION
13
250526208612
FOR SELECTION
13
3212620462
FOR SELECTION
13
3212622862
FOR SELECTION
13
3212620562
FOR SELECTION
13
3212622962
FOR SELECTION
13
3212620662
FOR SELECTION
13
3212623062
FOR SELECTION
13
3212620762
FOR SELECTION
13
250526208613
FOR SELECTION
13
3212622562
FOR SELECTION
13
250526208614
FOR SELECTION
13
3212622662
FOR SELECTION
13
3212622762
FOR SELECTION
Table: 3.2 Gear shaft and gear
49
3.1.
Conclusion:
This are the list of parts of the truck LPK 909 as per the company catalogue showing the
actual position of the parts in the vehicle. This helps us to understand the position of that part
very precisely. I have tried to put up all the possible parts of my concerned project system
into this report.
50
SUMMARY
In this 6 months of internship I not only gained knowledge about the theory and practical
knowledge about transmission and its maintenance but also how a company operates and it's
how things are done in the company. As we were given job to generate job cards and to
track vehicle we learned how to do a job. I even gained knowledge about which plant layout
is better for which type of company and also how to plot a best suitable plant layout,
moreover in another assignment I learned the safety measures taken and that should be taken
in the company. Another assignment taught me the detailed part wise structure of
transmission and differential.
Overall in this Internship taught me all the basic needs to be in a company as a employee and
how to work accordingly.
51
REFERENCES
1. http://www.panditauto.com/about-panditauto\
2. http://www.panditauto.com/achievements
3. https://en.wikipedia.org/wiki/Transmission_(mechanics)
4.
https://en.wikipedia.org/wiki/Manual_transmission
5.
https://en.wikipedia.org/wiki/Automatic_transmission
6.
https://en.wikipedia.org/wiki/Semi-automatic_transmission
7.
https://en.wikipedia.org/wiki/Continuously_variable_transmission
8.
https://en.wikipedia.org/wiki/Limited-slip_differential
9.
https://en.wikipedia.org/wiki/Locking_differential
10. https://en.wikipedia.org/wiki/Limited-slip_differential
11. http://www.slideshare.net/Nuumero1/plant-location-and-plant-layout
12. https://en.wikipedia.org/wiki/Plant_layout_study
13. http://www.slideshare.net/anks2027/plant-layout-ppt-by-me
52

Final Report Done1111

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Final Report Done1111

Uploaded by

Copyright:

Available Formats

A

Transmission and its maintenance

Shivam Anuj Agarwal

Sir Nilesh Janpandit (External Guide)

DEPARTMENT OF MECHANICAL ENGINEERING

Symbiosis Institute of Technology

Prof. Nitin Solke

Prof. Prabhakar Shinde

Department of Mechanical Engineering

Department of Mechanical Engineering

(Colour Photocopy/ Scan Copy of Company Certificate)

I am thankful to Prof. Nitin sholke , Head of Department of Mechanical Engineering, for

Mr. Shivam Agarwal

The purpose of internship is to provide engineering students with experience to the

The future work required to be completed as the continuation of a work performed

1.2.1 Vision and mission

1.2.2 Brief History

1.2.4 Product and or Service Profile

1.2.5 Product range and profile

Achievements of the company

Types of Machines present

Study of transmission and differential

3.3.1 Methodology used

Function of transmission and differential

3.6.1) Manual Transmission

3.6.2) Fully automatic

3.6.3) Semi automatic

3.7.1) open differential

3.7.2) Locking differential

3.7.3) Limited slip differential

3.7.4) Electronic Limited slip Differential

Types of transmission and differential in TATA motors

Study of plant layout

Determination of plant layout

Importance of plant layout

Objective of plant layout

Factor influencing plant layout

Dynamics of plant layout

Principle of plant layout

Process or Functional layout

Suitability of Process layout

Recent trends in plant layout

Factors in designing factory building

Plant layout and its implementation

Recommendation of plant layout

Introduction to industrial management

Significance of Industrial safety

Objective of industrial safety

Causes of industrial accident

Measures to ensure industrial safety

Four E' of safety

Recommendation of safety management

Inventory according to catalogue

Fully automatic transmission

Limited slip differential

Gear shaft and gear

Gear shaft and gear

Continuously variable transmission

Limited slip differential

Automatic Limited slip differential

Heavy commercial vehicle

Small commercial vehicle

Some basic information about the company is as follows:

Other plant location: Pune, satara, sangli and Kolhapur.