Escolar Documentos
Profissional Documentos
Cultura Documentos
been the
developed
countries
through
mechanization of
agriculture, it
was being agreed that India also should fall in line with these countries. Though
India was backward in the use of machines for agricultural operations, yet in the
past few years there has been an increase in the case of modern implements. The
phase of mechanization of farming in the country was slow during 1950s.
Thereafter particularly since the mid 1960s with the coming of the new agricultu
ral
technology, this has increased. An associated effect of the new agricultural practic
es. The preparation of land, the sowing of seeds, the watering of land, the control
of seeds, the use of pesticides, the quick harvesting of crops etc, are now done
more scientifically than even before.
After the Industrial revolution even the agriculture sector all over the
world witnessed a drastic change. A number of revolution occurred during the 19th
century. Higher productivity and greater output are the two major contributions
infarm mechanization. Tillers form an integral part of farm mechanization and
have a crucial role to play in increasing agricultural productivity. Tiller is a highly
versatile piece of machinery having a multitude of uses, used in agriculture both
for land reclamation and for carrying out various crop cultivation and also
employed for carrying out various operations connected with raising the crops by
attaching suitable implements and to provide the necessary energy for performing
various crop production operations involved in the production of agricultural
crops.
Tillers are capital intensive, labour displaying used as a mode of transport,
in electricity generation, in construction industry and for haulage operation. It has
now become an integral part of farm structure .The application of tiller for
agricultural activities which swept India during the last twenty years have erased
the problem of farmers. Farm mechanization program in India aims to integrate
the use of available human and animal farm power with mechanical sources of
power for increasing the productivity.
A rapid major change in the economy was noticed by the general
introduction of power driven machineries. The entry of engineering technologies
in agricultural sector for the purpose of large production of crops using
technological know-how, Kerala Agro Machinery Corporation Limited is the
leading company in India trying for establishing engineering green revolution in
India.
Chapter 2
Introduction about the company
KAMCO was established in the year 1973 as a wholly owned subsidiary
of Kerala Agro Industries corporation limited, Thiruvanandapuram for manufactur
e of agricultural machinery specifically Power Tiller. Subsequently KAMCO
becomes a separate Government of Kerala undertaking in 1986. The objectives of
the company is to manufacture in India, either in collaboration with or otherwise
or import and trade agricultural machinery like Power Tiller, Power Reaper,
Combined
harvesters,
Harvester,
transplanted
accessories
or
spares.
Kalamassery, Mala and Kanjikode. Athani unit is also the Registered Office of the
company. At present company employees approximately 750 persons in four units
. The company is working profitably for the past fifteen years. The company was
tools
Rendering other kinds of services for services for consideration
or otherwise.
Chapter 3
Product Details
Today KAMCOs well-known product range includes the KAMCO
power tiller. KAMCO power reaper, KAMCO Agria Garden tiller and last but not
the least, KAMCO Diesel Engine, each Of these products are time tested and
have proven their worth many times over for their owners. KAMCO at Athani, is
the prime centre for the manufacture of Power Tillers and Tractors.
Power tiller is the main product of KAMCO. It is a versatile machine that
has radically changed the old labour intensive methods of agriculture, by making
almost all farming operations faster, cheaper and easier. The cost on tiller is
around 1.10 lakh.
Features
majority of which are supplied by dedicated small and medium scale industries
from nearby states. Functionally critical components (almost 13) are manufactured
in KAMCOs house itself. Company has got a modern machine shop with special
purpose machines, which ensure conformity with prescribed quality standards.
Number of cylinders
:1
Bore stroke
: 95 105
Compression ratio
: 20:1
Rated Power
: 9 HP
: 190-210 g/HP/Hr.
: 0.3 mm
: 0.1 0.3 mm
: 0.15 0.25 mm
: 370 4300C
: 3 litre
: SAE 40/900C
: 5 6 cc/Hr.
: 4 litre
: 4 5 cc/Hr.
Valve clearance
: 0.15 0.25 mm
Injection pressure
Number of cylinders
:1
Compression ratio
: 18:1
Rated Power
: 12 HP
Rated Speed
: 2180 20
: 0.3 mm
: 0.1 0.3 mm
: 0.8 + 0.05 mm
: 370 4300C
: 3 litre
: SAE 40/900C
: 5 6 cc/Hr.
: 4 litre
: 4 5 cc/Hr.
Valve clearance
: 0.3 mm
Injection pressure
Chapter 4
Study of the Plant
The infrastructure of the plant consists of the following sections.
Machine shop
Assembly line
Quality assurance section
Pre treatment & Painting booth
Fig 4.1
4.2 Machine Shop
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which
ensures
conformity
with
prescribed
quality
standards.
Machine Shop is responsible for ensuring the conformity with prescribed standard
s, the workers in the machine shop are fully experienced. 14 components are
manufactured in the Machine Shop. These components are called as critical
components. The materials purchased by the Purchase Department, are then send
to the stores. From there the materials are forwarded to the Q.A. department. From
Q.A Department the materials are forwarded to the machine shop. Processes like
milling, drilling, boring etc are doing on the materials to get products which are
used in the assembly.They inspect the various stages of production. This reduces
rejection to a great extend. Shift officers are in charge of machine shop. From
machine shop the finished products are sent to Quality checking and from there
to stores.
The various processes in the machine shop of KAMCO are
4.2.1
: FN3V
: HMT, Pinjore
Machine no
Rated current
: 1997
: 22A
11
4.2.3
surfaces.
Specifications of machine:
Machine code: FN3H
Machine no: 1681
All other specifications same of FN3V.
4.2.4
The material of the side block is aluminum, which caused high sound
and jerking.
12
4.2.5
4.2.6
Grinding Machine
It is used for grinding of the top side of side block.
There are lot of electrical cams in it.
It has also stoppers in it to follow the electrical cams.
It has manual, semi-automatic and auto options.
A rough layout of the stoppers may be like this.
Capstan Lathe
Used for making the hole for Governor Level. It uses a coolant which is a
mixture of oil and water. The machine operates at speed of 500 rpm.
Specifications of the machine:
Type: HIC-4
Supply: 415V
Control voltage: 200V, 3-50Hz
F/C amps: 12.34A
Make: Mysore Kirloskar Ltd
4.2.8
Make: MT Hyderabad
Machine no: Y649
Operating voltage: 3, 50Hz, 415V
Connecting load: 22/30 KW/HP
Maximum fuel load current: 16.7A
Protective switch gear: 100A
4.2.9
14
during cam grinding and drilling of governer lever. The coolant is a mixture of
water and oil.
In each work stations properly designed jigs and fixtures are used to hold
work piece properly and guide the tool. Over head rail crain is used to transfer
work from one station to another. A Quality Assurance section is working for
assuring the quality of each parts. As the present work policy of KAMCO, each
worker is the customer of former and every customer should be satisfied.
4.3 Assembly Line
Assembly is one of the major sections in production department. All the
parts are assembled in this department. A chief mechanic is present in this section.
The engine assembly is one of the major works in the assembly. After testing the
assembled engines, it is sent to the painting section. Through different
transmissions in the assembly we get the finished product.
Assembly section consists of mainly three areas
Engine line
Transmission line
Engine line consists of five work stations namely E1, E2, E3, Engine
testing and Engine finishing. Transmission line consists of work stations namely
T1, T2 and T3. The work stations in the Tiller assembly line are K1, K2, K3 and
K4.
At the engine line, the assembly of entire engine takes place. The power
transmission gears are assembled in the sections T1, T2 and T3. The triller
attachments are assembled in the sections K1, K2, K3 and K4.
At E1, liner is inserted into the main engine block with o-rings. Stud is
fitted on the engine bock. Water and oil drain plugs are screwed. Engine number is
punched. The engine block is then placed on the conveyor system for furthur
assembling activities. Piston consists of two oil rings, two compression rings and a
top ring. After inserting all these rings piston is heated to expand and connecting
rod is connected to the expanded piston, using a sir clip.
15
shift fork which transmits power to the triller attachments. The clutch plate is used
to control the power from engine to the driver shaft (first shaft) of the main gear
case.
The tiller assembly line consists of four work stations namely K1, K2, K3 amd
K4. The tiller attachments are assembled in K1 section. Tiller attachments consists
of right and left side arm, frame, chain drive, blade and wheel hub. Only left side
arm consist of shaft and other is meant for suport. Chain drive is used to meet high
load requirements. Chasis number is punched and moved for cleaning (with air
and hot water) and painting (PU paint). The painted chasis is moved to section K2
and assembly of left and right side plate, mud guard, front cover, rear wheel
bracket, inner and outer pipe and rear cover takes place.
The incompleted chasis is then moved to the section K3. Here the asembly
of front frame, tyres, wheel cover, front stand, hub wheel auxillary, tensin pulley
and protector takes place. Front frame sould be able to carrry enough weight as
the engine block is placed over it. The front stand is provided with a spring
attachment to prevent slipping. The completed chasis is moved to the section K4.
Lubricants are applied and tested using an electric motor. After fixing the
problems, the chasis is move to the mounting section.
The engine block and chasis is mounted to form the finished product. The
wiring for head light is done. The fuel tank and fuel filter is fitted. After the
assembling is over the tiller will go to the quality assurance department for final
inspection .they will check the tillers as per assembly quality plans are satisfied
tillers will go to the central store department where they are stocked.
4.4 Quality Assurance Section
Quality Assurance clarifies the components into two critical component
and non critical components. Critical components are crank shaft, all engine parts,
gear wheels etc. non critical components are nuts, bolts, and screws etc. The
clarificationis mainly for ignoring the practical difficulty in checking. Complete
inspection occurs in critical components and only sample inspection in non critical
components. Practical difficulty in checking non critical components is the
problem there from herethe production department as their requirements takes the
components. After getting a finished product from the assembly department for
17
the final checking. If it is OK itis gone to the store. From these the machine will
enter into marker through dealers.
Calibration cell:- Q.A departments are equipped with all modal facilities.
The company has a calibration cell to check and correct the measurements of
allmeasuring instruments.
18
19
on a level surface the top edge will be parallel to that surface. If one roller is
raised by a known distance, usually using gauge blocks, then the top edge of the
bar will be tilted by the same amount forming an angle that may be calculated by
the application of the sine rule.
20
A good set of gauges will offer both convex and concave sections, and
allow for their application in awkward locations.
21
dial or micrometer mechanism. As the knob is rotated it moves the anvils in or out
with respect to the measurements. The knob usually has a slipping mechanism to
take the feel out of the device and increase reliability between measurements.
4.4.8 Thread gauge
22
23
24
measuring and user functions are clearly displayed on the large bright LCD
screen. Graphic help as well as on-line instructions guide the operator through
most of the measuring functions. The operating handle for the displacement of the
instrument, provided with programmable function keys, has been designed for
optimum operator comfort. The entire system floats on a air cusion to prevent
operator fatiuge. It has a particulaar extend of memory power as like a computer
and an output to a printer. The trimos should be calibrated after changing its probe
using standard height block.
4.5 Pre treatment & Painting booth
In KAMCO they are using a good advanced booth. After cleaning the
components it will go for painting through a conveyer belt and after painting it
will go to the oven through the belt. The painting process is full automated and
will done automatically through machine. Spray painting method is used for
painting process adopted with wet system and stowing enamel paint is used .
Mainly they are using two colours for painting, one is Ash and the other one is
Post office Red.
Tank pre-treatment process include
about 2 minutes.
Process 3: Acid treatment - Again the item is dipped in a solution
containing 35% HCl for about 20 minutes. This is mainly done to remove
rust.
Process 4: The component is again passed through two cold-water tanks
and rinsed.
Process 5: Phosphating - Again the item is dipped in a solution containing
phosphate content for about 45 minutes. After this process the surface of
25
26
Chapter 5
Conclusion
KAMCO is one of the profit making company in the state government.
The training was helpful in getting an understanding of the company, various
departments and their functions in a factory and overall operations of company.
The study enabled to collect much more information about the industry and have
helped in knowing the practica lsituation prevailing in the company. The training
enabled us to understand the assembly of engine, gear box and also helped to
collect more details about the various machine tools and instruments that are used
in the company.
Each and every staff of this company co-operated with us and so we were
able to understood almost all processes, plant layout and production details from
this short period of days. So we are expressing our sincere gratitude to this
company and its staff.
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