Summer Semester Internship

Project Report

IN

ESCORTS KUBOTA INDIA PRIVATE LIMITED

Submitted to : Submitted by : Narender

Prof. R.K Garg

Chairman Madhawanand Mishra session 2022-2023

 Candidate’s Declaration
I, NARENDER, hereby declare that the presented report of summer internship in ESCORTS
KUBOTA LIMITED is uniquely prepared by Me after the completion of FIVE WEEKS work
at ESCORTS KUBOTA LIMITED.

I hereby warrant that the work I have presented does not breach any existing copyright acts.

…………………………….
NARENDER
2100100429
DCRUST murthal
 Acknowledgement
I would like to thank my training manager, Mr. Dinesh Yadav, for his unflinching
desire to know what was going on in my projects and for those millions of
opportunities he gave me to share his ideas and knowledge in a large variety of
settings. His guidance and direction and methodology with which he taught us the
concepts was unparallel and unprecedented in every way . I am very much thank
full to him for his wise and synergetic help throughout my training period . I am
grateful to his for unending support and for all those good times we shared during
this project. I also express my gratitude to all the other employees of ESCORTS
LTD. for making my training at the company a wonderful experience .
PREFACE
Industrial training is now a day's one & the only one method to make students
familiar with the modern techniques. latest equipments & methods used in various
industries. During industrial training. students visit to various companies and make
themselves familiar with the practical aspect of the production method. This
training has provided an ultimate experience & opportunity to have practical
knowledge which has increased my level of thinking & dealing with different
kinds of people in all walks of life. It helps us a lot while appearing to the
interviews, Industrial training improves the theoretical and the practical concept of
the students about engineeringThe well planned properly executed & evaluated
industrial training helps a lot in inculcating good work culture. It provides Imkage
between the students & the industry in order to develop the awareness of industrial
approach to problem solving based on broad understanding plant.
 About Company Profile
Overview
ESCORTS KUBOTA LIMITED, the flagship company of the escorts kubota group is a leading
manufacturer and supplier of Agri Machinery Products, Construction & Material Handling
equipment, Auto suspension and Ancillary products and railway equipment.

A pioneer of farm mechanisation in India, Escorts Kubota Agri Machinery was launched in
1960. The company manufactures tractor under the brand names of Escort and Kubota,
FARMTRAC and POWERTRAC. Escorts Kubota Agri Machinery consists of four
manufacturing plants that cover an area of 134,000 sq.m. The company also has a plant in
Poland, which is a 100% subsidiary and functions in the name of Farmtrac Europe. The Escorts
Kubota Group is an Indian engineering company that operates in the sectors of Agri-machinery,
construction and material handling equipment, and railway equipment. Headquartered in
Faridabad, Haryana, the company was launched in 1960 and has marketing operations in more
than 40 countries. Escorts Group’s management team includes Nikhil Nanda as the Chairman
and Managing Director
Historical Background

Escorts came into being with a vision and a mission. A vision that led two brothers YUDI
NANDA and HARI NANDA to branch out from their family’s prospering transport
business and institute ventures that were to become the foundation of ESCORTS Ltd. Escorts
agents limited was born at Lahore on 17th Oct, 1944 with YUDI NANDA as managing director
and HARI NANDA as the chairman. After that owning to the opportunities lying in the Indian
villages Escorts (Agricultural Machines) Ltd., was launched in 1948 with YUDI NANDA as the
director. Tragically, he died in an accident in 1952. Then Escorts Kubota limited Agents Ltd.
And Escorts Kubota limited (Agricultural Machines) Ltd. Was merged in 1953 to create a single
entity Escorts Kubota limited Agents Pvt. Ltd. The company’s incorporation in its present name,
Escorts Kubota limited was effected on 18th January 1960.

Having initially started with a franchise for vesting house domestic appliances, Escorts Kubota
limited has come a long way in manufacturing and marketing a large range of products. It
has pioneered farm mechanization in India through import and distribution of agricultural
tractors.
The manufacturing operations commenced in 1954, and since then the following range
of products have been introduced in the country:-
 1954: Piston rings and Cylinder liner

 1960: Pistons
 1961: Assembly of tractors
 1962: Motorcycles and railway couplers
 1963: Automotive shock absorbers
 1965: Agricultural tractors under Escorts brand name
 1969: Agricultural tractors under Ford brand name
 1971: Industrial and construction equipment
 1979: Excavator loaders
 1981: 100cc motorcycles
 1985: Electronic PABXs
 1991: Harvester combines
 1992: VSAT Satellite Communication System
 1993: Mobile communications
 1995:
Fork lift trucks
 1996: Disengagement of joint venture collaboration with New Holland and launch
of FARMTRAC Tractor.

The single word completely described the character philosophy and success of the
company, which grew from a small beginning to one of the ever-changing dimensions. For five
decades Escorts Kubota limited has been in the core sectors like Agriculture, Transportation, and
Construction &Resources for engineering change through optimum product performance. From
its inception Escorts has firmly believed that success inspiring on being close to the
customer thus every corporate endeavour addresses it to end used, adjusting to ever changing
markets. At every step of the way, Escorts Kubota limited had inducted the latest technology by
forming alliances with the world’s most advanced Engineering and Electronic companies,
constantly adopting their technology according to India’s need and situation. To make sure the
finished product delivers on its promise the company had created an extra-ordinary distribution
and service network that stays with the customer.
Escorts Kubota limited came into its own with a far reaching vision for the future to stay over
close to the customers with products made in India to international standards. The source of
Escorts Kubota limited consistent growth is commitment and contribution to the core needs of
the country. Escorts Kubota limited have firmly believed that success depends on being close to
the customers. As early as in 1944 while others were concentrating on selling their
goods .Escorts sought to “Escorts Kubota limited” its merchandise right up to the customer’s
doorstep. This meant staying close to the customer, understanding their needs, giving them a
product that met these needs ensuring that it worked smoothly thereafter.
Today with Mr Nikhil Nanda as a Chairman the ideals have not changed. Thus, every
corporate endeavour addresses to the end users and the ever-changing market, substantial man-
hours are being devoted to planning a new range with the objective of consistently offering
greater value to the customer.
“In every area we touch our task has always remained one of engineering change” Nikhil

Nanda. In every step, Escorts has induced the latest technology to make products that are not
merely “better” but those meet international standard. For Escorts, these are two benchmarks of
industrial achievements, the distinct, undisputed edge of technology and the
internationalization of business.

In five decades Escorts has grown to become one of the top industrial conglomerates in
the country
FIVE DECADES OF ENGINEERING CHANGE

 THE DECADE OF CREATION: 1944-1954

The launch of Escorts Kubota limited Agents Pvt .In Lahore and setting it all up again in Delhi
after the country’s partition .The beginning of an industry legend, with a tractor franchise,
followed by India’s first institute of farm mechanization and the company’s first industrial
venture, Goetze (India) Ltd., at Patiala, in equity collaboration with Goetze of Germany.

 THE DECADE OF AUTOMATION: 1955-1964

Escorts goes public. A full-fledged manufacturing orientation takes roots with the
commencement of Escorts own brand of tractors and next major field of operation: motorcycles.
The company joins hands with Mahler to produce India’s most advanced pistons.
  THE DECADE OF CONSOLIDATION: 1965-1974
The foundation of the Ford-Escorts alliance for India’s finest tractors, soon to make the group
the largest selling tractor manufacturing .Escorts Kubota limited Employees Ancillaries
Ltd., a unique. Venture in industrial democracy, comes into being. Escorts Kubota limited
receives FICCI Award for outstanding contribution to Indian agriculture .The company
crossed national boundaries with its first export of 400 tractors to Afghanistan, won in a global
tender. A triumph of Escorts quality and competitiveness, this was perhaps the world’s largest
ever commercial airlift of its kind.

 THE DECADE OF DIVERSIFICATION: 1975-1984

One with Knorr Bremse follows an epoch-making alliance with JCB for India’s first
Excavator-loaders for railway breaks. With the Yamaha collaboration, Escorts become the
country’s largest motorcycle manufacturer. Acknowledged leadership in automotive ancillaries-
Mahle pistons and Goetze rings.

1. THE DECADE OF GLOBALISATION: 1985-1995

Escorts enters into joint venture with buy back arrangement with Class (Harvester

Combines) and Herion (Hydraulic valves) providing an entry to world markets. A tie-up with
Faun, powers the company to supremacy in hydraulic mobile cranes. Escorts fights an epic battle
against a corporate raid, the ultimate victory providing the unshakable confidence of the
company’s small shareholders countrywide. Escorts Heart Institute commissioned, hailed as
among Asia’s most advanced. Escorts turnover crosses Rs. 15 billion. In the sunrise telecom
sector, alliances with JS telecom, a Bosch company, and Hughes Network systems, world leaders
in VSAT networks.

2. THE DECADE AHEAD: 1996

The Mission is Globalization and the emphasis will be on core sector investments. Escorts

is going in for a global network and for mega projects in the 21st century.
According to the release, Nikhil Nanda continues to be the
Chairman and Managing Director (CMD) of the company.

"Our partnership with Kubota in Escorts Kubota Limited has been welcomed by all
our stakeholders and investors. Consequently, the process was completed
smoothly. We are now well poised at a very interesting time in global history to
contribute at much higher levels to India and the world's quest for food security,
sustainable agriculture and smart agriculture," Nikhil Nanda, CMD, Escorts
Kubota, said.

Yuichi Kitao, President and Representative Director, Kubota, Japan, said, "We are
very pleased to partner with Escorts Kubota Limited at a time when we can
combine our strengths to provide advanced farm mechanisation solutions to
address global food security and enhanced farm productivity needs."

ESCORTS KUBOTA LIMITED: RESTRUCTURING

Escorts Kubota Limited is all set to meet the future by drawing on its 50-year equity gained from
its
Inherent strengths, a strong presence in the Core Sector providing complementary product lines
and a vast marketing network; combining them with India’s intrinsic cost advantages to become
a global source point for high value engineering products.

Escorts Kubota Limited Limited is all set to meet the future by drawing on its 50-year equity
gained from its inherent strengths, a strong presence in the Core Sector providing complementary
product lines and a vast marketing network; combining them with India’s intrinsic cost
advantages to become a global source point for high value engineering products.

In order to meet the challenge of the future and to leave an indelible mark on industrial scenario,
Escorts has restructured the group along 4 business lines, each headed by an independent CEO.
The business groups are as follows:-

1) Agri Machinery Group

2) Construction Equipment’s
3) Automotive Ancillaries
4) Financial Services
 Escorts Kubota limited – THE GROUP INFRASTRUCTURE
The flagship of the Escorts Kubota limited group is Escorts Kubota limited in the words of Mr.
Nikhil Nanda. Chairman
Escorts Kubota limited. “In the last 50 years Escorts Kubota limited has been more than merely
one of India’s largest Engineering Companies. It has been a prime mover on the industrial
front; at every stage introducing products and technologies that helped take the country
forward in key areas. Today as the nation engages in its most momentous economic
transformation ever, we are once again adapting ourselves towards being catalysts for
qualitative growth by Engineering Change with a global perspective.”
The group infrastructure comprises:-
23 main associates/subsidiary companies

1) 12 manufacturing locations
2) A full-fledged R&D facility
3) Nearly 10,000 employees
4) 24 regional marketing offices
5) Nearly 500 ancillaries forming the vendor base
6) 4 financial services companies
7) Asia’s best training institute of Farm Mechanization with 100 acre demonstration farm.

EDDAL Escorts Kubota limited Dealer Development Association providing management and
financial support to dealers.
THE ESCORTS KUBOTA GROUP
3. THE FLAGSHIP COMPANY
 Escorts Limited
4. OPERATING DIVISIONS
 Agri machinery division
 Engineering division
 International business division
5. SUBSIDARY COMPANIES
 Escorts construction equipment Ltd. (cranes, exvators, truck loaders)
 Esconet services
 Escorts Automotive(Investment)
 Escosoft technologies
 Escortal tele communication ltd.
 Cell next solutions
 Auto matrix India
  Escorts Kubota limited heart institute & research centre
 Escorts Kubota limited hospital & research centre
Medical care (erstwhile division of Escorts lived off 100% subsidy)
6. ASSOCIATE COMPANIES
 India Ltd. GOETZE (India) Ltd.
 GOETZE TP (India) Ltd.
 GOETZE (India) assets management Ltd.
 Escorts Kubota limited securities ltd.
 Escorts Kubota limited Mahle Ltd
 Escorts Kubota limited Employees Ancillaries Ltd.
 Escorts Kubota limited Finance Ltd.
 IFS India Escorts Kubota limited
 Hughes Escorts Kubota limited communication ltd.
 Carraro (India) ltd.

ESCORTS GROUP CORE BUSINESS

BUSINESS GROUP PRODUCTS

Agri Machinery  Tractors

Construction equipment  Earth moving Machines

 Vibratory Rollers
 Material Handling Equipment’s

Auto motives  Pistons, Piston Rings

 Aluminium Cylinders
 Shock Absorbers
 Carburettors
  Magnetos
 Clutches

Railways  Air Brakes

 Couplers
 Electro-Pneumatic Brakes
 Shock Absorbers

Telecom  Cellular Telephone services

 VSAT Services (satellite communication
system)

Financial services  Automobile Financing

 Consumer Finance
 Mutual Funds
 Fixed Deposits

Manufacturing Facilities  Machining, painting and assembly

Product units(PUS)  Engine PU

 Transmission PU
 Rear Axle PU
 Assembly/tractor PU
Departments  Personnel & HRD
 Finance
 Manufacturing Engineering
 Plant Engineering & Machine
Maintenance
 Information Systems

BASICTable:-
OF1.1TRACTORS

About Tractor:-
Tractor is an engineering vehicle specially used in agriculture or construction. Tractor is also
used for the use of tractors to pull heavy machines and to carry heavy goods from one place to
another. Use is done to get high tar in slow speed

Basic of Tractor
Engine: -
The engine is the main part of the tractor, which is also called the heart of the tractor. Its work is
to transfer chemical energy into mechanical energy and transfers mechanical energy to the
transmission through the flywheel. By which the tractor is given the force to speed and work
according to need
 Transmission: -
Gear mechanism, which is used by the engine to transfer mechanical energy to the rear wheel
according to need, is called transmission. It is a series of gear in which the drive main gear shaft and
drine counter top of the ratchet. According to the work of the tractor, it provides wheel-over speed
with more torque.

Hydraulic: -
It is an integral part of the tractor which is installed on the transmission differential housing.
Hydraulic oil is a device that is used in lifting the load and doing the work of agriculture according
to the requirement. Hydraulic lift is used to do all the work of agriculture.

Main parts for shaping the tractor: -

The equipment, transmission and hydraulic which are planted on the top of the tractor, which
together make a complete tractor, and by applying the equipment, a tractor gets the right size. The
exterior parts are called clutch pedal, brake pedal, foot board, fuel tank, lower link, fender, tire,
radiator and sheet metal parts.

When all these parts are added together, a true size tractor is formed.

Complete tractor assembly process: -

Engine Tracto Tracto
Tracto
& r r
r
Trans assem Chassis assem Tracto
testing
missio bly line paint bly r
& PDI
n - shop After Dispat
proces
assem Before paint ch
s
bly paint line

Identification of the main parts of tractor: - RH side

Identification of the main parts of tractor: - LH side

Back View of Tractor:-

Front View of Tractor:-
Use of last big tire in tractor: -
Traction force of 1 tractor enhances the ability of pulling, so that the gravity force of the tractor
goes forward and the tractor can pull more load without further advance.
2. All the work from hydraulic lift, such as lifting the load or the enhancement to a higher height,
is the reason for the big tire.
3. Due to the large tire, the RPM in the tractor is reduced by getting more torque rear wheels so
that all the related work related to agriculture can be easily done.
4. Construction work from tractors is also possible due to large tires

Engine

Portable engine. A portable engine is a type of self-contained steam engine and boiler
combination that may be moved from site to site. Although bearing a strong family
resemblance, in both appearance and (stationary) operation, the portable engine is not classed as
a traction engine as it is not self-propelled.
Working of Engine:-

In some of the tractor, engines are fitted with an ECUEGR with is a new technology. The EGR
is an Exhaust Gas Recirculation valve and ECU is an Electronic control Unit
KA Type fuel injection pumps delivery even better mileage/fuel efficiency, improved engine
pickup in heavy load capacity conditions and better starting ability in cold conditions.
FT6060/6065/6075/TCI Engines/4455 BT+/Euro 60 are some of the farmtrac and Powertrac
engines where ECUEGR is used.
 ABOUT THE PLANT

The plant is equivalent with the following units: -

1. Engine Productive Unit (EPU)
2. Transmission Productive Unit (TPU)
3. Rear Axle Productive Unit (RAPU)
4. Tractor Productive Unit (TPU)
5. Paint Shop
Now transmission productive unit and rear axle productive unit have been merged and now it is
one productive unit known as transmission and rear axle productive unit.

The plant is equipped with the following facilities: -

MACHINE SHOP: EPU, RAPU AND TPU have separate machine shops equipped with
several purpose machine (SPM) as well as Computerized Numerically Controlled (CNC
machine)
.
1. The different components machine in these shops with their respective sections
are listed below:
 Cylinder Head, Cylinder Block and Connecting Rod.
 Case Transmission
 Canter Housing & Trumpet Housing.
 Tool Room.
 Turning, CNC, Gear Cutting, Grinding & Heat Treatment.

2. In heat treatment shop following facilities are available:

 Gas Carbonizing, Hardening & Tempering
 Induction Hardening

3. Following facilities are available in the various productive units:

 Transmission assembly
  Rear axle assembly
 Engine assembly and testing
 Tractor assembly

Brief description about engines in Powertrac and Farmtrac tractors.

Powertrac engines

Farmtrac engines in champion series

Other Farmtrac engines

Fuel tank capacity (in litres) in tractors according to model

Rear Tyre size in Powertrac
Rear Tyre size in Farmtrac

PTO Speeds (PTO RPM@what ERPM) – Powertrac

PTO (Power Take Off) Multi & Reverse speeds

PTO Speeds (PTO RPM@what ERPM) – Farmtrac

Powertrac Hydraulic lifting Capacity (Kg)
Farmtrac Hydraulic lifting Capacity (Kg)
Brakes

Classification of brakes

Dry Disc Brake Oil Immersed Brakes

 Single Reduction Single Reduction
 Hub Reduction (HR) Epicyclic Reduction(EPR)
 Inboard Reduction (XL) Hub Reduction(HR)
Inboard Reduction (XL)
Powertrac- Features of Brakes
Farmtrac- Features of brakes
 KAIZEN

Kaizen is a Japanese word meaning continuous improvement. It's made up of two characters in
Japanese: kai, which means “change” and Zen, which means “good”.
The concept is that small steps on a regular basis will lead to large improvements over time.
Kaizen is a slow but ongoing process of improvement, not a 'blitz' or quickly implemented set

Two kaizen approaches have been distinguished:

 Flow kaizen
 Process kaizen
The latter means the improvement of individual work stands. Therefore, improving the way
production workers do their job is a part of a process kaizen.
The use of the kaizen model for continuous improvement demands that both flow and process
kaizens are used, although process kaizens are used more often to focus workers on continuous
small improvements.
In this model, operators mostly look for small ideas which, if possible, can be implemented on
the same day.
This is in contrast to traditional models of work improvement, which generally have a long lag
between concept development and project implementation.

HISTORY:
The small-step work improvement approach was developed in the USA under Training within
Industry program (TWI Job Methods).Instead of encouraging large, radical changes to achieve
desired goals, these methods recommended that organizations introduce small improvements,
preferably ones that could be implemented on the same day.
The major reason was that during WWII there was neither time nor resources for large and
innovative changes in the production of war equipment. The essence of the approach came down
to improving the use of the existing workforce and technologies.

IMPLEMENTATION:
The Toyota Production System is known for kaizen, where all line personnel are expected to
stop their moving production line in case of any abnormality and, along with their supervisor,
suggest an improvement to resolve the abnormality which may initiate a kaizen.
The cycle of kaizen activity can be defined as: "Plan → Do → Check → Act". This is also known as
the Shewhart cycle, Deming cycle, or PDCA.

In the Toyota Way Fieldbook, Liker and Meier discuss the kaizen blitz and kaizen burst (or
kaizen event) approaches to continuous improvement.
The basic concept is to identify and quickly remove waste.
In the 1990s, Professor Iwao Kobayashi published his book 20 Keys to Workplace Improvement
and created a practical, step-by-step improvement framework called "the 20 Keys". He identified
20 operations focus areas which should be improved to attain holistic and sustainable change. He
went further and identified the 5 levels of implementation for each of these 20 focus areas. 4 of
the focus areas are called Foundation Keys. According to the 20 Keys, these foundation keys
should be launched ahead of the others in order to form a strong constitution in the company.
The four foundation keys are:

 Key 1 - Cleaning and Organising to Make Work Easy, which is based on the 5S
methodology.
 Key 2 - Goal Alignment/Rationalising the System.
 Key 3 - Small Group Activities.
Key 4 - Leading and Site Technology.
Few Examples of Kaizen:-
 SOS (STANDARD OPERATING SHEET)

DEFINATION:
A detailed listing of all components related to a particular process. Often including elements like
design, manufacturing and distribution, a standard operating sheet will provide an estimate of the
time required to complete each stage.

It is also frequently divided into two sections, manual and robot, to further define the time spent
between the two types of manufacturing labour. A standard operating sheet is a tool used in lean
manufacturing that aims to improve the process as a whole through standardization.

Contains:

 Completion time per unit

 Required cycle time
 Standard operations routine sheet
 Standard WIP
 Actual cycle time
 Layout (with positions of quality checks)

Purpose:

 Teaches worker about each operation

 Insures standards are met
 Tool to evaluate performance and improvement

Rules:
1. SOS sheets must always be dated to identify when they were revised last
2. SOS sheets should be revised regularly
3. Standard operations:
3(a). Are always imperfect
3(b). Should never be considered fixed
3(c). Must be adapted to reflect changing demand, worker skills, etc.
Format of SOS:-

Example:-
PROJECT 1
# ZERO OIL SPILLAGE #
1. Reason to take this project:
* Wastage of oil.
* uncomfortable surrounding.
* Wastage of resources eg.
* Disregard of 5’s.
* Hazardous for the people who working there.
* Oily and Slippery floor.
2. Theory:
Initially we get to this project and matching the f codes of
several models of tractor with given appropriate quality of oil
of different types that to be putted in them and found some
hash there in the given data or there may be a fault by the
worker in scanning the bar code. Then we get stuck with that
part and found all the faults there and now it would be good
than earlier.
3.Initially
We get around 20 cans of wate oil initially
4.AFTER

No can of waste oil would be found unless any mistake done

by a person working there.
# RESULTS #
 Zero oil spillage
 no extra efforts are used to done
 clean floor and conveyor
 good environment to work
 follows 5’S
 zero wastage if resources
 # PROJECT 2 #

KITTING SYSTEM

1.Reasons to take this project:

 wastage of resources
 wastage of time
 inappropriate way to work
 a lot of struggle has to be done to collect parts
 inappropriate order
 no proper layout

2.THEORY:
It is found that there was an inappropriate way of working
with a lot of struggle and lot of hard work there was no
proper way to do that work in less time with less efforts
and ease because in our kitting trolley there was no space
to put the several hardware unit various parts eg. For
muffler we need two studs of M8 a gasket and two nuts
and muffler itself but in our kitting trolley we get muffler
only other parts are taken from sides and sometimes many
 of parts were not found on that particular state so we
decided to provide all these parts in the kitting trolley itself
we made a better kitting trolley than the existing one that
will contain all various parts and hardware units within it
to reduce efforts and wastage of these nut bolts this will
provide a better plan to do work . it improve whole layout
and order of kitting trolley.

3.INITIALLY

Hardware units that are being putted aside and worker need to
collect them at every stage from there.
Initially trolley that collect major parts except small hardware
units of these parts.
Then we tried that if our idea works or not by putting several
hardware units of specific models in trolley and what we found
it really works .
4.AFTER
Final model of our trolley that solves all our issues easily

It contains all the hardware units and main parts with name tag
and their codes which makes easy to find that parts or sub part.