TRAINING REPORT

OF
SIX WEEKS INDUSTRIAL TRAINING
AT

BAJAJ AUTO LIMITED

ON
VEHICLE ASSEMBLY
SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE
OF
BACHELOR OF TECHNOLOGY
IN
DEPARTMENT OF MECHANICAL ENGINEERING

Submitted by:
Samarth Shah
B.Tech (Mechanical)
130020201073

1|Page

Under the guidance of:

S.P. Atole and S.M Alande
Department Manager
Vehicle Assembly

2|Page

I. PREFACE
As a part of the Engineering curriculum and in order to attain practical knowledge and depth in
the field of mechanical, I am required to make a report on Summer Internship. The basic
objective behind doing this project report is to gain knowledge and experience of Automobile
industry.
In this project I have included the processes at Bajaj Auto LTD. for production of different
categories of motorcycles. I have also included the policies used by Bajaj to run their plants and
manage labor.
During my training of six weeks, it helped me to enhance my knowledge regarding my loved
field of automobiles and helped understand my career objective.

3|Page

II. ACKNOWLEDGEMENT
The internship opportunity I had with Bajaj Auto LTD. was a great chance for learning
development. Therefore, I consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it.
And for this opportunity I would express my gratitude to my college faculty and,
thank Mr. Bhagyesh Gadade and Mr. Akash Singhal (Asst. Manager, HRD) for providing me
with the opportunity of doing an internship at Bajaj Auto Limited, Chakan Plant.
I choose this moment to acknowledge my project mentors Mr. S.P Atole, S.M Alande along with
Mr. Vinod Vahadene for their valuable guidance and giving necessary advices. I would like to
appreciate all the other staff members for being friendly and helping in every way possible to
understand the working throughout my period.
I perceive this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives.

4|Page

Table of Contents
I. PREFACE ................................................................................................................................................ 3
II. ACKNOWLEDGEMENT..................................................................................................................... 4
III. COMPANY PROFILE ........................................................................................................................ 6
IV. KEY POLICIES ................................................................................................................................... 9
V. CHAKAN PLANT AN OVERVIEW .............................................................................................. 10
V.1. BRIEF HISTORY ........................................................................................................................... 10
V.2. VISION ........................................................................................................................................... 12
V.3. MISSION ........................................................................................................................................ 12
V.4. OBJECTIVE ................................................................................................................................... 12
V.5. GOAL.............................................................................................................................................. 12
VI. INTRODUCTION TO ASSIGNED JOB ......................................................................................... 13
VI.1. ALUMINIUM MACHINE SHOP ................................................................................................. 13
VI.2. STEEL MACHINE SHOP............................................................................................................. 16
VI.3. ENGINE ASSEMBLY .................................................................................................................. 18
VI.4. VEHICLE ASSEMBLY ................................................................................................................ 20
VI.5. MATERIAL FLOW CHART ........................................................................................................ 23
VI.6. PROCESS FLOW CHART ........................................................................................................... 24
VII. PROJECTS........................................................................................................................................ 25
VII.1. DEFECTS IN PETROL TANK COVER ..................................................................................... 25
VII.2. DEFECTS IN FAIRING .............................................................................................................. 27
VII.3. DEFECTS IN COUPLER- K1 ..................................................................................................... 28
VIII. INDUSTRY APPLICATION ......................................................................................................... 29
IX. CONCLUSION ................................................................................................................................... 30
X. BIBLIOGRAPHY ................................................................................................................................ 31

5|Page

III. COMPANY PROFILE

The Bajaj Group is amongst the top 10 business houses in India. Its footprint stretches over a
wide range of industries, spanning automobiles (two-wheelers and three-wheelers), home
appliances, lighting, iron and steel, insurance, travel and finance. The group's flagship company,
Bajaj Auto, is ranked as the world's fourth largest two- and three- wheeler manufacturer and the
Bajaj brand is well-known across several countries in Latin America, Africa, Middle East, South
and South East Asia. Founded in 1926, at the height of India's movement for independence from
the British, the group has an illustrious history. The integrity, dedication, resourcefulness and
determination to succeed which are characteristic of the group today, are often traced back to its
birth during those days of relentless devotion to a common cause. Jamnalal Bajaj, founder of the
group, was a close confidant and disciple of Mahatma Gandhi. In fact, Gandhiji had adopted him
as his son. This close relationship and his deep involvement in the independence movement did
not leave Jamnalal Bajaj with much time to spend on his newly launched business venture. We
are celebrating 125th Birth anniversary of Shri. Jamnalal Bajaj on 4th of November 2014.

His son, Kamalnayan Bajaj, then 27, took over the reins of business in 1942. He too was close to
Gandhiji and it was only after Independence in 1947, that he was able to give his full attention to
the business. Kamalnayan Bajaj not only consolidated the group, but also diversified into various
manufacturing activities. The present Chairman of the group, Rahul Bajaj, took charge of the
business in 1965. Under his leadership, the turnover of the Bajaj Auto the flagship company has
gone up from INR.72 million to INR. 120 billion, its product portfolio has expanded and the
brand has found a global market. He is one of Indias most distinguished business leaders and
internationally respected for his business acumen and entrepreneurial spirit.
Bajaj Auto is the flagship of the Bajaj group of companies. The group comprises of 34
companies and was founded in the year 1926.

6|Page

The companies in the group are:

Bajaj Auto Ltd.

Bajaj Holdings & Investment Ltd.

Bajaj Finserv Ltd.

Bajaj Allianz General Insurance

Company Ltd.

Bajaj Allianz Life Insurance Co. Ltd

Bajaj Financial Solutions Ltd.

Bajaj Auto Finance Ltd.

Bajaj Allianz Financial Distributors Ltd.

Bajaj Auto Holdings Ltd.

P T Bajaj Auto Indonesia (PTBAI)

Bajaj Auto International Holdings BV

Bajaj Electricals Ltd.

Hind Lamps Ltd.

Bajaj Ventures Ltd.

Mukand Ltd.

Mukand Engineers Ltd.

Mukand International Ltd.

Bajaj Sevashram Pvt. Ltd.

Jamnalal Sons Pvt. Ltd.

Rahul Securities Pvt Ltd

Shekhar Holdings Pvt Ltd

7|Page

Madhur Securities Pvt Ltdthere

Niraj Holdings Pvt Ltd

Shishir Holdings Pvt Ltd

Kamalnayan Investments & Trading Pvt Ltd

Sanraj Nayan Investments Pvt. Ltd.

Hercules Hoists Ltd.

Hind Musafir Agency Pvt. Ltd.

Bajaj International Pvt. Ltd.

Bachhraj Factories Pvt. Ltd.

Baroda Industries Pvt. Ltd.

Jeevan Ltd.

Bachhraj & Co Pvt Ltd.

The Hindustan Housing Co. Ltd.

Hospet Steels Ltd

8|Page

IV. KEY POLICIES

9|Page

V. CHAKAN PLANT AN OVERVIEW

V.1. BRIEF HISTORY
The foundation stone of this plant was laid on 9th of March 1998, the factory was inaugurated by
late Smt. Savitridevi Bajaj (Mother of Chairman, Mr Rahul Bajaj) on 20th October, 1999 and the
start of commercial production took place on 1st of March, 2000.
People

Lean and agile structure of 1200 employees with average age of 25 years.

Multi-skilled; autonomously manage production, quality and equipment maintenance.

Empowered to take decisions for smooth working.

The employees here follow the famous quote of founder Shri Kamalnayan Bajaj,
Do what you think is best, but be the best in whatever you do.

Concepts

There is no formal quality control department- Quality is built in the process.

High clarity and transparency.

Commonly shared facilities like transport, canteen and toilets.

Direct on line concept, no stores, single sourcing.

Bajaj Auto Limited, Chakan has put thousands of Vehicles on the road, in India and abroad. This
state-of-the-art facility has produced ungeared scooters like Saffire, Spice and Spirit in the past
and is currently producing motorcycles like Pulsar, Avenger and KTM variants. The ability to
cater to the changing times is achieved as a result of constant efforts to implement the Bajaj
policies of higher quality and continuous improvement in all fields. As BAL Chakan was
fortunate to receive most of the learning from existing two plants, i.e. Akurdi and Waluj, it has
incorporated most of the improvements by using past experiences and negative points were taken
care of from the inception of the plant itself. Having tasted fruits of TPM activities at other
plants, BAL Chakan also decided to go for TPM activities.

10 | P a g e

BAL Chakan Plant

11 | P a g e

V.2. VISION

To attain World class Excellency by demonstrating value added products to customers.

V.3. MISSION

Focus on value based manufacturing.

Continual improvement.

Total elimination of waste.

Zero defects.

Pollution free and safe environment.

V.4. OBJECTIVE

Bajaj Limited is to cater the market needs of transportation by providing two wheeler and
three wheeler vehicles.
BAL has been producing the catalogue products to cater to the changing market
requirements based on the customer feedback, improvements are being made
continuously in the existing products.

V.5. GOAL
To catapult Bajaj Auto as the countrys largest automobile company.

12 | P a g e

VI. INTRODUCTION TO ASSIGNED JOB

My first and foremost job in this plant was to capture and learn as many things as possible which
are related to my interest of automobile industry. The plant consisted of various shops; Steel
machine shop, Aluminium machine shop, Engine Assembly shop and Vehicle assembly shop.

VI.1. ALUMINIUM MACHINE SHOP

The aluminium machine shop at BAL, Chakan mainly did the finishing of crank case, cylinder
head and cylinder block which are important components of an Engine.

1. Crankcase: Crankcase is a drilled metal frame that houses several parts, notably the
crankshaft. Its main universal function is to shield the crankshaft and the connecting rods from
debris. Most modern crankcases are made out of aluminum, which provides a lightweight yet
strong design capable of withstanding the pressures exerted during normal engine use. Proper
care of the crankcase and its internal components is essential to the smooth running of an engine.

Fig. VI.1

13 | P a g e

These involve following processes:

Drilling: A radial drilling machine or radial arm press is a geared drill head that is
mounted on an arm assembly that can be moved around to the extent of its arm reach.
The most important components are the arm, column, and the drill head. The drill head of
the radial drilling machine can be moved, adjusted in height, and rotated. Aside from its
compact design, the radial drill press is capable of positioning its drill head to the work
piece through this radial arm mechanism.

Milling: This is the process done in two stages. The first machine is machining on top
and bottom faces and the other is on the side faces.

Fig. VI.2

Boring: It is a process of enlarging a hole that already exists. It is done to achieve

greater accuracy of the diameter of a hole.

Fig. VI.3

14 | P a g e

2. Cylinder head: The cylinder head of an engine determines the engine's properties in
terms of operating behavior, e.g. power output, torque and exhaust gas emission
behavior, fuel consumption and acoustics, like almost no other component assembly of
the engine. It contains the key elements for mechanically controlling the gas exchange or
combustion. Valve control is of particular importance here.

Fig. VI.4

3. Cylinder block: Cylinder block which is also called as engine block is the main
structure of the engine which give the space for the cylinders, and it also give passages
for the coolant, exhaust, and in take gases to pass over the engine and host for the
crankcase and cam shafts. Engine block is the main housing of hundreds of parts found in
modern engines.

15 | P a g e

VI.2. STEEL MACHINE SHOP

The finishing of two important parts of an engine; Camshaft and Crankshaft are done here.

1. Camshaft: The cam shaft is a steel rod that controls the operation of the intake and exhaust
valves. The cam shaft has lobs on it which are egg shaped and they rub against the top of the
valve and when the egg shaped part of the lob rubs on the top of the valve it opens it up and
allows the air to enter the engine and the same thing happens for the exhaust valve.

Fig. VI.5
There are different machines used in the plant, namely:

NTC lobe Grind.

Induction Hardening.

Lobe Mill.

Micrometer Grinding Machine

FRD Keyway Mill.

Deburring Machine.

16 | P a g e

2. Crankshaft: It is a mechanical part able to perform a conversion between reciprocating

motion and rotational motion. In a reciprocating engine, it translates reciprocating motion of the
piston into rotational motion; whereas in a reciprocating compressor, it converts the rotational
motion into reciprocating motion.

Fig. VI.6
There are different machines used in the plant, namely:

Optical Grinding Machine.

Keyway Milling Machine.

Wheel Head grinder.

Lapping Machine.

Washing Machine.

Cap press Machine.

Balancing Machine.

17 | P a g e

VI.3. ENGINE ASSEMBLY

The plant has three divisions within the shop for lower end engines, mid-end engines and high
end engines. The engines assembled at Chakan plant are: KTM (390cc, 200cc, 125cc), Pulsar
DTS-I (150cc, 180cc, 200cc, 220cc).

The following is the procedure in which the engine for K4, K14, and K8 are assembled:
Left Hand Side
1. Body balancer assembly.
2. Output shaft float and freeness.
3. Drive-Driven gear pair matching.
4. Rotor assembly and tightening.
5. Cam shaft clip locking.
6. Coolant passage leakage testing with hose pipe.
7. Engine Oil.
8. Cylinder head gasket fitment.
9. Presence of rod clutch bearing.
Right Hand Side
1. Verification of engine number punching and bar code sticker.
2. Input shaft float and freeness.
3. Block fitment.
4. Cam shaft assembly.
5. Collets fitment.
6. Neutral indication working.
7. Engine leakage test.
8. Magneto cover.
9. Stator coil fitment.

18 | P a g e

The following are the important components involved in the engine:

Cylinder head

Clutch

Input and output shaft

Drum

Cam shaft intake and exhaust

Gear and gear shift

Oil Pump

Primary drive

Input and Output fork

Cylinder block

Cam holder

Gear starter

Crank shaft

Crank case

19 | P a g e

VI.4. VEHICLE ASSEMBLY

Vehicle Assembly Line consists of 5 conveyors (as shown in Material Flow Chart) on which
different models of Pulsar, Avenger, and KTM are assembled.
For these conveyors, there are 6 dynamometer chambers available for dynamic testing of the
bikes assembled. Sub-assembly of fairings of K-16A, K-16B is done at the stores itself. For the
rectification of defects and enhancing surface appearance, there are following sections in
addition to online reworks:

3M Coating Section

Engine Rework Section

General Reworks (handled by QSR)

The daily planning and scheduling of production is done at PPC Office (Production Planning and
Control). The general controlling of work is done from the Vehicle Assembly Office. The
Quality Assessment (QA) Office analyses the quality of parts/bikes assembled. Daily at 10 a.m.
Quality Status Review (QSR) Meeting takes place to address the frequent issues pertaining to the
quality of vehicles being assembled or the defective parts that are being received from the
vendors. Generally, this meeting is presided over by Mr Makarand Pinjarkar (DGM, Production).
The concerned persons are informed about the issues and instructed to look into the matter,
representatives of vendors are also approached to in this meeting.

20 | P a g e

The functioning of Vehicle Assembly QSR can be explained through the following
flowchart:

21 | P a g e

The procedure followed for assembling all the models are:

1. Chassis number punching
2. Rear tyre loading
3. Greasing at joints
4. Rear axle insertion
5. Fork fitment
6. Rear and front fender
7. Front wheel loading
8. Engine and engine hanger bracket fitment
9. Checking of the chain lock direction
10. Gear shifting lever fitment
11. Stator motor cover
12. Tail light and handle bar fitting
13. Carburetor fitment
14. Brake kit fitment
15. Silencer fitment
16. Accelerator connection
17. Seat and petrol tank cover fitting and tightening
18. Dynamometer testing: Electricals test, engine noise and brakes, CO

22 | P a g e

emission.

VI.5. MATERIAL FLOW CHART

23 | P a g e

VI.6. PROCESS FLOW CHART

24 | P a g e

VII. PROJECTS
VII.1. DEFECTS IN PETROL TANK COVER
The Petrol Tank Assembly consists of the Petrol Tank and the Petrol Tank Cover. The Petrol
Tank is fabricated at TSN and painted in Paint Shop at BAL. While the Petrol Tank Covers
parts (tank top and side fairings) are made by Varroc Polymers and assembled at Vasumati
Industries.

The following are the observed defects in the petrol tank cover:

Scratches (Major) and dents.

Presence of metal chips.
Bubble in the decal.
Paint overflow, Paint uncover, orange peel.
Bracket missing and tapping while fitting with the petrol tank.
Clip nut hardness more resulting in breakage.
No templet used for PTC pad.
Excess gap after fitting with petrol tank.
The defects could be caused On-Line and Off-Line.
On- Line defects are caused by:

Nut runners too close to polished surface.

Abrasion of parts (uncovered) while sliding in order to assemble.
Slip of nut runner caused due to miss-match or tapping.

25 | P a g e

Off-Line defects are caused due to:

Scratches caused due to Transportation and handling defects.

Changes made to reduce/ remove defects are:

Checkpoint added to prevent excess gap at Vasumati.

Two templet provided for two stations

Rubber tubes and velvet cloth suggested in the trolley and working area.

Chamfering of Allen bolt from the top suggested.

26 | P a g e

VII.2. DEFECTS IN FAIRING

The main defects in the fairing observed are:

Scratches.

Paint uncover, paint overflow, orange peel.

Bracket and Allen bolt missing.

Gap with speedo cover was found to be excess of 0.5mm.

Major reasons for the defects:

Improper handling and care at Gajanan Enterprises.

No boxes or trolley used.

Changes made to remove the defects:

Padded boxes advised to Gajanan.

Three checkpoints added.

Fig. VII.2.1

27 | P a g e

Fig VII.2.2

VII.3. DEFECTS IN COUPLER- K1

The following are the possible reasons that the speedometer coupler gets damaged:

It is not fully covered by the bellow cover while its loaded in the Chassis shop.

The major possibility of it getting damaged is when the engine number punching is done
on the first stage of the conveyor

While fitting the headlight of Pulsar 150.

Coupler comes in between the chassis and engine while loading the engine.

Changes that can be made to avoid these defects are:

Change the plastic of speedometer coupler as the other couplers.

Provide coupler with rubber coating at the top edges.

Checkpoint at chassis shop to ensure that the bellow cover is totally covered.

Fig VII.3.1

28 | P a g e

Fig VII.3.2

VIII. INDUSTRY APPLICATION

Bajaj Auto Limited is an Indian automotive manufacturing stalwart. It is a division of one of the
10 largest business conglomerates in India- The Bajaj Group, which was founded in 1926. Bajaj
Auto Limited, the flagship company of the Bajaj Group, is ranked fourth amongst the largest
two-wheeler and three-wheeler manufacturers in the world. It is primarily involved in
manufacturing and selling of motorbikes and scooters (two-wheelers) and auto-rickshaws (threewheelers).

29 | P a g e

IX. CONCLUSION
In my six weeks of training, I got to understand the process of manufacturing an automobile
from the first stage to the last stage.
I learnt in detail about manufacturing and major components involved in Engine and Vehicle
assembly. Seeing what you have been reading in books was an exhilarating experience and I am
sure it will help me in my coming years.
The atmosphere at BAL Chakan plant was very friendly and lively despite working at the same
station for eight long hours. Each and every staff member were unhesitant in transferring
knowledge.
During my training, I even learnt about the different policies used to run a manufacturing plant

30 | P a g e

X. BIBLIOGRAPHY
All the information used in this report has been sourced from the following:

Company site: http://www.bajajauto.com/bajaj_corporate.asp

Company server

From the Company workers and mentor

31 | P a g e