Industrial Visit report 11

INDUSTRIAL VISIT
AT
KAL, TRIVANDRUM
ON 19/03/2011
Dept. of Mechanical Engg MACE,Venjaramoodu


Industrial Visit report 11

INTRODUCTION
Kerala Automobile Limite! "KAL#, i$%or&orate! i$ 19'(, a a )o*er$me$t o+ Kerala
u$!erta,i$- i etu& i$ t.e &i%ture/ue ba%,!ro&, 10 ,m out. o+ T.iru*a$a$t.a&uram i$ a ti$1
*illa-e %alle! Aralumoo!u, i$ Ne11ati$,ara t.alu,2 T.e %om&a$1 ma$u+a%ture t.ree 3.eeler
uitable +or &ae$-er a$! -oo! tra++i% i$ t.e bra$! KAL a$! are %o$i!ere! a mot
e%o+rie$!l1 *e.i%le2 T.ere i a tro$- a$! .i-.l1 moti*ate! 3or,+or%e i$ t.e %om&a$12 T.e
au4iliar1 u$it !e*elo&e! b1 t.e %om&a$1 arou$! t.e +a%tor1 %om&le4 i a li*eli.oo! +or
.u$!re! o+ &ero$2
Si$%e %omme$%eme$t o+ &ro!u%tio$ i$ 19(5, t.e %om&a$1 .a ma$u+a%ture! a$!
mar,ete! more t.a$ 60000 t.ree 3.eeler, KAL !iti$-ui.e! itel+ a a +or%e 3ort. re%,o$i$-
i$ t.e automobile i$!utr1 i$ I$!ia2 T.e %om&a$1 .a alo e4&orte! a $umber o+ t.ree 3.eeler
to Sri La$,a, Ne&al, Su!a$, 7ot3a$a, 7a$-la!e., )autemala, Ni-eria, 8-1&t a$! Sout.
A+ri%a2 T.e %om&a$1 %oul! a%.ie*e a re%or! tur$o*er a$! %oul! tur$ t.e %or$er +or t.e +irt time
i$ 199391995, a$! -e$erate! &ro+it i$%e t.e$2 T.e %om&a$1 mai$tai$ t.e tre$! o+ &ro+it
ma,i$- till !ate2 T.e a%%e&tabilit1 o+ KAL t.ree 3.eeler i$ t.e t.ir! 3orl! %ou$trie &ea, +or
utilit1 a$! /ualit12
KAL i alo ma$u+a%turi$- a$! u&&l1i$- o&.iti%ate! %om&o$e$t to be ue! i$ &a%e
&ro-ramme o+ I$!ia, 3.i%. %all +or tri$-e$t /ualit1 ta$!ar!2 T.i it i a tetimo$1 o+ t.e .i-.
le*el /ualit1 %o$%iou$e o+ KAL2
FABRICATION SECTION
Dept. of Mechanical Engg MACE,Venjaramoodu


Industrial Visit report 11

T.i e%tio$ !eal 3it. %utti$- a$! i:i$- o+ .eet to &ro!u%e *ariou ,i$! o+ %.a$$el
ue! i$ t.e %.ai %o$tru%tio$, &ro!u%tio$ o+ bra%,et, %lam& et%2 .ere t.e rear a4le .oui$-
are %ut to i:e a$! 3el!e! 3it. t.e !i++ere$tial %o*er member2 T.e i!e member are alo %ut to
i:e a$! t.ee are 3el!e! b1 ar% 3el!i$- to -et t.e +i$al ri-i! +rame o+ t.e t.ree 3.eeler2
A$ o*er*ie3 o+ t.e ma%.i$e at t.e e%tio$ i -i*e$ belo3;
12 Ar% 3el!i$- u$it
22 S&ot 3el!i$- ma%.i$e
32 Verti%al ba$! a3
52 15T &$eumati% &re
62 (0T &re bra,e
02 (0T .eari$- ma%.i$e
'2 10T &re
(2 8$ter&rie ma%.i$e
92 <ori:o$tal ba$! a3
102 MI) 3el!i$- u$it
112 =e$ter lat.e
122 Tube be$!i$- ma%.i$e
132 Nibbli$- ma%.i$e
152 Abrai*e %utter
162 7e$%. -ri$!er
102 >o3er blo3er
1'2 100T &re
RAW MATERIALS
Metal .eet
12 126 mm =R S.eet
22 3 mm =R .eet
32 226 mm =R .eet
52 2 mm =R .eet
62 1226 mm =R .eet
02 1 mm =R .eet
'2 02( mm =R .eet
Metal tube
12 D36?0 mm
22 D50?3 mm
32 D60?3 mm
52 D50?226 mm
PARTS PRODUCED
@rame %om&o$e$t
Dept. of Mechanical Engg MACE,Venjaramoodu


Industrial Visit report 11

12 Mai$ beam
22 Dieel i!e beam
32 =ro &i&e rear
52 Lo$- member to&
62 7eam lo3er"L<#
6. 7eam lo3er"R<#

OTHER COMPONENTS
7elo3 are t.e *ariou %om&o$e$t &ro!u%e! at t.e .o&A
Dieel +iller bra%,et
Steeri$- %olum$
Air +ilter aembl1
Mai$ beam
Double be$! bra%,et "L<#
A4le .oui$- "L<#
8$-i$e be!
Rear a4le bra%,et "R<#
MACHINE SHOP
T.e bul, o+ o&eratio$ +or %o$*erti$- t.e metal &art i$to ue+ul %om&o$e$t to
be ue! i$ t.e t.ree 3.eeler are !o$e i$ t.e ma%.i$e .o&2 T.i i t.e bi--et e%tio$ at
KAL .a*i$- t.e lar-et .are o+ /uali+ie! 3or,+or%e2 T.i e%tio$ e$ure t.e /ualit1
ta$!ar! at t.e or-a$i:atio$2 T.e e%tio$ .a a lar-e $umber o+ o&.iti%ate! ma%.i$er1,
bot. automati% a 3ell a, emi automati% to &ro!u%e t.e %om&o$e$t at +at &a%e a$!
ati+1i$- tri$-e$t /ualit1 ta$!ar!2 At ea%. le*el o+ o&eratio$ i$&e%tio$ are !o$e to
ta,e a&&ro&riate a%tio$2
T.e ra3 material ue! .ere at t.e ma%.i$e .o& i$%lu!e t.oe +abri%ate! at t.e
+abri%atio$ .o& a$! alo %ati$- a$! +or-i$- im&orte! +rom ot.er +a%torie2 T.e
ma%.i$e .o& alo !oe %o$tra%t Bob +or t.e &a%e &ro-ramme o+ ISRO2
A$ o*er*ie3 o+ ma%.i$e;
@i$e bori$- ma%.i$e "@7M'35#
Verti%al ma%.i$i$- %e$ter "VM=(00#
Verti%al tool %e$ter "TV=#
Verti%al ma%.i$i$- a$! bori$- "VM7(#
Dept. of Mechanical Engg MACE,Venjaramoodu


Industrial Visit report 11

=N= lat.e "8=ONO =N=#
Ra!ial arm !rilli$- ma%.i$e "RD32, RD26, RD01#
)ear .a&i$- ma%.i$e
T.rea! roller
<ori:o$tal .obbler
7roa%.i$- ma%.i$e
Ta&&i$- ma%.i$e
<o$i$- ma%.i$e
=.u%, mate
Verti%al milli$- ma%.i$e "@N2V1, @N2V2#
<ori:o$tal milli$- ma%.i$e "@N28<2, @N28<1#
84ter$al -ri$!i$- ma%.i$e "K130U, K130>#
I$ter$al -ri$!i$- ma%.i$e ")I@(0#
=o&1i$- lat.e
Turret lat.e
=e$ter lat.e "2D, 2D1, 5D#
PARTS PRODUCED AT THE MACHINE SHOP
7ra,e !rum
Di++ere$tial %ai$-
=o$$e%ti$- ro!
=1li$!er
I$ertio$ %ou&li$-
@ro$t 3.eel a4le
)ear bo4 %o*er
C.eel +la$-e
@ro$t 3.eel a4le
)ear bo4 %o*er
)ear %.a$-e .a+t
@irt -ear
Se%o$! -ear
=luter -ear
@ro$t bra,e %ae
Tra$miio$ .a+t
Taili$- li$, "R<#
Dept. of Mechanical Engg MACE,Venjaramoodu


Industrial Visit report 11

ASSEMBLY SHOP
STAGES OF ASSEMBLY
Wheels and tyres
KAL *e.i%le ue &ree! teel !i% 3.eel o+ !i*i!e! t1&e2 T.e t3o .al*e are e%urel1
+ate$e! to +orm a rim .a*i$- t3o +i4e! +la$-e2 T.e t1re 3it. tube i t.e +i4e! o$ to t.e 3.eel2
KAL ue MR@9SAVARI bra$! t1re +or it *e.i%le2
Ba! "late asse#$ly
T.e !rum bra,e 1tem ue! %o$it o+ t3o bra,e .oe 3it. +ri%tio$ material a%tuate!
b1 a 3.eel %1li$!er2 A %am a%tuate t.e &ar,i$- bra,e2 Retra%tor &ri$- ue! +or releae o+
bra,e2 Te$io$ &ri$- are &la%e! be$eat. t.e bra,e .oe
D%&&erent%al asse#$ly
Mat%.i$- &la$et a$! u$ -ear are ele%te! a$! +i4e! o$ t.e eat &ro*i!e! i$ t.e
!i++ere$tial %a-e2 T.e$ t.e %ro &i$ i i$erte! a$! t.e me.i$- o+ -ear are %.e%,e! to ee i+
t.ere i a$1 ba%,la.2
Pr'"eller sha&t asse#$ly
T.e &ro&eller .a+t %o$it o+ t3o u$i*eral Boi$t a$! a li!i$- Boi$t2 7e*el &i$io$ i
atta%.e! to o$e e$! *ia t.e u$i*eral Boi$tA +le4ible ri$- t1&e u$i*eral Boi$t i ue!2
Handle $ar asse#$ly
<a$!le bar %o$it o+ me%.a$im +or a%tuati$- %lut%., a%%elerator a$! bra,e2 It alo
.oue t.e 3it%. aembl1 +or li-.t a$! ot.er a%%eorie2
Asse#$ly l%ne
T.e tra!ema$ +it t.e 3el!e! +rame o$ to t.e trolle1 o+ t.e aembl1 li$e2 T.e$ t.e
aemble! rear a4le i +itte! to t.e +rame *ia t.e lea+ &ri$-2 No3 t.e bra,e &e!al i +itte! a$!
mater %1li$!er +itte!2 T.e mater %1li$!er i +ille! 3it. bra,e +lui!2 7ra,e li$e are +itte!2 A+ter
%om&letio$ t.e .1!rauli% bra,e aembl1 t.e &ar,i$- bra,e i +i4e!2
Dept. of Mechanical Engg MACE,Venjaramoodu


Industrial Visit report 11

T.e *e.i%le i .i+te! to t.e !ome aembl1 e%tio$ +or +itti$- t.e !ome a$! %.e%,i$- t.e
bra,e aembl12 <ere t.e teeri$- %olum$ a$! +ro$t 3.eel aemble! alo$- 3it. t.e .a$!le bar2
T.e *e.i%le i .i+te! to t.e e$-i$e aembl1 e%tio$ 3.ere t.e e$-i$e9-ear bo4 aembl1 i
+itte! to t.e %.ai +rame ui$- rubber eat2 No3 t.e *e.i%le u$!er-oe !etaile! teti$-2
Dept. of Mechanical Engg MACE,Venjaramoodu