INDUSTRIAL TRAININGREPORT

at

“CNH INDUSTRIAL ( New Holland )”

Submitted in partial fulfilment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by
NAME :- ENROLLMENT NO :-
VEER PRATAP SINGH 00714811123

DEPARTMENT OF MECHANICAL ENGINEERING

MAHARAJA AGRASEN INSTITUTE OF TECHNOLOGY

PSP AREA, PLOT NO. 1, SECTOR-22, ROHINI, DELHI-110086
2022-2023
Self-Assessmentof Industrial Training by Student
1. Student Name: VEER PRATAP SINGH
2. Name and Address of Industry: CNH INDUSTRIAL (NEW HOLLAND ) -
PLOT NO. 3 , UDYOG KENDRA , GREATER NOIDA – 201306 , UTTAR
PRADESH , INDIA
3. Guide/Trainer from Industry with designation: MITHILESH KUMAR SINGH
4. Contact details of Guide/Trainer: 9999534274
5. Date of commencement and end: 16-JUNE-25 TO 25-JULY-25

I hereby declare that I have learnt following skills during my Industrial training:
a) CNC Manufacturing and Operations
b) Engine Testing and Components
c) Transmission and Hydraulic Testing
d) CBS ( CNH Business System )
e) Cycle Time Study
f) Basic Tools Usage
g) Industrial Exposure

Date: Signature of Student

 ACKNOWLEDGMENT

I would like to express my heartfelt gratitude to all the faculty members of Maharaja
Agrasen Institute of Technology for their constant guidance, encouragement, and support
throughout my learning journey. I am especially thankful to Dr. Vaibhav Jain, Head of the
Department of Mechanical Engineering, for his valuable mentorship, insightful advice, and
motivation, which have played a crucial role in shaping my academic and professional
growth.

I am equally thankful to the entire team at New Holland for providing me with the
opportunity to learn and gain hands-on experience in an industrial environment. Their
guidance, cooperation, and willingness to share knowledge have helped me understand
practical applications of my academic concepts and enhanced my technical skills. This
experience has been invaluable in my development as an aspiring engineer.
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COMPANY PROFILE
CNH INDUSTRIAL (NEW HOLLAND)
CNH Industrial is a leading global capital goods company specializing in the design, production, and sale of
agricultural and construction equipment, commercial vehicles, and powertrain solutions. With a strong presence
in over 180 countries, the company operates through well-known brands such as New Holland Agriculture, Case
IH, CASE Construction Equipment, and FPT Industrial. CNH Industrial focuses on innovation, sustainability, and
advanced technology to meet the diverse needs of farmers, builders, and industries worldwide, while maintaining
high standards of quality, efficiency, and customer support.

The New Holland Agriculture manufacturing plant in Greater Noida, Uttar Pradesh, is one of CNH Industrial’s
most advanced facilities in Asia. Established to serve both domestic and international markets, the plant produces
a wide range of tractors and agricultural machinery with modern manufacturing processes and stringent quality
control systems. It integrates advanced robotics, precision engineering, and lean manufacturing practices to
ensure world-class productivity. The Greater Noida plant not only supplies products to Indian farmers but also
exports to multiple countries, reflecting CNH Industrial’s commitment to “Made in India” excellence and global
competitiveness.

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CNH Industrial has a strong global manufacturing presence, operating around 64–67 plants strategically located
across various regions of the world. These facilities are spread over approximately 180 countries, enabling the
company to efficiently serve diverse markets with agricultural, construction, and industrial equipment. This
extensive network not only supports local economies but also ensures that CNH Industrial can deliver products
tailored to regional needs while maintaining high standards of quality, innovation, and sustainability on a global
scale.

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TABLE OF CONTENT

[Link] CHAPTER
1. Machine Shop
2. CNC (Computer Numeric Control)
2.1 CNC Introduction
2.2 CNC Used
2.3 Machining Process
2.4 Spindle Movement and Axis
2.5 CNC Coding
2.6 Breakdown and Alarm
2.7 Fixtures
3. TOOLS AND SEFETY EQUIPMENTS
3.1 Basic Tools and Equipments
3.2 Safety Equipments
4. CBS (CNH Business System)
4.1 DMS
4.2 SMAT
4.3 5S
4.4 AM
4.5 SOP
4.6 OPL
5. ENGINE TESTING AND COMPONENTS
5.1 Engine Testing
5.2 Engine Components
6. CONTRIBUTION

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CHAPTER 1

MACHINE SHOP
A machine shop is a specialized workshop where various machining processes are carried out to convert raw or
semi-finished materials, such as castings or forgings, into precise and functional components. These shops are
equipped with a range of tools and machines used for cutting, shaping, drilling, and finishing metal workpieces.
The primary goal is to achieve the required dimensions, surface finishes, and tolerances as per the design
specifications of the final product.

One of the most important functions of a machine shop is the finishing process, which involves removing excess
material from a raw part to achieve accuracy and usability. Common finishing operations include milling, where
a rotating cutter removes material to produce flat or contoured surfaces; drilling, which creates precise holes in a
component; and tapping, which is used to make internal threads in drilled holes. These operations are often
required to make the part suitable for assembly, fastening, or other functional purposes. Additional processes like
reaming or boring may be used for extremely tight tolerances and fine surface finishes.

Modern machine shops extensively use CNC (Computer Numerical Control) machines, which allow high-
speed and highly accurate machining through programmed instructions. CNC technology ensures repeatability,
precision, and efficiency, making it ideal for both small-batch and mass production. It also allows the machining
of complex geometries that would be difficult or impossible to achieve manually.

In a typical production workflow, a raw casted product—such as a axle casing or master clutch housing—is first
inspected and then machined using a combination of CNC milling, drilling, and tapping. These processes
gradually refine the raw shape into a precise, usable product by creating smooth surfaces, accurate holes, and
threaded features. After final dimensional and quality checks, the component is ready for use in larger assemblies
or as a standalone finished part.

In a machine shop, critical components such as axle casings, master clutch housings, hydraulic lift bodies, and
trumpets undergo precise machining processes to achieve their final, functional forms. These parts are typically
cast or forged initially and then brought into the machine shop for finishing operations. Using CNC machines,
components are milled, drilled, bored, tapped, and turned to achieve tight tolerances and smooth surface finishes.
This ensures proper fitment, alignment, and mechanical performance when assembled in the final product, such

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as tractors or heavy vehicles. The machining process enhances dimensional accuracy, removes casting defects,
and prepares the parts for assembly, coating, or further processing.

In our machine shop, we work on components for three different series of tractor assemblies: the 56 Series,
Normal Driveline, and Modern Driveline. Each series includes a range of critical parts such as axle casings,
master clutch housings, hydraulic lift bodies, and trumpets. The 56 Series typically follows legacy designs,
whereas the Normal Driveline incorporates standard updated geometries. In contrast, the Modern Driveline
represents the latest engineering improvements with enhanced performance, requiring more precision machining
and tighter quality control.

Fig 1.1 Axle Casing

Fig 1.2 Master Clutch Housing

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Fig 1.3 Hydraulic Lift Body

Fig 1.4 Trumpet

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CHAPTER 2
CNC (Computer Numeric Control)
2.1 CNC Introduction
CNC (Computer Numerical Control) is an advanced manufacturing technology that uses computerized systems
to control machine tools for various machining operations like milling, turning, drilling, tapping, and grinding.
Unlike traditional manual machines that rely on human operators, CNC machines follow pre-programmed
instructions written in a specialized code, usually called G-code, to automate and control every movement and
function of the tool. These machines read the design data from CAD (Computer-Aided Design) files and convert
it into precise mechanical actions, allowing for high accuracy, repeatability, and consistency in the production of
complex parts. CNC technology is used in industries such as automotive, aerospace, electronics, and tool-making
due to its ability to manufacture components with tight tolerances and smooth finishes. It also reduces human
error, increases productivity, and allows for mass production of identical products. CNC machines come in
various forms, including CNC lathes, CNC milling machines, CNC laser cutters, and CNC routers, each suited
for specific applications. Overall, CNC machining has revolutionized modern manufacturing by enhancing both
speed and quality in production processes.

2.2 CNC Used In Machine Shop

2.2.1 HELLER CNC Machine:

HELLER CNC machines are known for their high-performance and durability in heavy-duty machining
applications. They are widely used in the automotive and aerospace industries for machining complex engine and
structural components. HELLER machines offer advanced multi-axis capabilities, precision control, and efficient
chip removal systems, making them ideal for high-volume production. With a strong focus on automation and
flexibility, HELLER CNCs support various machining processes such as milling, drilling, and boring with
exceptional accuracy and speed.

2.2.2 MAKINO CNC Machine:

MAKINO is globally recognized for its cutting-edge CNC machines that deliver superior precision and surface
finish, especially in die and mold making, as well as aerospace components. MAKINO machines are equipped
with high-speed spindles and advanced thermal control systems that ensure consistent machining performance

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even in tight tolerance applications. Their user-friendly interfaces and rigid structures allow for high-speed
milling and ultra-fine finishing operations, contributing to improved productivity and reduced

2.2.3 MAZAK CNC Machine:

MAZAK is a leader in multi-tasking CNC technology, offering machines that combine turning, milling, and
drilling operations in a single setup. These machines are highly versatile and are commonly used in industries that
require complex and customized parts. MAZAK CNCs feature advanced automation solutions, smooth control
software, and hybrid machining capabilities, making them suitable for both small-batch and mass production.
Their adaptability reduces setup time and enhances production flexibility on the shop floor.

2.2.4 DOOSAN CNC Machine:

DOOSAN CNC machines (now under the DN Solutions brand) are well-regarded for their robust construction,
reliability, and cost-effectiveness. These machines are suitable for a wide range of machining tasks including
turning, milling, and boring. DOOSAN offers both horizontal and vertical machining centers that are capable of
handling everything from simple to complex parts. Their CNCs are commonly used in general engineering, oil &
gas, and automotive sectors, and are favored for their ease of maintenance, efficient performance, and strong
support network.

2.3 MACHINING OPERATIONS

Drilling:
Drilling is the process of creating round holes in a solid material using a rotating drill bit. In CNC, drilling is
highly precise and is commonly used for holes needed for bolts, fasteners, or further machining processes.

Boring:
Boring is used to enlarge and finish a pre-drilled hole with better accuracy and surface quality. It is often
performed after drilling to meet tighter tolerances, especially in components like engine cylinders

Milling:
Milling involves removing material using a rotating multi-point cutting tool. CNC milling can produce flat
surfaces, slots, pockets, and complex 3D shapes with high precision. It’s widely used in die-making and part
shaping.

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Tapping:
Tapping is the process of cutting internal threads into a previously drilled hole. This operation is essential for
parts that require bolts or screws to be fastened securely. CNC tapping ensures consistent thread depth and pitch

Turning:
Turning is a machining process where the workpiece rotates while a stationary cutting tool removes material. It is
mainly used to create round shapes such as rods, shafts, and rings on CNC lathes.

Facing:
Facing is done on a lathe where the cutting tool moves across the end of the rotating workpiece to produce a flat,
smooth surface. It helps to square the ends and is often the first operation on round bars.

Threading:
Threading involves cutting helical grooves (internal or external) on a part to create screw threads. CNC threading
can produce high-precision threads that fit perfectly with bolts or nuts, ensuring proper mechanical connection.

Reaming:
Reaming is a finishing process that slightly enlarges a pre-drilled hole and improves its accuracy and surface
finish. Reamers remove minimal material and are used where tight hole tolerances are required.

Grooving:
Grooving is the process of cutting narrow channels or slots into a workpiece. It is used for parts that need O-rings,
snap rings, or retaining features. It can be done on both internal and external surfaces.

Knurling:
Knurling creates a patterned texture (like a diamond or straight line) on the surface of a cylindrical part. It is
mainly used on hand-held parts like knobs or handles to provide better grip.

2.4 Spindle Movement and Axis

2.4.1 Work offset

In CNC machining, work offset refers to the positional adjustment made between the machine’s fixed coordinate
system (machine zero) and the actual position of the workpiece (part zero). This allows the machine to correctly

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locate the part on the table and begin machining operations accurately without changing the program for each
setup.

2.4.2 Spindle Axis

The spindle axis represents the direction in which the machine’s spindle rotates and moves. The spindle is the
part of the CNC machine that holds the cutting tool and performs the cutting by rotating at high speeds. In most
vertical CNC machines, the spindle moves along the Z-axis, while in horizontal machines, it may be aligned
differently. The spindle’s speed (measured in RPM) and rotation direction (clockwise or counterclockwise) are
crucial factors that affect machining quality and are controlled by specific commands in the program.

2.4.3 Axis

In CNC machining, the X, Y, and Z axes represent the three primary linear movements that define the machine's
ability to cut and shape materials in a three-dimensional space. The X-axis controls the left-to-right movement of
the tool or table, the Y-axis controls the front-to-back movement, and the Z-axis controls the vertical movement
— up and down. These three axes allow for precise positioning and machining on flat and contoured surfaces. In
more advanced CNC machines, a B-axis is added, which is a rotational axis that typically rotates around the Y-
axis. This allows the tool or the workpiece to tilt at different angles, enabling more complex operations such as
angled drilling, multi-face machining, or contouring curved surfaces without repositioning the part manually. The
inclusion of the B-axis significantly increases the flexibility and capability of the CNC machine, especially in 4-
axis and 5-axis configurations.

2.5 CNC CODING

In CNC (Computer Numerical Control) machining, codes are the language through which instructions are given
to the machine. These instructions control every aspect of machining, including tool movement, cutting paths,
spindle speed, and auxiliary functions. CNC codes are standardized so that they can be understood by most CNC
machines, regardless of brand or model. The two main types of CNC programming codes are G-codes and M-
codes. They work together in a program to ensure that the machining process is carried out with high precision,
efficiency, and repeatability.

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2.5.1 G-Codes (Geometric Codes)

G-codes are used to control the movement and positioning of the machine tool. They define how the cutting tool
approaches, travels, and retracts from the workpiece. For example, G00 is used for rapid positioning, G01 for
controlled linear cutting, and G02 or G03 for clockwise or counterclockwise circular movements. G-codes also
manage functions like setting work offsets, defining cutting planes, and controlling feed rates. Essentially, G-
codes tell the CNC machine “how” and “where” to move the tool to shape the workpiece according to the
programmed design.

2.5.2 M-Codes (Miscellaneous Codes)

M-codes control the non-motion functions of the CNC machine, often referred to as auxiliary commands. These
include actions like starting or stopping the spindle, turning coolant on or off, changing tools, or ending a
program. For instance, M03 starts the spindle in a clockwise direction, M05 stops it, M08 turns on the coolant,
and M30 ends and resets the program. While G-codes handle the geometry of machining, M-codes handle the
operational aspects, ensuring that the machine’s supporting systems work in coordination with the cutting
movements for smooth and safe operations.

Fig 2.5.1 CNC Control Screen

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2.6 BREAKDOWN AND ALARMS

In CNC (Computer Numerical Control) machines, alarms are warning or error messages that appear when the
machine detects a fault, malfunction, or unsafe condition. These alarms help protect the machine, workpiece,
tooling, and operator by stopping operations until the issue is resolved. CNC alarms can be related to mechanical
problems, electrical faults, programming errors, or safety issues. They act as a built-in safety and diagnostic
system, ensuring that any abnormal condition is identified immediately so corrective action can be taken.

ATC Alarm (Automatic Tool Changer Alarm) – Occurs when the tool changer mechanism fails to pick up,
place, or change the tool correctly. This may be caused by a misaligned tool, obstruction in the tool magazine, or
sensor failure.

Spindle Alarm – Triggered when the spindle motor faces problems such as overload, overheating, or speed
mismatch. It can also occur if the spindle orientation is incorrect for tool change.

Coolant Alarm – Happens when the coolant flow is interrupted due to low coolant level, clogged coolant lines,
or pump malfunction. Without coolant, overheating and tool damage can occur.

Hydraulic Alarm – Appears when the hydraulic system’s pressure is too low or too high. This is critical for
machines that use hydraulics for clamping, tool change, or axis movement.

Lubrication Oil Alarm – Warns about low lubrication oil level or pump failure, which can lead to increased
wear and tear on machine components.

Overtravel Alarm – Occurs when an axis moves beyond its programmed or physical travel limits, often due to
incorrect programming or faulty limit switches.

Power Supply Alarm – Triggered by unstable or insufficient electrical supply, which may damage sensitive
machine electronics.

Servo Motor Alarm – Indicates a fault in the servo drive or motor, such as overload, overheating, or feedback
signal loss.

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2.7 CNC FIXTURES

A fixture is a specialized device used in manufacturing and machining processes to securely hold, support, and
locate a workpiece in a fixed position during operations such as milling, drilling, or turning. Unlike a vice or
clamp, which can be adjusted for general purposes, a fixture is designed for a specific component or set of
components, ensuring repeatability, accuracy, and efficiency in production. Fixtures eliminate the need for
repeatedly measuring and aligning the workpiece, as they are built to maintain precise positioning and alignment.
They also help improve safety by preventing workpiece movement during machining and reduce production time
by enabling faster setup and consistent results in mass production.

2.7.1 TYPES OF FIXTURES

Hydraulic Fixture
A hydraulic fixture uses pressurized fluid to clamp and release the workpiece automatically. It offers high
clamping force, consistent pressure, and faster operation, making it ideal for mass production where speed and
precision are important. Hydraulic systems reduce operator fatigue, allow automation, and can hold complex
shapes securely, but they require a power unit, maintenance of hydraulic lines, and higher initial cost.

Manual Fixture
A manual fixture uses hand-operated devices like screws, levers, or clamps to secure the workpiece. It is simpler
in design, low-cost, and easy to maintain, making it suitable for small batch production or job work. However,
manual clamping is slower, depends on operator skill for consistency, and may cause fatigue during repeated use,
which can affect productivity and uniformity.

Fig 2.7.1 CNC Fixture OP10 and OP20

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CHAPTER 3

TOOLS AND SAFETY EQUIPMENTS

3.1 BASIC TOOLS AND EQUIPMENTS

Torque Wrench
A torque wrench is a precision tool used to tighten bolts or nuts to a specific torque value. It ensures fasteners are
neither over-tightened, which can damage threads, nor under-tightened, which can lead to loosening. Commonly
used in automotive, aerospace, and machinery assembly.

Bore Gauge
A bore gauge measures the internal diameter of holes, cylinders, or pipes with high accuracy. It uses a measuring
head and dial indicator to detect size variations, ensuring parts meet dimensional tolerances in manufacturing and
quality checks.

Ring Gauge
A ring gauge checks the external diameter of cylindrical components like shafts or pins. It usually has “Go” and
“No-Go” sides—where the Go side should fit if within tolerance, and the No-Go side should not fit if the part
exceeds limits.

PPG (Plug Plug Gauge)

A Plug Plug Gauge is used to verify the internal dimensions of holes. It works with Go and No-Go ends—the Go
end must fit smoothly, while the No-Go end should not enter if the hole is within tolerance. Ideal for quick
inspection in mass production.

TPG (Thread Plug Gauge)

A Thread Plug Gauge checks the accuracy of internal threads in nuts or tapped holes. The Go end ensures correct
pitch and diameter for fit, while the No-Go end confirms the thread is not oversized or out of tolerance.

3.2 SAFETY EQUIPMENTS

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Safety Gloves
Safety gloves protect hands from hazards such as cuts, abrasions, heat, chemicals, and sharp edges during
machining or material handling. They are made from materials like leather, rubber, or cut-resistant fibers, chosen
based on the specific work environment.

Safety Shoes
Safety shoes protect feet from heavy falling objects, sharp materials, or slipping hazards in workshops. Most have
steel or composite toe caps and slip-resistant soles, providing both impact protection and stability on oily or wet
surfaces.

Safety Goggles
Safety goggles shield the eyes from flying chips, dust, sparks, or chemical splashes during machining, grinding,
or welding. They are designed to fit snugly and often have anti-fog or scratch-resistant lenses for clear visibility.

Earplugs
Earplugs protect hearing by reducing exposure to high noise levels generated by CNC machines, grinders, or
other heavy equipment. They are lightweight, easy to insert, and help prevent long-term hearing damage in noisy
industrial environments.

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CHAPTER 4

CBS (CNH Business System)

4.1 DMS (Daily Management System)

The Daily Management System (DMS) is a structured approach used in manufacturing and service industries to
track, review, and improve performance on a day-to-day basis. It ensures that issues are identified quickly and
resolved before they become bigger problems. The goal is to maintain smooth operations, standardize processes,
and drive continuous improvement.

In DMS, we often consider five key focus areas — Safety, Inventory, Quality, Delivery, and Tool/Cost —
each tracked daily on visual boards or digital dashboards.

Safety
Safety ensures that all work is performed without risk to employees, machines, or the environment. In DMS,
safety metrics like accident-free days, near misses, PPE compliance, and unsafe condition reports are monitored
daily. Any safety issue gets top priority for resolution because no production target is worth compromising
worker safety.

Inventory
This involves controlling raw materials, work-in-progress (WIP), and finished goods to avoid shortages or
overstocking. DMS helps teams check daily inventory levels against the plan, ensuring smooth production
without excess storage costs or material wastage.

Quality
Quality metrics (defects per batch, customer complaints, rework rates, etc.) are reviewed daily to ensure the
product meets standards. If a defect occurs, a root cause analysis is triggered immediately, and corrective actions
are taken to prevent recurrence.

Delivery
This tracks whether products or services are delivered on time and in full (OTIF). DMS uses daily production
and shipping schedules to monitor progress against deadlines, allowing quick action if a delay is expected.

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Tool Cost
Here, “Tool” refers to the health and availability of equipment, jigs, and fixtures, while “Cost” involves
monitoring expenses such as material wastage, downtime, and operational efficiency. DMS ensures tools are
maintained, breakdowns are minimized, and costs remain within target limits.

4.2 SMAT (Safety, Material, Audit, and Training)

SMAT is a workplace inspection and engagement process aimed at improving safety performance. It involves
supervisors or managers regularly observing work areas, checking for unsafe acts or conditions, ensuring proper
use of materials, and interacting with employees about safety practices. The purpose is to build a proactive safety
culture, identify risks before they cause harm, and reinforce safe working habits through real-time feedback and
training.

UC (Unsafe Condition)
An Unsafe Condition refers to any physical state in the workplace that could lead to an accident or injury if not
corrected. Examples include oil spills on the floor, faulty machine guards, poor lighting, or improperly stored
materials. UC inspections and reporting are a critical part of safety management, as identifying and fixing unsafe
conditions promptly reduces the risk of incidents and improves operational safety.

UA (Unsafe Act)
An Unsafe Act is any action by a person that increases the risk of an accident or injury. This could include
operating machinery without required PPE, bypassing safety procedures, running in the workshop, or using tools
incorrectly. Unlike unsafe conditions (which are environmental), unsafe acts are behavioral, and controlling them
requires awareness, training, and consistent enforcement of safety rules.

4.3 5S

The 5S methodology is a Japanese workplace organization system designed to improve efficiency, safety, and
productivity through five steps: Seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), and
Shitsuke (Sustain). It starts by removing unnecessary items to reduce clutter, then arranging necessary items for
easy access. The workplace is kept clean to maintain safety and identify issues early, followed by creating
standard procedures to ensure order is maintained. Finally, discipline is developed so these practices become a
regular habit, resulting in a clean, organized, and highly efficient work environment.

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Seiri (Sort) – Remove all unnecessary items from the workplace to avoid clutter.

Seiton (Set in Order) – Arrange tools and materials so they’re easy to find and use.

Seiso (Shine) – Keep the workplace and equipment clean to prevent problems.

Seiketsu (Standardize) – Create rules and schedules to maintain cleanliness and order.

Shitsuke (Sustain) – Build discipline so 5S becomes a habit and continuous improvement continues.

4.4 AM

An AM (Autonomous Maintenance) calendar is a planned schedule used in manufacturing and maintenance

systems to organize and track routine cleaning, inspection, and minor servicing tasks performed by machine
operators themselves. It is a core element of Total Productive Maintenance (TPM) that focuses on empowering
operators to take responsibility for the basic upkeep of their equipment. The AM calendar outlines what needs to
be done, when it should be done, who should do it, and how frequently it should be performed. Tasks may include
checking oil levels, cleaning filters, inspecting belts, tightening bolts, and ensuring safety guards are in place. By
following this calendar, small issues are detected early, preventing unexpected breakdowns and improving overall
equipment effectiveness (OEE).

The calendar is usually divided into different sections based on machine areas, such as the control panel, coolant
system, hydraulic unit, lubrication system, and chip removal system. Each activity is assigned a specific
frequency—daily, weekly, monthly, or quarterly—and may also indicate the time required, the status of the
machine during the task (running or stopped), and safety precautions to be followed. Color-coding or symbols are
often used for quick identification of routine checks, quality inspections, and cleaning activities. This structured
approach ensures that every part of the machine gets regular attention without overloading operators in a single
shift.

Implementing an AM calendar not only keeps machines clean and well-maintained but also builds a sense of
ownership among operators. It reduces dependency on the maintenance department for small issues, promotes
safety, and extends machine life. Over time, this proactive maintenance culture minimizes unplanned stoppages,
reduces repair costs, and improves productivity, making it an essential tool in any lean manufacturing or TPM
program.

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4.5 SOP (Standard Operating Procedure)

SOP stands for Standard Operating Procedure, which is a set of step-by-step instructions designed to guide
employees or team members in performing specific tasks in a consistent, safe, and efficient manner. SOPs are
created to standardize work processes so that the same results can be achieved every time, regardless of who
performs the task. They are widely used in industries like manufacturing, healthcare, education, and service
sectors to ensure quality, compliance with regulations, and smooth operations.

An SOP typically includes the purpose of the task, responsibilities of the people involved, step-by-step procedure,
safety precautions, and any required tools or materials. By clearly defining the process, it helps avoid mistakes,
improves productivity, and ensures that work meets quality standards. For example, in a factory, an SOP might
detail how to operate a CNC machine, including startup checks, operational steps, and shutdown procedures.

SOPs also play a crucial role in training new employees and maintaining safety in workplaces. When everyone
follows the same documented process, it reduces confusion, minimizes risks, and ensures compliance with legal
or industry-specific standards. This consistency is especially important in high-risk environments, where even
small errors can lead to major accidents or losses.

Fig 4.5.1 SOP MAZAK m/c on/off Process

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4.6 OPL (One Point Lesson)

OPL stands for One Point Lesson, which is a short, focused document or visual aid used to explain a single
concept, skill, improvement, or safety point in a simple and clear way. It is commonly used in manufacturing,
maintenance, and quality management systems to quickly share knowledge among team members. Unlike lengthy
manuals or SOPs, an OPL is designed to be concise—often just one page with minimal text and more diagrams or
photos for easy understanding.

The main purpose of an OPL is to train or refresh knowledge on one specific topic at a time. For example, it
might explain the correct method to tighten a specific bolt, clean a sensor, check a gauge, or handle a particular
tool. OPLs are especially useful for addressing small but important improvements or changes in processes,
ensuring everyone is on the same page without needing lengthy training sessions.

In workplaces, OPLs are posted at workstations, machines, or notice boards so that operators can refer to them
whenever needed. This method helps maintain consistency, reduces errors, improves safety awareness, and
supports continuous improvement in day-to-day operations.

Fig 4.6.1 OPL For Number Punching

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CHAPTER 5

ENGINE TESTING AND COMPONENTS

5.1 ENGINE TESTING
Engine testing is carried out to evaluate the performance, efficiency, and overall health of the engine under
specific operating conditions. During the test, the engine is run at various speeds and loads to measure key
operating parameters. These parameters help in determining if the engine meets the desired specifications and
functions reliably under expected working conditions. The test setup ensures that measurements are taken without
any external load, unless specified otherwise.

One of the major sets of parameters checked during engine testing includes performance indicators such as engine
power output, torque, and fuel consumption. These parameters give an insight into the engine’s efficiency and
capability to perform under different speed ranges. In addition, the test also monitors the speed settings for high
idle, low idle, and rated torque conditions to verify that the engine operates within its designed limits.

Another important category involves monitoring temperatures and pressures to assess the engine’s thermal and
lubrication systems. This includes recording oil temperature in the sump, cooling water inlet temperature, boost
pressure, and exhaust back pressure. These measurements ensure that the engine’s cooling and lubrication
systems are working effectively to prevent overheating and excessive wear.

Furthermore, air intake conditions are also evaluated during the test. This involves checking air boost pressure,
intake manifold pressure, and other related values to ensure optimal combustion. Fuel-related measurements, such
as fuel rack travel and governor settings, are also inspected to confirm correct fuel delivery. All these parameters
combined provide a complete overview of the engine’s operational health and readiness for service.

5.1.1. PURPOSE
The purpose of engine testing is to ensure that the engine meets its design specifications, performs efficiently, and
operates safely under various working conditions. It helps identify any defects, deviations, or performance issues
before the engine is installed in a vehicle or put into service. By simulating real-world operating conditions,
testing ensures that the engine can handle the required loads, speeds, and temperatures without failure.

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Engine testing is important because it validates the reliability and durability of the engine. It ensures that critical
systems—such as fuel delivery, lubrication, cooling, and air intake—are functioning correctly. This reduces the
risk of breakdowns, improves fuel efficiency, and enhances overall performance. Moreover, it helps in
compliance with emission norms and quality standards, ensuring the engine is both environmentally friendly and
safe to use.

5.2 ENGINE COMPONENTS

An internal combustion (IC) engine is a heat engine in which the combustion of fuel takes place inside the engine
cylinder, producing high-temperature and high-pressure gases that push the piston to generate mechanical power.
It is widely used in automobiles, tractors, motorcycles, and generators due to its compact design, high efficiency,
and ability to deliver power directly to the crankshaft. The main types of IC engines include petrol and diesel
engines, with components designed to work together for air–fuel intake, combustion, power transmission, and
exhaust.

Some Engine components are :-

• Head Gasket: Seals the combustion chamber between the cylinder head and block to prevent leakage.

• Camshaft: Operates inlet and exhaust valves in proper timing.

• Crankshaft: Converts reciprocating piston motion into rotary motion.

• Oil Pump: Circulates lubricating oil to reduce friction and wear.

• Fuel Pump: Delivers fuel from the tank to the injectors under pressure.

• Strainer: Filters impurities from the oil before circulation.

• FPD Gear, Idler Gear: Transfer motion between crankshaft and camshaft or fuel pump.

• Water Pump: Circulates coolant to maintain engine temperature.

• Injector: Sprays fuel into the combustion chamber for mixing with air.

• Alternator: Generates electrical power for vehicle systems.

• Intake Valve / Exhaust Valve: Allow fresh air–fuel mixture in and release exhaust gases.

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• Intake Manifold: Distributes air (or air–fuel mixture) to cylinders.

• Exhaust Manifold: Collects exhaust gases from cylinders to expel outside.

• Fuel Filter / Oil Filter: Remove impurities from fuel and lubricating oil.

• Tappet Cover & Gasket: Cover valve mechanism and prevent oil leakage.

• Rocker Arm: Transfers camshaft motion to valves.

• Timing Cover & Seal: Protect timing gears and prevent oil leakage.

• Starting Motor: Cranks engine during starting.

• Turbocharger: Compresses intake air for better combustion efficiency.

• Piston: Moves up and down inside the cylinder to convert gas expansion into force.

• Connecting Rod: Connects piston to crankshaft.

• Gudgeon Pin: Attaches piston to connecting rod.

• Piston Rings (Oil Ring, Scraper Ring, Compression Ring): Seal combustion chamber and control oil
consumption.

• Crankshaft Pulley / Water Pump Pulley: Drive auxiliary components via belts.

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CHAPTER 6

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CONTRIBUTION
During my internship, I actively contributed to maintaining workplace discipline and efficiency by implementing
5S methodology—Sort, Set in order, Shine, Standardize, and Sustain—across my assigned area. This helped
ensure a clean, organized, and safe working environment, reducing waste and improving workflow. Alongside
5S, I followed and supported the Daily Management System (DMS), which involved monitoring key parameters
like safety, quality, delivery, cost, and inventory, thereby ensuring consistent performance and smooth operations.
I was also involved in SMAT (Safety Management Assessment Tool) activities, focusing on identifying
potential hazards, promoting safety culture, and ensuring compliance with CNH Industrial’s safety standards.

These included conducting coolant gun audits to ensure proper functioning, cleanliness, and safe handling of
coolant systems, as well as vacuum cleaner audits to maintain equipment efficiency and workplace hygiene. By
performing these audits, I contributed to improving equipment reliability, reducing downtime, and ensuring
compliance with maintenance standards. My involvement in these activities strengthened my understanding of
industrial best practices and gave me hands-on experience in maintaining high operational standards.

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