A PROJECT REPORT

On

MANUFACTURING OF AUTOMOBILE

At

ATUL AUTO LIMITED

UNDER THE GUIDENCE & SUBMITTED TO

Mr. JAYDIP RAYTHTHA ASSISTANT MANAGER HR ATUL AUTO

Ltd.

BY

Mr. SAHIL JAT

B.Tech (Mechanical)

ARYA INSTITUTE OF ENGINEERING AND TECHNOLOGY, JAIPUR

AFFILIATED TO RAJASTHAN TECHNICAL UNIVERSITY, KOTA

(RAJASTHAN)

1
 DECLARATION

I, undersigned Sahil Jat, a student of the Arya Institute of engineering and

Technology, hereby declare that the following project entitled “Industrial
Training Report on Atul Auto Limited” – on the working of the
production plant in Atul Auto Limited, is my own work. No part it is
plagiarized from any website or journal. If any material is borrowed from
anywhere it has been duly citied.

The information presented in this project is gathered from

understanding the working of the plant with the help of Engineers in Atul.
This information will not be misused.

In case of any fault, no blame must be thrown on anyone except on me, as I

bear the full charge of writing this report.

Place: Rajkot Sahil Jat

Date: AIET,Jaipur

2
 ACKNOWLEDGEMENT

I would like to start by thanking the plants Chairman & Managing Director –
Mr. Jayantibhai J. Chandra. Without his permission I could not
have completed this project report. I would also like to thank the
Board of directors for giving me this opportunity.

Next I would like to thank all the members of Atul Team and all the
engineers who helped me with the visit and this report. They explained the
whole process to me until I fully understood it and answered all my
questions patiently. Without their help, this project would not exist.

I would also like to thank my family for supporting me through this project.
My parents and my sister boosted my morale many times.

Lastly I would like to thank all those who helped me with this project. If your
name is not here, please pardon me. I could not, possibly have
named each one of you. However, you will not be forgotten and shall stay,
forever in my heart. Your kindness will be remembered.

Sahil Jat

3
 TABLE OF CONTENT

S.NO. PARTICULARS PAGE NO.

1 Introduction 5
2 Automotive Industry in India 6-7
3 Atul Auto 8-9
4 Board of Directors and Share Holding 10
5 Mission Statement 11
6 Atul Products 12-17
7 Production Plant 18
8 Plant Basics & Plant Stages 19-43
1.Storage
2.BIW
3.CED
4.Painting
5.Assembly Line
6.Testing
7.PDI
8.Store House

9 Conclusion 44
10 Reference 45-46

4
INTRODUCTION
An auto rickshaw is a daily mode of transportation
for millions of family of Indians and a mode of
revenue of many others. In fact it is used in many
other countries, it is found in South Africa,
Bangladesh, Pakistan, China, France, Italy and
many other countries. It is found in most Indian cities
carrying passengers from one place to another
place. The auto rickshaw is a common form of
transport, both as vehicle for hire and for private
use.

Most of the Auto rickshaw used is of a one brand

that is Atul. They all originated from one factory,
located in a place known as Sahapar – about 30Km
away from Rajkot, a city in Gujarat. This place is
where the Atul Auto plant is located.

This project deciphers the process behind the

making of the beautiful three legged machine. It
states all the stages that this machine goes through,
right from the its making various small parts to its
assembling and Quality Test, before it is sold in the
market. This project is my observation of the plant in
my own words.

5
 Automotive Industry in India
The automotive industry in India is the fourth-largest in the
world as per 2021 statistics. In 2022, India became fourth
country in the world by valuation of automotive industry. As of
2020, India is the 5th largest country in the world, surpassing
Germany in term of sales. Currently Indias auto industry is
worth of more than US$100 billion and contributes 8% of
the countrys total export and accounts for 2.3% of Indias GDP.

The automobile industry in India dates back to 1942, when

Hindustan motors was launched for the first time in India. Later,
Mahindra & Mahindra was established in 1945. All this was
before Indias Independence.

After Independence, the government of India appointed traffic

followed acommission
policy known as licenseandraj,
to co-ordinate lookrecommended by of
over the working traffic
the
the commission, that Industry.
automobile allowedInitally
only thea growth
certainwasnumber of toto the
slow due
automobile license
manufactured
raj (theby the automobile
government, at that companies
time, and if be
they want manufacture more, they need to upgrade their license. to
be
The policy also cleaned out manufactures with only import as well as those
companies with no Indian partner. These made the license raj
quite stringent!). The beginning of 1970 saw a rise in the automobile,
cars and jeeps were still machine for the elite.

Eventually, post 1992, companies such as Suzuki and Toyota were allowed
to invest in the Indian market. Maruti Suzuki became the first and the most
famous company at that time. Later, in 2000, the government even started
encouraging local manufacturers as well.

6
The Indian automobile industry is divided into three major sectors:

Sector 1:
Around Chennai – accounting for 35% of the revenue generated by the
automobile industry.
Sector 2:
Near Mumbai – this accounts for 33% of the revenue generated.
Sector 3:
In the north, around Delhi, this accounts for 32% of the revenue
generated.

In these sectors, the major players are:

General Motors India Pvt. Ltd.

Hindustan Motors Ltd.
Honda Siel Cars India Ltd.
Hyundai Motors India Ltd.
Maruti Udhyog Ltd.
Skoda Auto India Pvt. Ltd.
Tata Motors Ltd.
Toyota Kirloskar Motors Pvt. Ltd.
Force Motors Ltd.
Mahindra & Mahindra Ltd.
Ashok Leyland Ltd.
Volvo India Pvt. Ltd.
Atul Auto Ltd.
Bajaj Auto Ltd..
TVS Motors Co. Ltd.
Royal Enfield Ltd.
Suzuki Motor Cycle India Pvt. Ltd.
Yamaha Motors India Pvt. Ltd.

7
 Atul Auto

Atul Auto
Plant, Rajkot Atul’s journey began in the 1970s,
when the automobile industry was still in its initial stages,
growing slowly. Atuls founder, Mr. Jagjivanbhai Chandra, has
envisioned a company that developed a convenient and affordable
automobile that could traverse the rural, even roads of Saurashtra
(Gujarat). He turned his vision into action when he developed
the first three – wheeler automobile based on the design of a
motorcycle, and adapted the engine from a golf cart, giving rise to
the first ‘Chakkada’. Mr. Jagjivanbhai Chandra then started this
company that we know as Atul Auto.
Atul Auto was Incorporated
(became a corporation by law) in 1986. Thereafter, in the year
1992, it began its production.
The company began
by producing ‘Chakkada’. It also
started
improving upon the existing
technology, constantly updating it to meet the norms and
competition around it. Mr. Jayantibhai Chandra took
over the company from his
father and furthered his mission of providing a convenient
transport to Indians by developing a Diesel ‘Chakkada’. Soon,
Atul started manufacturing new varieties. It manufactured Shakti
– convenient rickshaw, and many other vehicles under its brand
name such as Commercial 3-wheelers, half ton vehicles (carrying
capacity) and more.

Currently, Atul is leading

manufacturers of three wheeler transport in Gujarat. Installed
capacity of 60,000 units per annum at Rajkot Plant
Caters to diverse customer base in 8
the Cargo & Passenger segment available on both the platforms i.e.
350kgs payload capacity and 500kgs payload capacity, multi fuel
choice, i.e. Diesel, Petrol, CNG, LPG and E- Vehicles and enjoying
During the financial year 2021-2022 Atul endeavoured to
maintain inclusive growth
Sales increased by 42% from 3,460 cr to 4,929 cr
Net worth increased by 16% from 3,711 cr to 4,316 cr
Gross block increased by 14% from 1,839 cr to 2,098 cr
Profit before tax* increased from 773 cr to 804 cr
Social work undertaken via 34 initiatives under six program of
national importance

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Board of Directors and Share
Holding
J J Chandra Chairman and Managing Director
M J Patel Whole Time Director & CFO
Niraj J Chandra Whole Time Director
Dr. Vijay K Kedia Non Executive Director
CA Hemant Bhatt Independent Director
Hasmukh Adhvaryoo Independent Director
Adv. H J Lalakiya Independent Director
Dr. Margie Parikh Independent Director

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 MISSION STATEMENT
Mission Statement:
To devote ourselves to cater to the common man’s transportation needs by
introducing environment-friendly vehicles which are empowered by latest
technological advances.

Vision:

To contribute in eradication of poverty by making the common people self-

dependent with our state of the art technology, products and services.

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 ATUL PRODUCTS
ATUL RIK
RIK + CNG
RIK CNG
RIK PETROL
RIK LPG

FEATURES
More space
40L CNG tank
Double shock absorbers
Stylish and sports cheetah headlight
Semi digital cluster
Carlike dashboard
Hassel free ingress – egress for driver and passenger
Powerful engine 6.75kW (9.05hp)
Duel fuel system (CNG/Petrol)
Duel sided entry for easy servicing

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ATUL GEM

GEM CARGO DIESEL

GEM DELIVERY VAN
GEM CARGO CNG
GEM CARGO CNG – AQUA 6F
GEM PAXX CNG
GEM PAXX DIESEL
GEM PAXX CNG AQUA 3P
GEM PAXX PETROL

FEATURES
New sporty graphics
Attractive stitched seat cover
Mini fan for driver
New wheel Rims/Caps
LED cabin lamp
Charge ON GO
Single touch smart
Smart console cluster
Multi focal head lamp with halogen bulb

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ATUL GEMINI

GEMINI PETROL
GEMINI CNG
GEMINI PETROL CARGO

FEATURES
HIGH POWER – 8.6Kw
Jerk free clutch
Robust & strudy chassis
FM radio system
High capacity fuel tank
Single large windshield glass with powerful wiper
Mono unit cluster
Head lamp
USB port incorporated with vehicle
Push start
Lowest turning radius
Spacious driver cabin

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ATUL ELITE E-RICKSHAW

ELITE WITH LI-ION BATTERY

ELITE+ WITH ACID LEAD BATTERY
ELITE CARGO WITH LI-ION BATTERY
ELITE CARGO

FEATURES
Strong metal roof top protected in all weather
Ample space best-in-class legroom
Superior front suspension with hydraulic twin double acting shock
absorbers
FM/Music system with speakers
Stylish alloy wheel
Seamless single piece windshield
Stylish LED tail lamps
Stylish spare wheel cover

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ATUL SMART CARGO CNG

FEATURES
Highest wheel base
Lowest turning radius
Semi lug tyre
Front engine
6.5ft cargo deck
Spacious cabin

16
ATUL SHAKTI FEATURES
Powerful MFL head light for safe night driving
Attractive wheel guard
Comfort seating for driving
Push button electric start
Mono unit cluster
USB mobile charger

17
 Production Plant
Basics Information

Currently, the Atul auto plant can produce about 130 rickshaws
per day.

ATUL has emerged as the only player with complete range of 3

wheeler products across the fuel range – Diesel, Petrol, CNG,
LPG, and Electric.

Its annual turnover, in terms of number of vehicles, is 50,000

vehicles.

For future, they would continue to innovate new and better

technology to make transportation easy and affordable for Indians.
Here are few vehicles which are under planning:

 Micro Commercial Vehicle to carry 750 Kg. Payload

 Range of Electric Commercial Vehicles
 4-Wheeler One Tonner LCV

18
 PLANT BASICS
Any automobile can be divided into two parts:

The Chassis of the Automobile:

The Chassis is the outer frame of an automobile which houses the engine.
It also houses the body of the automobile.

The body of the Automobile:

The body of an automobile is the part where an object is carried. For

instance, in a truck, the rectangular container forms the body of
an automobile, while in an auto rickshaw, the seating compartment forms
the body.

PLANT STAGES

The Production Plant is divided into eight stages:

•Warehouse / Storage
•BIW
•CED
•Paint
•Assembly line
•Testing
•PDI – Pre Delivery Inspection
•Storage of Rickshaws

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1. STORAGE
There are three stores departments.
1.1 Fabrication stores of the BIW department

This is the department where all the goods used in the BIW department
are kept. According to the requirement, the goods are transferred to the
BIW department by the transportation department.

1.2 Receive Stores

This is the department where all the raw material, except for the
BIW department, available from outside are kept. From here the
material goes to the required department again done by the
transportation department.

1.3 General Stores

This is the store where all the finished parts from a department are kept.
Meaning, if a chassis has been made by the BIW department and
cannot be taken to the next department on the same day, then it
is stored in the general stores. All in all the Storage department stores
the raw material or the produced parts for later stages.

The Storage department

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 2. BIW

The BIW department in Atul

The very first step in the production process is BIW.

BIW is the department where the chassis is assembled. BIW stands

for Body in White. White here signifies no color. The name is such
because the chassis is not colored yet, it is in the very first stage
where all the welding marks can be seen.
The parts used to assemble the chassis come from various dealers. They
are imported by Atul and kept in a warehouse (BIW shop). These parts are
then taken to the BIW workshop, where they are assembled into
a rickshaw. The parts for Gem Paxx and Gemini are made from the
same
material, however, their assembly is different. This assembly is what makes
the Gemini rickshaw lighter.

21
In the BIW department various processes take place:

Spot Welding:

Welding is the process of joining two metals together. Spot wielding is the
welding of two metals by passing a high current.
The two metal plates to be joined are held together by clamps fixed in the
spot welding machine. The spot welding machine consists of two
copper alloy electrodes. A high current is passed through these electrodes.
These
electrodes, in turn, concentrate this current on a particular spot. This
high current melts the metal, thereby joining the two pieces together.

Spot Welding Method CO2 Gas welding method

CO2 Gas Welding:

CO2 Gas welding is done in order to join two metal plates together. It
utilizes a third metal to do so. Thus, it melts the third metal in order to join
the two base metals.

The material to be welded with is made the electrode in this case.

This material is electrified by a high current/arc. The high current melts
the material, thereby joining the two base metals with this material.

22
CO2 is used as a shield, it protects the welded material and the base
metals from getting oxidized and from reacting with Nitrogen or
its compounds (since the metal and the material are at a high
temperature, they react readily with Oxygen or Nitrogen Compounds).

CO2 Gas welding is much stronger than spot welding. However, it is

not used to joint every part of the chassis. The reason is that, although it
forms a stronger weld, it is very expensive. Spot welding is faster and
cheaper than CO2 Gas welding. Thus, CO2 Gas welding is used only
in specific areas where the metals need to be joined strongly.

Drilling:

After the above two processes are done, the metal chassis formed is drilled
to fix the bolts. This drilling is done by a drilling machine with drills of various
diameters.

Drilling Machine

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Brazing:

The next step is Brazing.

Brazing is like soldering a metal. In Brazing, a metal, in this case Brass, is

melted to join two metal parts together. The metal used for joining
has a lower melting point than the metal the parts are made of.
Brazing differs from Welding in that it does not involve the melting of
the parent or the base metal. It differs from soldering since it uses a lower
temperature than used in soldering.

Brazing Process

Grinding:

The last step in this cycle is grinding.

Grinding is the process of removal of any extra metal from the part. A
grinder is like a toothbrush with metal teeth. The metal teeth are
rotated and the grinder is moved against the part to remove the extra metal.

This is the last step since it is like adding the finishing touch to the chassis.

24
Quality Check:

There are three quality checks held before the chassis is passed on to the
next department.

 The First Quality check for each part, or each attachment of the chassis
is done at the place of its fixture. For example, if a part is fit in the
frame using the CO2 Gas welding machine, a quality check
department guy is present there to ensure that the proper fixing of the part
takes place.

 The second Quality check is done after the whole chassis is assembled.
This is done by the BIW department workers.

 The third Quality Check is done by the Quality Check Department

Workers (PDI Department). Some representatives from the PDI department
are present in the BIW department, and they ensure that each joint is
perfectly fixed and the chassis is ready.

The chassis is now ready to be transported to the next department.

Chassis of a Rickshaw In the final stages in the BIW department

25
Cooling in BIW:

The electrodes in the Spot Welding machine, and the various

machines need to be cooled since the high current can easily heat them up.
For this, a cooling plant is installed outside the BIW department.

The cooling plant has two pipes connecting it with the BIW
department. One is colored red and the other green. The green pipe brings
cold water from the cooling plant to the machine, to cool them, while
the red one transports the hot water back to the cooling plant, so that
it could be recycled.

On top of these two pipes, another pipe runs in the BIW department
– a blue pipe. The blue pipe contains compressed air to be used in
various machines.

Other departments:

In the whole plant while the workspace is named after one particular
department, many departments work together, coherently to give the
final product. For instance at the BIW department many other departments
such as the Maintenance department (for maintaining the machines in case
they break), the quality check department (checking if every step is done in
the proper order and not piece comes out faulty) and the
transporting department (transporting and checking that every part required
to make the chassis is in the right place, with the right person) are at work.

26
3. CED
The chassis from the BIW department and the Body of the Automobile
from the warehouse are transported to the CED Department.

CED is the department where the chemical processes happen. The

chassis or the body is cleaned and a layer of a chemical is applied on the
parts, to make the paint stick to them easily. CED stands for
Cathode Electron Deposition. This is a process that happens in this
department. Since this is the main process, the department is named
after it.

This is a fully automated department. Only the consoles for the

machines need to be controlled. Rest, the dipping of the chassis or the
body and all the other process are taken care of by programmed
machines. However, various manned checkpoints are installed
throughout the process, where the engineers vigilantly observe the
whole working. In case of any fault, they jump right in!

The chassis or the body is connected to a metal frame by chains.

The metal frame is then picked up by the huge machines wandering
overhead. A metal frame is used so that the big machines do not harm
or break the part.

Step 1:

The first step in this process is the Pre-Degreasing tank. The part
of the automobile is dipped in this tank. The tank has an Alkali based
Solution in it for the removal of Oil and Grease from the surface of the
part (as explained by an engineer, the oil and grease are not added
in Atul’s Plant. Rather, they come on the surface because the parts
that come from the dealer – from outside – are oiled). The
temperature of the bath, the tub where the alkaline solution is kept,
is about 50°C – 60°C. The chemicals used to make the alkaline
solution are Guardo Clean VP 4292-A and R.O. Water. The process
time for this step (time taken to complete the step) is 120 seconds.
After this time, the machines pick the frame and take it to the next step.

27
Step 2:

The next step in the process is again Pre-degreasing. This is done in Tank
two. The temperature of the bath and the chemicals used are the same as in
the previous step. However, the process time here is 180 seconds.

The Pre-Degreasing tanks look something like this

Step 3:

The third step is Water Rinsing. Water Rinsing is

done for the removal of the anti-degreasing chemicals
used in the previous steps, so that they do not
contaminate and hinder the chemical process in the next
step. The PH of the water used here is between 7.5 and
8.5. The chemical used is R.O. Water and the process
time is 60 seconds.

Step 4:

The fourth step in the process is de-rusting. In this step,

the respective part is dipped in a bath filled with acid
(also known as the acid tank). This removes the
corrosion, if it is present, from the metal. The chemicals
28
used here are Gardacid 2055 and R.O. Water. The
process time for this step is 240 seconds.
Step 5:

The fifth tank is again a Water Rinsing tank (Water Rinse 2). It is used
to remove the chemicals from the previous step. The pH of the water here is
between 3.5 and 5.5. The chemical used is R.O. Water. The process time is
60 seconds.

Step 6:

Tank 6 is the Activation tank. This tank is responsible for activating

the metal surface, to prepare the chassis or the body for the next
step (deposition of a fine and uniform coating of Phosphate). The
chemicals used in this step are Gardolene ZM and DM Water. The pH of
this mixture is between 8 and 9.5. The process time is 120 seconds.

Step 7:

Tank 7 is the Phosphate tank. This tank is responsible for the deposition of
a fine and even layered coating on the respective part. The layer of
phosphate is deposited to inhibit corrosion and to increase the durability of
the paint that would be applied in further steps.The temperature of the
chemical mixture used in this tank is between 50°Cׄ and 60°C and the pH
is between 2.8 and 3.5. The process time is 180 seconds. This
is an important process and is supervised thoroughly by the engineers.

The Phosphate tank

29
Step 8 & 9:

Next, the chemicals from the previous steps are removed by 2 Water
rinsing Tanks. The pH of the Water used (D.M. Water) is between 5.5 and
7.5 and the process time is 60 sec.

Step 10:

Tank 10 is the CED tank. In this tank, the chassis or the body is inserted in
an electrolyte made of various pigments, emulsion solvent, pH
regulators and D.M. Water. The part inserted acts as the anode with the
current being passed to the part from the frame holding it, while the
cathodes are kept on the inner lining of the tank. The cathodes contain
the chemical to be applied on the part to make the part easily available for
painting. A rectifier is used to supply the voltage to the anode and cathode.
The process takes 180 seconds to complete. The temperature of the
bath is between 30°C and 34°C and the pH of the electrolyte is between 5
and 6.

Body out from the CED Tank

Step 11 & 12:

Tank 11 and 12 are the Ultra filtration tanks. In this tank the excess
chemical from the previous step if any, is removed from the body and the
chassis and a smooth finishing is obtained. The chemical used here is D.M.
Water at a pH of 4.5 – 5.8. The process time for this step is 60 seconds.

30
Step 13:

Tank 13, the final tank in the process, is RCDM. RCDM stands for Removal
of Contaminants using DM water. And this is what it does. It removes
all the contaminants and the chemicals on the surface of the chassis
or the body, before sending it for the next step. The pH of the D.M. water
used is between 5.5 and 7.5 and the process time is 60 seconds.

The whole process takes about 1320 seconds or 22 minutes

(when counted directly) + the amount required for the machines to carry the
part from one tank to another. Thus, after every 30 minutes
(approximately) a chassis or head is taken out of the CED process and
inserted in the CED oven.

The CED oven is much like the ovens we use, it is used to bake things. The
parts from the CED process are baked in the CED oven at a temperature of
180°C ± 5. This ensures that the chemical sticks to the metal surface
properly. After baking, the parts are sent to the next department.

The chassis looks something like this when it comes out of all the CED tanks

31
4. PAINTING
The next Department is painting.

For painting the part, the parts are loaded on a conveyor belt.
The conveyor belt keeps on moving, at a certain designated
speed, and the engineers keep on working on the parts. Before being
painted, each part is cleaned using a tag rag. A tag rag is a rag (a
discarded cloth) with pores in it. It also has certain chemicals in it that
help in cleaning the dust from the parts of the automobile. The parts
are also aired, i.e. compressed air, air with a high velocity, is used to
clean the parts and remove dust from them. The parts are then painted.

The painting of the parts, also known as the Top Coat

Painting, is done in three steps:

•Primary Coat
Applying the first coat of paint

•Base Coat
Applying the next coat

•Clear Coat
Applying the third coat to ensure that no part of the chassis or the body is
left without color

32
These steps take place as the conveyor moves the part forward.
These steps are done in order to ensure that no portion of the part is
devoid of color. After this step the parts are again baked, now in a
bigger oven, to ensure the proper application of paint.

The finally painted part is now sent to the quality department engineers in
the painting department. They determine whether the particular part
has been painted well and if it is ready to be sent to the assembly line.

It is possible that an error happens in the painting process. This would be

pointed out by the quality department. For instance there could be a
rundown error in the paint (one of the most common errors) – which means
that some extra paint is sprayed by mistake. In this case, the faulty part is
sent to the rework area located in the painting department. Engineers from
the painting department are available there who fix the fault and pass
on the part to the next department.

The next department in line is the Assembly Line.

The chassis of a rickshaw with pain coatings

33
5. ASSEMBLY LINE
There are two assembly lines in the Atul plant at Sahapar. One is for
Gem Rickshaws while the other for the Gemini Rickshaws.
Their fitting is different and thus they need to be separated at this
point. However, the major process and the quality check followed in
each line is the same.

The assembly line is divided in two major stages –

•The Pre-conveyor Line:

This is the line where the chassis is completed - i.e. parts such as
the engine, the gears, the steering wheel, parts which lie in the chassis,
are fit.

•The Main Assembly Line:

This is the line where the body is fit and the rest of the work –
such as tightening the bolts, fixing some wires, fixing the fuel tank
and the battery etc. is done
The chassis from the paint department is transferred to the Pre-
Conveyor line. In the Pre-Conveyor Line the engine is pushed
forward through the use of Rails. After an engineer is finished with
his/her work, he/she pushes the chassis forward. The chassis moves to
the next Pre- Conveyor step in this manner.

The Pre-Conveyor line is further divided into four parts:

•Pre-Conveyor 1
•Pre-Conveyor 2
•Pre-Conveyor 3
•Pre-Conveyor 4

The working of the Pre-Conveyors cannot be separated from each

other, since it is interrelated. Thus, I have described it together here
most of the work is done manually in this Line. The chassis is first
cleaned and checked for any dent or scratch marks.
Then, the front wheel is added using a special triangular structure
34
that is fixed in the front part of the chassis. Next, the rear wheel mounts
and rear
wheels are added. Next a triangular Cone is added to the front of the
engine for the fixing of the steering wheel. The steering wheel (also called
the steering column) is then added. Then, the engine and the
gearbox, which are together known as a power pack, and added. The
brakes are added and fixed properly. The wiring for the brakes, the fuel and
other parts is done as well.

All the parts added over here, such as the Engine, the gear box and
the steering wheel are obtained from various dealers. They are stored
in the warehouse and then brought to the Pre-Conveyor by the
transporting department. These parts are, however, not fully assembled.
Thus, they are assembled by engineers in the Pre-Conveyor line, in its
sub-divisions known as the Sub-Assembly. There is a Sub-
Assembly for Steering wheels, for Engines, for Gear Box and for many
other parts.

The chassis is now partly ready and is transported to the main assembly.

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 Main Assembly Line

The Main Assembly line is further divided into 14 divisions. Each division is
responsible for fixing a certain area or a certain part of the Automobile.
The chassis from the Pre-Conveyor line moves to the first Division, where it
is lifted onto a conveyor belt. The speed of the conveyor belt is fixed such
that it gives ample time to the engineers of one division to complete
their work. Depending upon this time, the manpower for a particular
division is allotted as well.
The divisions are:

•Division 01:
The first Division, to which the chassis from the Pre-Conveyor line reaches,
is responsible for the tightening of bolts.

•Division 02:
The second division fits the fuel tank, the diesel filter tank and the air
filter tank in the chassis.

•Division 03:
The Third division fits the headlights, Indicators (for sides) and the cover.

36
04. Division 04 & 05:
The Fourth and Fifth division are responsible for the Fitting of the Handle
bar and the Brakes.

•Division 06:
The Battery assembly and the Tire fitting is done by the sixth division.

•Division 07:
All the cables are connected in this division.

•Division 08:
The eighth division is responsible for the assembly of the silencer.

•Division 09:
The door is assembled along with the door locks.

•Division 10:
The glasses of the Automobile are assembled.

•Division 11:
An important division, the body is assembled here and the battery
connections fixed.

•Division 12:
The driver’s seat and the passenger’s seat (if it is a passenger rickshaw) are
attached.

•Division 13:
Stickers are attached. Taillight is attached. All other small additional parts
are attached.

•Division 14:
The Wiring and all the Electrical Components are checked ones again the
automobile is now ready. It comes off the conveyor belt and a sensor
kept in front increases the count on a board by one, indicating
the production of one more rickshaw. Remember, while all this is
happening, the maintenance guys and the quality guys are
present, attentively observing the whole process, ready to find any mistake
or error or to fix any machine.

37
A checklist followed by the engineers in the Assembly line is shown.
This checklist is kept inside the rickshaw and is ticked by the
respective engineers as the automobile passes through each division.
This checklist lists all the parts that are to be fixed and with what
specifications. If there are any parts missing, or if any fault is observed in
the design or structure, the engineer mentions this in the remarks section.

38
6. TESTING
The next department is the Testing Department. This is where the
various tests are done to confirm that the automobile meets the required
standards
.

A list of tests is shown. All these tests are performed in the Testing area
by a group of Engineers.

39
7. PDI
The PDI department – Pre Delivery Inspection Department – is the
final department in the production assembly. Here the whole
Automobile is assessed by a group of engineers. Each part of the
engine is examined. The whole process of making the automobile is
put under microscope. Nothing misses the eye of the engineers in the
PDI department. From here, we get the final product.
The PDI department also follows a check sheet. This is displayed below.

40
This check sheet has two parts, one for any faults in the assembly section
and second, for any faults in the paint section.

41
If there are faults found in the Automobile that correspond to the Assembly
line, then the engineer inspecting the Automobile writes on this sheet, in the
remarks sections, corresponding to the faults that have been displayed. The
automobile then goes to the Assembly line’s Managing Director and from
there on he directs it to the particular division where the fault can be
resolved. The automobile then arrives back to the PDI section and the
quality check is continued.

If there is a fault that could be fixed by the paint department, then the
inspecting engineer writes on the sheet and also marks the faulty part with a
tape. The automobile is then carried to the rework Paint department, located
nearby, where engineers from the paint department are present to resolve
the fault. The quality check is thereafter continued.

The check sheet shown previously is the outcome of a lot of work done and
a lot of surveys conducted and complaints of the dealers and the buyers
considered. The top right corner of the first page of the check sheet displays
this information. The Rev No. refers to the number of times this check sheet
has been revised since its creation. The Revision Date shows the last date
when the sheet was revised, while the Effective Date shows the date of
creation. Thus, this check sheet was revised 15 times in the past 4 years.
This shows the dedication and the amount of effort Atul’s engineers takes to
incorporate the suggestions and the complaints of the consumers of their
product.

The Automobile – rickshaw – is now ready and is taken to the Store House
for Storing.

42
8. STORE HOUSE
The storehouse stores all the rickshaws – the final products.

43
 CONCLUSION
To conclude, it has been really great experience learning in the Atul
Factory. I have learnt the whole process of manufacturing an Atul
Auto Rickshaw. It is indeed a marvel how such compact a machine
requires such huge a process to be manufactured.

Besides learning about the process, I tried to relate this project to my

engineering course as well. This project has enhanced my
understanding of many concepts that I already knew. I have also learnt new
concepts that I can apply in my course, especially in the BIW
department and the Assembly line which taught me things in physics.

Well, now I must say goodbye to you all. It has been great journeying with
you through the factory. I hope this project stood up to your standards.

44
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 “Cathodic Electrocoating.” Web.
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