VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI, KARNATAKA

An Internship Report on
“STANDARDIZED WORKFLOW”
Submitted in the partial fulfillment for the award of Bachelor Degree in
Mechanical Engineering for the academic year 2019 – 2020

Submitted by
NAME: CHIRAG RAGHAVENDRA USN: 1AT16ME017

Under the guidance of

Coordinator: External Guide:
Mr. Anjan Kumar Mr. Sanjay Raina
Assistant Professor Production Manager
Department of Mechanical Engineering Volvo Construction Equipment
Atria Institute of Technology Peenya, Bengaluru-58

ATRIA INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING
BENGALURU-560024, KARNATAKA
 ATRIA INSTITUTE OF TECHNOLOGY,
DEPARTMENT OF MECHANICAL ENGINEERING
BENGALURU-560024, KARNATAKA, INDIA

CERTIFICATE
This is to certify that an internship report entitled “Standardized Work Flow’’ has
been successfully carried out by CHIRAG RAGHAVENDRA, bearing USN
1AT16ME017 in partial fulfillment for the award of Bachelor of Engineering /
Bachelor of Technology in Mechanical Engineering of the Visvesvaraya Technological
University, Belagavi during the 2019-2020 in the Atria Institute of Technology. It is
certified that all corrections/suggestions indicated for has been incorporated in the
report. The report has been approved as it satisfies the academic requirements in
prescribed for the said degree.

Name & Signature of the Internal Guide Name & Signature of the External Guide

Signature of the HOD

External Viva

Name of the examiners

Signature with date

2
 ACKNOWLEDGEMENT

True knowledge is assimilated when applied practically. Engineering is a discipline that is

dynamic. This makes it prudent for all engineering students to get an experience in an
industry. I am extremely grateful to Volvo Construction Equipment for giving us an
opportunity to do so.

The satisfaction that comes in the successful completion of the task would be incomplete
without mentioning the people whose ceaseless cooperation made it possible, whose
constant guidance and encouragement crowns all efforts with success.

I feel immense pleasure in showing my gratitude to all the people who have made this
work possible, by offering help and guidance whenever required. I express my sincere
gratitude to Mr. Sanjay Raina (Production manager) with whose kind permission this
internship could shape into success.

I thank all the people of Volvo Construction Equipment, for making me a part of their
family. The values of dedication, discipline, work ethics, and patience that I imbibed here
will remain the guiding force throughout my life. I thank them all for helping me become
technically adopt and practically wiser person.
 ABSTRACT
This internship is pursued at Volvo Construction Equipment Pvt Ltd, Peenya, Bengaluru.
This report contains an overview of the Sand Compactor Assembly Line and Fabrication
of Sand compactor.

The important subject matter learned through this internship are techniques incorporated
for time management, focus on safety and environment care. Report also includes a brief
detail about the fabrication, Production System, Sand Compactor Assembly Line, Sand
Compactor Feeders and Cycle time.
 CONTENTS OF REPORT

CHAPTER-1: ABOUT THE COMPANY

1.1 VISION
1.2 MISSION
1.3 HISTORY
1.4 VOLVO CE JOURNEY IN INDIA
1.5 POLICIES OF VOLVO CE
1.6 VOLVO PRODUCTION SYSTEMS

CHAPTER-2: ABOUT THE DEPARTMENT

2.1 INTRODUCTION TO MANUFACTURING FACILITY
2.2 MODELS ASSEMBLED IN PLANT
2.3 5S METHADOLOGY
2.4 LAYOUT OF RM LINE
2.5 LAYOUT OF EXCAVATOR

CHAPTER-3: TASKS PERFORMED

3.1 A STUDY ON DRUM FEED ASSEMBLY

CHAPTER-4: REFLECTION NOTES

4.1 PERSONAL EXPERIENCE
4.2 RESULT/DISCUSSION
4.3 CONCLUSION
CHAPTER-1
ABOUT THE COMPANY VOLVO CONSTRUCTION EQUIPMENT

Volvo Construction Equipment – Volvo CE – (originally Munktells,

Bolinder-Munktell, and Volvo BM) is a subsidiary and business area of the
Volvo Group that develops, manufactures and markets equipment for
construction and related industries.
Volvo Construction Equipment (VCE) was started in 1832
in Esk0ilstuna, which makes it the oldest industrial company in the world still
active in construction machinery business. VCE has grown and developed
over the years through a number of mergers and acquisitions. The company
manufactures construction machines such as Articulated Haulers, Excavators,
Wheel Loaders Compactors & Pavers. VCE is a part of the Volvo Group
which has approximately 100,000 employees, production in 25 countries and
operates in more than 185 markets.
VCE has approximately 15,000 employees worldwide VCE has a wide market
share of 7% of the construction equipment industries market worldwide.
Wheel loaders are the second largest business area after excavators within
VCE, representing 24% of VCE’s total sales.

1.1 COMPANY PROFILE - VOLVO GROUP.

The Volvo Group is one of the world’s leading manufacturers of trucks, buses,
construction equipment and marine and industrial engines. The Group also
provides complete solutions for financing and service.
 The Volvo Group, with its headquarters in Gothenburg, employs about
100,000 people, has production facilities in 19 countries and sells its products
in more than 190 markets.
In 2014 the Volvo Group’s net sales amounted to about SEK 283 billion. The
Volvo Group is a publicly-held company. Volvo shares are listed on Nasdaq
Stockholm.
Although the two firms are still often conflated, Volvo Cars, also based in
Gothenburg, has been a totally separate company since it was sold off in 1999.
The companies still share the Volvo logo and co-operate in running the Volvo
Museum.
Volvo was established in 1915 as a subsidiary of SKF, the ball bearing
manufacturer.

VISION
➢ To be the most desired and successful transport solution provider in the
world.
➢ Creating value for customers in selected segments
➢ Pioneering products and services for the transport and infrastructure
industries
➢ Driving quality, safety and environmental care

MISSION
• Driving prosperity through transport solutions: Modern logistics is a
prerequisite for our economic welfare: transport helps combat poverty.Volvo
contributes to prosperity and make the world a better place.
• On the road: Volvo products help ensure that people have food on the table
and roads to drive on.
• In the city: Volvo products are part of the daily life. They take people to work,
collect rubbish and generate power. Volvo Group is developing tomorrow’s
public transport solutions. • At sea: Whether at work on a ship, on holiday in
your pleasure boat or need urgent help from the sea rescue services.
• Off road: Volvo contributes to the extraction of some of the world’s most
important raw materials. Volvo Group’s engines, machines and vehicles can
be found at mining and construction sites.
 HISTORY
The Volvo Construction Equipment story began over 180 years ago in
Eskilstuna, Sweden. In the mid-1800s, three men laid the foundation for Volvo
Construction Equipment: Johan Theofron Munktell and the brothers Jean and
Carl Gerhard Bolinder. Over the years – through mergers and acquisitions, as
well as in house development and organic growth the company became a one
of the major global construction equipment manufacturers.

EVOLUTION OF VOLVO CE
➢ 1972 - Volvo introduced ROPS, a cab with a structure designed to protect the
operator if the machine overturned
➢ 1982- Rigid Haulers are added to complement the Hauler line, following the
acquisition of AB Kockum Landsverk.
➢ 1985-The VME Group is formed. Volvo allies with Clark Equipment and
enters the America’s Chigan Wheel Loaders and Euclid Rigid Haulers are
added to the portfolio.
➢ 1990-Compact Wheel Loaders are added to the range thanks to the
acquisition of Zettelmeyer Baumaschinen GmbH.
➢ 1991 Volvo acquires Åkermans Gjuterioch MekaniskaVerkstad and adds
Excavators to its product offering
➢ 1995 ME becomes a fully owned Volvo company and changes name to Volvo
Construction Equipment. Compact Excavator line is extended through the
acquisition of Pel-Job.
➢ 1997 The road range is initiated as a result of the launch of the Motor Grader
line and the acquisition of Champion Road Machinery. The new 30-ton Wheel
Loader Volvo L220D impressed with its productivity and low fuel consumption.
➢ 2001 Volvo Construction Equipment announced the successive introduction of
a new range of Backhoe Loaders of own design.
➢ 2002 Launch of in-house designed Backhoe Loader.
➢ 2003 Production of our Skid Steer Loader begins in Asheville.
➢ 2005 EC700B – an Excavator in the 70-ton class – is launched by Volvo
➢ 2006 Volvo G900-series Graders see the light of day.
➢ 2007 Volvo launches world’s first full-suspension Articulated Hauler.
➢ 2014 Volvo Construction Equipment finalizes the acquisition of the Hauler
business from Terex.
 VOLVO CE’S JOURNEY IN INDIA

VOLVO CE, BANGALORE

Volvo Construction Equipment part of Volvo Group India Pvt. Ltd
and a subsidiary of VOLVO AB, Sweden. The Bangalore facility is one
among the Asia operations which manufactures Road Machinery like Asphalt
Compactors, Soil Compactors, Pavers, Pneumatic Tyres and Excavators.
Volvo CE, located in Peenya, Bangalore is a part of global Volvo
Construction Equipment under Volvo Group India Pvt Ltd entity. Volvo
Construction Equipment Operations facility in Bangalore has a total area of
approximately 57000 sq. meters with factory occupying over 27000 sq.
meters.
This plant originally started its operations in the year 1978 by
Ingersoll Rand to cater the needs of mining industry and road construction
sector. The Volvo group took over this plant in the year 2007 and later
expanded to cater to the needs of the construction equipment industry by
manufacturing Excavators. Out of 204 permanent employees there are 144
white collars (including Purchasing & Technology) and 60 Industrial Workers
in the facility. Over 58% of people work for operations. Women employees
contribute 13% of total white collars.
Peenya facility is certified for QMS/EMS and OHSAS and complies
to AB VOLVO safety and security guidelines. Their core values are Safety,
Quality and Environmental care. With over 15 dedicated dealers spread across
India, Volvo sells approximately 2000 construction equipment machines per
annum to various customers ranging from Road Building Industry, Earth
Moving Contractors, Mining etc.
 POLICIES OF VOLVO CE

Environmental Policy:
• Holistic View.
• Continual Improvement.
• Technical Development.
• Resource Efficiency

Quality Policy:
• Customer Focus.
• Commitment and Participation by Everyone.
• Process Approach and Continuous Improvement.

Safety Policy:
• Customer Focus.
• Product and Service Focus.
• Employee Commitment.
• Open Communication.

Code of Conduct:
• Business principles.
• Principles of human rights and social justice.
• Environmental principles.

.
 VOLVO PRODUCTION SYSTEM (VPS)
VPS was first introduced in 2007 as a way to continuously improve the
quality, delivery and productivity. VPS is the Volvo in actions to words. It
contains practical tools that when used correctly helps the organization to
work towards its shared goals. VPS has 5 core principles which are.

JUST IN TIME:
• It is a production strategy to improve the company’s return on
investment by reducing the in- process inventory and it’s carrying
cost.
• Just in time refers to the manufacturing and conveyance of only what
is needed.
• This enhances efficiency and enables quick responses to change.
• Volvo believes in the storage of unused inventory is a waste of
resources.
• Inventory is seen as incurring cost instead of adding value.
• In Volvo just in time is built upon the five basic principles - Pull
system, Continuous flow processing, Flexible manpower, Takt time
and Material supply.
 FLEXIBLE MANPOWER:
• This means preparing a production line so that it can meet changing
production requirements with any number of workers without lowering
productivity.
• A fixed manpower line is one that always requires a fixed number of workers.
• No adjustment can be to it whatsoever to meet changes in production demand.

PULL SYSTEM:
• One of the basic requirements of just in time.
• The pull system refers to the system of manufacturing in which following
production process withdraw from proceeding processes the parts they
needed, when they need them, in the exact needed amount.

MATERIAL SUPPLY:
• It is a fully integrated application designed to close the loop between you and
your supplier by supporting the outsourcing of your manufacturing.
• The system facilitates insurance of component materials to supplier in
conjunction with the placement of purchase order.

TAKT TIME:
• It is the time which should be taken to produce a component or one
complete product.
• Takt time = available work time per day/ customer demand per day.

CONTINUOUS FLOW PROCESSING:

• This means eliminating the stagnation of work in and between process and
carrying out one piece at a time production
CHAPTER-2
ABOUT THE DEPARTMENT

INTRODUCTION TO MANUFACTURING FACILITY

Volvo Construction Equipment – Volvo India Private Limited, Bangalore is a
subsidiary of Volvo AB. The Bangalore Plant manufactures – Soil Compactors,
Excavators, Pavers and rollers. This manufacturing facility is located in the heart of
Bangalore’s - Peenya Industrial Area where the company has two assembly lines.
• Road machinery assembly line
• Excavator assembly line
This manufacturing facility is consisting of six departments.
1. Assembly Shop
2. Fabrication Shop
3. Parts Paint Shop
4. Test Drive Inspection
5. Touch Up Paint Shop.
 2.1 Models Assembled in Plant

I. ASPHALT COMPACTORS
The Volvo DD100 Compactor is the Ideal Roller for Asphalt Contractor
operations of varying sizes, working in versatile applications. From roadways
and highways to large parking lots and airport runways, this is the Compactor
suited to a wide range of conditions and widths. By getting the job done as
efficiently as possible in the fewest amount of passes the DD100 will help us
complete our jobs with greater profitability. All with visibility and comfort
you expect from Volvo. DD90B is one more variant in the class.
I. PNEUMATIC TYRE COMPACTORS
The Volvo PT220 Compactor is the 22-24 tons Pneumatic Tyre Road Roller
that delivers ideal smoothness for Asphalt Compaction finish work. This
Asphalt Roller features eight air-filled rubber tyres and is ideal for Paving
Compactors working in highway applications. The Volvo PT220 Compactor
efficiently follows double drum compaction machines, to provide smooth,
even asphalt mass with less passes. The PT220 is built by Volvo for
dependability and long operation life. PT240 is an export variant with extra
load bars to add up more weight.
II. SOIL COMPACTORS
The Volvo Compactors are designed with mind for all of your compaction
applications and features to help you tackle even the most demanding jobs.
Volvo Soil Compactors are versatile machines ready to efficiently compact
varying soils and aggregates in applications such as highways, utilities, water
retention structures and in large residential, commercial and industrial site
preparation.
The Volvo SD110 Soil Compactor is the 11-ton class Soil Compaction Roller
built to help you roll on to more profitable jobs. It’s the versatile machine
ready to efficiently and effectively compact varying soils and aggregates in
applications such as highways, utilities, water retention structures and in large
residential, commercial and industrial site preparation. For even more
versatility, the SD110 Soil Compactor is available in a smooth drum with an
optional clamp on pad foot shell that is easy to install and remove.
 III. EXCAVATORS
Volvo small and large Excavator has your solution for dependable Excavating
equipment. On Crawler Tracks or on the road with wheeled versatility, we are
on our way to more profit in site preparation, landscaping, trenching,
excavation, demolition, truck loading.
Top features for the range of Volvo excavators include:
• Dependable Volvo engines deliver class-leading fuel economy.
• Volvo care cabs provide the safety and comfort to reduce operator fatigue
and increase productivity.
• Ease of service, with ground level access to routine service points, for
maximum availability.
• Advanced hydraulic systems for highly-responsive performance.
• Versatile quick fix systems, for easy bucket and tool change out.
• Some of the variants manufactured are EC300DL, EC300X1, EC210D,
EC210X1, and EC210DL.
EXCAVATOR:
5. EC210D
6. EC290D
7. EC210DVLC
IV. PAVERS
Powerful paving machines for rigorous job- sites, Volvo’s ABG tracked
Pavers meet all your paving needs. With ample reserve power, robust and
sturdy design, Volvo ABG tracked pavers are ideal for medium and large-
scale projects. Also wheeled pavers are produced.

Features
• Designed with global technology and valuable input from our customers.
• Ample reserve power, robust and sturdy design and high paving outputs for
maximum reliability and cost-effectiveness.
• Unique operating panel- widely recognized as the most intuitive system on
the market.
 5S METHODOLOGY

“VOLVO CE FOLLOWS 5S WORPLACE”

The word “5S (five S)” was generalized in 1980’s in manufacturing sector in
Japan, as Toyota Production System (TPS) became famous in the sector and
“5S activities” were set as one of the bases of TPS.

WHAT IS THE 5S SYSTEM?

The 5S concept is one of several lean manufacturing (“Lean”) tools designed
to improve workplace efficiency through facility-wide organization and
cleanliness. Each of the 5S guidelines help managers and workers achieve
greater organization, standardization, and efficiency—all while reducing
costs and boosting productivity. Some core principles of the 5S concept
involve creating and maintaining visual order, organization, cleanliness, and
standardization. With these goals in place, the hope is that workplaces can
become more efficient, organized, and equipped to carry out daily tasks in a
safe manner.

ASSEMBLY LINE-COMPACTORS
Road Machinery assembly line, which consists of SEVEN main stations on
the main assembly line and NINE feeder stations that sub assembles various
parts and send it to the main station line that will be mounted on main frame
of the Road Machinery.
The standardized process carried out at each work station and feeder is
discussed at the later stages of report.
The feeder time and station assemble time are all synchronized in such a way
that the sub assembled parts from feeder, station arrives to the main station
line at the right time when needed to mount on the main frame of Road
Machinery.
The Road Machinery assembly line is monitored by ANDON system. There
are several improvements (KAIZEN) implemented in the assembly line of
Road Machinery.
Similarly, there are several improvements on POKA – YOKE and KAIZEN.
 LAYOUT
The layout of road machinery assembly line is as follows:

The 9 feeder stations of the road machinery assembly line are (In particular SD110)
1) Feeder Station 1 (F1) –Axle Sub Assembly Area
The frame is bought into the feeder. The required valves are prepared and
placed in the frame. The hose pipes are placed at appropriate positions. The
electrical harness (main harness) is placed and fixed, sent to station 1.
2) Feeder Station 2 (F2) – Tank Sub Assembly Area
The fuel tank’s i.e. the diesel tank and hydraulic tank are pre-assembled.
Swivel frame is taken and the bolt is fixed into it, sent to the station 2 for
fixture.
3) Feeder Station 3 (F3) – Engine Sub Assembly Area
The engine imported from Germany is bought into the feeder and the capacity
of the Engine is 4 – cylinder, 133 HP, 99 KW, 2200 RPM. The vibration pump
and the steering pump is connected to the shaft. The required hose pipes are
joined. The engine oil is filled (15 litres).
4) Feeder Station 4 (F4) – Console Sub Assembly Area
The seat console frame is taken into the feeder and the steering pump and the
fuses is connected to the frame. The seat assembly is attached to the frame.
The required hose pipes are connected.
5) Feeder Station 5 (F5) – Hood Sub Assembly Area
The filters are fixed onto hood. Then the hood is attached to its second part of
it.
6) Feeder Station 6 (F6)– Drum Frame & Exhaust Sub Assembly Area
The railings are fixed to the main frame. The centre console control system is
fixed (switches). The roof is pre-assembled and fixed in the station 6.
7) Feeder Station 7 (F7) – Ropes, Scrapper, Tyres
The ropes mounting is used to fix the roofs. The scrappers of the drum (drum
cleaner)are fixed. The pre-assembled tyres are bought into the feeder and sent
to the station 7.
8) Feeder Station 8 (F8) – Drum Cell
The fabricated and painted (inner) drum is placed in this feeder and the carrier
and spindle alignment, the vibration pump is fixed and the leak test is done
before filling the drum oil.
9) Feeder Station 9 (F9) – Drum Sub Line
The components are first washed and the sleeve is inserted into the speed
sleeve. The pin is fixed into it using a journal pressure pin fixture. The speed
sleeve is then attached to the spindle and this assembly is fixed using a nut and
a bolt. The carrier and spindle assembly are done by using templates and cold
as well as hot bearings.

The 7 Main stations of the road machinery assembly line are:

1) Main Station 1 (S1) –Main Frame and axle Installation
The rear axle is bought and placed on the main assembly line and the main
frame is placed onto it and it is fixed. The required hose and harness are fixed
and sent to next station.
2) Main Station 2 (S2) –Tanks and Swivel Frame Installation
The sub-assemblies of the swivel frame and the tanks are bought into the
assembly line and assembled. The swivel frame is fixed using a hydraulic
torque wrench. The appropriate hose pipes and harness are connected and sent
to next station.
3) Main Station 3 (S3) –Engine Installation
The engine assembly is bought into the assembly line and it is aligned to the
desired position in the frame and it is assembled. The required hose and
harness are connected and sent to station 4.
 4) Main Station 4 (S4) –Battery and Silencer Installation
The pre-assembled battery is placed and connected to the engine. The silencer
is connected to the exhaust of the engine. The seating console is bought into
the assembly line and assembled into the frame.
5) Main Station 5 (S5) - Cowling, Hood, Hydraulic Piping Installation
The hydraulic piping is installed into with the swivel frame and it is attached
to the hydraulic tank. The engine hood is fixed to the engine. The hood locking
is aligned using a template and drilled and fixed to the hood.
6) Main Station 6 (S6) –Drum Frame, Ropes and Railing Installation
The fabricated drum frame is moved to the assembly line, aligned and then
fixed with a plate to hold it with the swivel frame. The fabricated rops are also
moved, aligned and fixed to the main frame at its appropriate position in the
frame. The railings near the seating console are aligned and fixed to the frame.
7) Main Station 7 (S7) –Scrapper, Tyre, Electrical Battery Routing
Installation
The assembled drum is moved to the assembly line, aligned to the drum
frame and fixed to the drum frame using a hydraulic torque wrench. The tyres
are bought into the assembly line and fixed to the rear axle of the machine. All
the left over hosing and harness connection is done. Including the head light,
tail light, and the number plate (front and back). Then it is sent for test driving.
8) Feeder Station 8 (F8) - Main Control Valve Sub Assembly
MCV is placed on the oil drain fixture. Sub assembled tank is positioned. The
O ring is inserted and the hydraulic pipe is installed. The next operation is to
connect hydraulic hoses on front side and back, RH top side and LH side.
 ASSEMBLY LINE-EXCAVATOR
Excavator assembly line consists of 9 main stations on the main assembly line
and 15 feeder stations that sub assemble various parts and sends it to main
station line that will be mounted on main frame of the Excavator.
The standardized process carried out at each work station and feeder is
discussed in the latter stages of report.
The feeder time and station assemble time are all synchronized in such a way
that the sub assembled parts from feeder station arrive to the main station line
at the right time when needed to mount on the main frame of Excavator.
The Excavator assembly line is monitored by ANDON system.
There are several improvements (KAIZEN) implemented in the assembly line
of Excavator. Similarly, there are several improvements on POKA – YOKE
and KAIZEN
LAYOUT
The layout of Excavator assembly line is as follows:

The 12 feeder stations of the Excavator assembly line are:

1) Feeder Station 1 (F1) Block Sub Assembly
The main upper frame arrives to the station line. The cleaning process is
carried out for the upper frame. After cleaning is done, fixing of grease plate
and headlight is on the frame. Later stages the light cover, coolant pipes are
fixed on to frame.
2) Feeder Station 2 (F2) Bottom Plate Sub Assembly .
At this station bottom plate is lifting to the sub assembly fixture. Joystick
pedals and foot rest brackets are laid on the frame. Electric harness flanges are
fixed at next working stage of this station. AC vents are connected; the RCV
hoses are attached to the block. After all the operations are completed; the
bottom plate sub assembly is lifted and mounted on main frame.
3) Feeder Station 3 (F3) Boom Cylinder and Radiator Sub Assembly
At this station AC condenser is fixed. The boom cylinder is placed on
the fixture. The hydraulic solid pipe, greasing adapters are assembled on to
the boom cylinder. The next operation is to mount the radiator on the frame
and the radiator guard is attached. Hoses are connected to the radiator. The
sub assembly is mounted on the main frame.
4) Feeder Station 4 (F4) COWL Frame Sub Assembly
The COWL sub assembly consists of cowl doors and cowl frame.
They are assembled on the cowl frame table. The sub assembled parts are
lifted and mounted on the engine and radiator.
5) Feeder Station 5 (F5) Swing Motor Sub Assembly
At this feeder, the swing motor is placed on the fixture. Adapters and
nipples are attached to the swing motor while on the fixture. Hydraulic oil is
pumped to the swing motor and is ready to be assembled to the main frame.
6) Feeder Station 6 (F6) Cabin Sub Assembly
The readymade cabin arrives to the feeder station. Here the various
parts that have to be mounted inside the cabin are placed and fixed inside the
cabin.
7) Feeder Station 7 (F7)
Boom and Arm Docking. The boom and arm arriving from feeder
station 15 with bushes are put together and docking pins are inserted.
8) Feeder Station 8 (F8) Main Control Valve Sub Assembly
MCV is placed on the oil drain fixture. Sub assembled tank is positioned.
The O-ring is inserted and the hydraulic pipe is installed. The next operation
is to connect hydraulic hoses on front side and back, RH top side and LH side.
9) Feeder Station 9 (F9) Engine Sub Assembly
At this feeder station, engine block is lifted and placed on the
fixture. The next operation is to remove the clamps. Certain brackets are
placed and tightened. The muffler pipe is connected along with electrical
harness. The oil hose clamps are fixed. The AC Compressor is mounted and
belt drive for compressor is fixed and radiator outlet is connected. The next
operation is to fix various adaptors, water supply hose and connecting electric
harness to different compartments. Lastly the engine oil is filled, to prevent
accidents/ mistakes. POKA-YOKE is implemented to stop the engine cart
from moving unless oil is filled with the help of stopper.
10) Feeder Station 10,11,12,13 (F-10,11,12,13) Lower Frame Sub Assembly
Lower frame sub assembly is divided into four subassembly departments:
• Lower Frame Sub Assembly 1 (F10) • Lower Frame Sub Assembly 2 (F11)
• Lower Frame Sub Assembly 3 (F12)
• Lower Frame Sub Assembly 4 (F13)
The following process takes place in all the four lower frame sub assembly
work: -
• The lower frame with swing gear is installed on resting fixture and inverted.
The sprocket track motor assembly is assembled on to the lower frame. The
idler wheels are sub assembled frame and is installed. on to the frame. Recoil
springs are installed to the frame absorbed shocks.
• The track motor chain belt is placed on the wooden fixtures and the assembled
frame is lifted and placed on the chain. After the chain belt is fixed to the
frame, the swing gear is lubricated with 17kgs for model EC210 and 34kgs
for EC290 excavator.
11) Feeder Station 15 (F15) Boom and Arm Sub Assembly
The bushes are inserted to boom and arms of the excavators. The
bushes are placed in a tank and liquid nitrogen is poured and closed for few
minutes until it cools and contracts. After few minutes, the bushes dipped in
nitrogen are picked up and inserted into the arm and boom of the excavator
pressure to fit bush into the hole. After the bush is inserted, the boom cylinder
is installed and various hose pipe for hydraulic oil are mounted and locked.
The assembled boom and arm sent to the main station.
 The 9 Main stations of the Excavator assembly line are:
1) Main Station 1 (S1) - MCV and Tank Insertion
The sub assembled parts from MCV feeder arrive on to the main station
along with block sub assembled from the opposite feeder station. At this
station, MCV unit is mounted on to the main frame of excavator and bolted.
2) Main Station 2(S2) – Bottom Plate Insertion
At this station, bottom plate sub assembly from feeder station 2arrives
along with engine sub assembly from feeder station 9. It is mounted on main
frame and fixed.
3) Main Station 3(S3) – boom Cylinder Placement
Seat and battery box are mounted and fixed to main frame of
excavator along with the routing of various hoses.
4) Main Station 4(S4)- Cowl Frame Insertion
Radiator and hydraulic cylinders are installed and fixed on the upper frame
of excavator.
5) Main Station 5(S5)- Swing Motor Insertion
Engine and radiator cowl frame and cowl door is installed on the main
frame in which radiator and engine is already mounted.
6) Main Station 6 (S6) – Lower & Upper frame Alignment
The assembled main upper frame with all the parts on ready to be mounted
on the lower frame which arrives from feeder 13. With the help of a crane upper
frame is mounted on the lower frame and bolts are inserted and tightened.
7) Main Station 7 (S7) – Fuel Filling
The lower frame and upper frame assembled in the excavator now
arrives to this station. At this stage the fuel, coolant and hydraulic oil is
pumped. POKA – YOKA is used while pumping to avoid any mistakes.
8) Main Station 8 (S8) – Counter Weight Insertion
After the oil, coolant and fuel is filled, the excavator is switched on for
the first time and moved to this station. Here cabin sub assembled at earlier
stages arrives and is mounted on the excavator. A counter weight is added to
balance the weight of excavator at back.
9) Main Station 9 (S9) –Arm and Bucket Placement
Boom and arm installed at this station to the Excavator which arrives
from feeder 15 with bushes already inserted along with hydraulic cylinders
and moved outside assembly line to texting area.
CHAPTER 3
TASK PEFORMED
A STUDY ON DRUM FEED ASSEMBLY
CHAPTER -4
REFLECTION NOTES

4.1 PERSONAL EXPERIENCE

As a part of academics under VTU, B.E, final year students need to do their
internship program for duration 1 month in a company or an organization to get
exposure of concepts studied in our academics in real time applications. Recently I
got an opportunity to do my internship at VOLVO Construction Equipment, Peenya.
The chief coordinator, the trainers and other facilitators in Volvo CE welcomed us
on day-1. They introduced me and various students who have come from other
engineering colleges like BNM Institute of Technology (Bangalore),
GAT(Bangalore), DBIT(Bangalore), BMSIT to do the internship. Volvo CE is
consisting of various road machinery equipment making a way to thought, whether
I will be allowed to work on those but the fact that they allowed us every day to get
a hand on experience and I am happy being a part of this internship program.
As part of this training program, I was introduced to assemblies of road
machineries such as excavators, compactor, and paver. Each and every student was
assigned to different units and made us to work individually. After teaching us the
concepts they were giving us assessments to solve, trainers helped us if we stuck
in the middle. There exist hands on training on each module which made us to
understand even much better.
All the way in my training there was no hurry to finish the work assigned in that
way every doubt was cleared, gave time to understand each and every concept, some
few minutes of time between each and every product was given. It was an amazing
experience, meeting different kind of people who are from different places and by
sharing their knowledge. I got an opportunity to explore myself to the industry. I had
training classes for about four weeks, in which it is thought that what actually the
industry needs from the employee and the technical things on which more
concentration is needed, is known. This gave me chance to find out which areas I
want to work in after my education.
The conversation through e-mail is also an important learning moment for me during
my internship. This internship was definitely beneficial for me and I am grateful and
thankful that I got to experience, learn many things and good industrial exposure
providing world class infrastructure facilities which inspired me to execute the
project connected to the modules we learnt.
4.2 RESULT/DISCUSSION
The assessment of an internship is very important for any of the internship
Program. Assessment is actually weighing the pros and cons of any internship.
The good and bad of any internship are expressed by assessing it about some
objects. I would like to access my internship as follows.
➢ Guides were helpful, approachable, provided feedback on my progress and
skills.
➢ Level of responsibilities was consistent with my abilities.
➢ Fellow workers accepted my work and treated me appropriately.
➢ This internship provided me the opportunity to use my academic preparation.
➢ This provided me the opportunity to develop my interpersonal and technical
skills.
➢ It gave me the opportunity to develop my verbal and written communication
skills.
➢ This was a valuable learning experience and I grew as a professional.
➢ This internship gave experience that may help me get a job.
➢ It helped me define my career goals and next career step.
➢ This provides a way to identify areas for personal and professional growth.
➢ I had the opportunity to use the resources that are not available in campus.
➢ It was a good place where I had opportunity to experience situations and
have exposure to diverse population.
➢ This internship provided opportunity for self-directed learning.
4.3 CONCLUSION
This internship may have a good impact on my academic and career plans.
Teaching approaches may vary significantly from academic program to
another. But one approach that seems to be universally valued across
disciplines is that of the internship. Internship experiences help us connect
learning to life, as they provide with the opportunity to apply the knowledge
and skills they have learned in the classroom to real-life situations.
Internship help to push further the pyramid of Blooms Taxonomy, into the
deeper understanding found within the application level of learning. At the
beginning I did not have any experience of working in an industry. I
understood better the functioning like the organization structure and setting up
projects. In the beginning the dependence and uncertainty was there, but it
forced me to be flexible and to see what other things I could do. My mentor
during my internship was Mr. Sanjay Raina, production manager and
supporting staff from whom I have learned a lot during my internship. He was
very helpful and always willing to give me advice and feedback which I
appreciate. I have tried to learn as much as possible from him and from the
interns during my internship.

I also became strong in my verbal and written communication through the

social media tools and writing my internship report. I have improved my
language skills by communicating with the interns that I have worked with
relevant materials and guidance by the lecturers helped in shaping the report.
Teachers gave us an outline to create report and alarmed us to do it in timely
basis which immensely helped me. It was a fabulous experience with VOLVO
Construction Equipment, by gaining lot of things both technically and non-
technically. Throughout this journey reports were made to the internal guide
in the college who immensely supported for shaping this report. Time
management was another big challenge during the course of internship. At the
beginning the training went on very slow and we realized that the time left out
for the completion of the internship is approaching and managed to complete
work in time. Time for completing my project was long compared to the time
of training. But somehow utilized and divided time for the completion of the
assigned projects.
 NON-TECHNICAL SKILLS
➢ I also came to learn non-‐technical skills by living in such a new
environment.
➢ Making friends with people from different ages and backgrounds is one
thing, but my largest challenge was to work independently.
➢ Even though I had a supervisor, I am the one who decided how much work I
should do, whether it was enough or not, or whether I should work harder.
➢ This sense of independence is the biggest source of my worry, yet it is the
most exciting part of being able to work in an office.