CHAPTER-1 COMPANY PROFILE

Chairman: - Sh. L. D. Mittal

Vice-Chairman:- Sh. A. S. Mittal

Managing Director: - Sh. D.K. Mittal

Sonalika Group started its journey of success during 1976 with the foundation of small scale unit to fabricate & assemble Wheat harvesting machines was laid. With passage of time this small initiative taken by Mittals in 1976 turned into great success due to the undulated efforts of promoters & thousands of employees who worked unfiltered throughout.

The great success provided further motivation ultimately resulting in setting up a new plant in the name of International Tractors Limited for the production of tractors, the demand & requirement of which was steadily growing at that time. Now Sonalika group consists of 4-companies:

1. International Tractors Limited.

2. Agriculture division.

3. Three-wheeler division.

4. Automobile division.

5. International Cars and Motors Limited.

MISSION: -

The Sonalika Group offers quality product with distinctive features at reasonable price the company ensure better than best after sale service for satisfaction of the customer. Company is exporting its tractors, MUVs and agri machinery to different Asian as well as African countries.

TRAINING & LEARNING: -

All classes of employees are trained. Non-skilled are trained to become skilled worker & skilled are trained to acquire multiple skills. Diploma & graduates are trained for 1 year.

WORK CULTURE: -

The ICML seeks to create a culture where each employee, vendor, & dealer feels himself as a part of enterprises. Every member respects 5F formula.

1. Fast

2. Focused

3. Fair

4. Friendly

5. Fun

FUTURE PLANS:-

To provide superior quality products all over the world, with new technology at reasonable rates & to become No.1 automobile industry. The newly launched MUV Rhino and the proposed SUV are leaps towards that goal. There's good news for whoever thought that British cars came in price tags of crore plus, in India.

If the British Bentley is the dream car for the rich and famous, the Indian middle class could soon be zipping around in British Sports Utility Vehicle (SUV) at affordable prices.

The eighteen hundred crore Sonalika group that makes tractors with French collaboration at Hoshiarpur has launched a Multi Utility Vehicle in collaboration with MG Rover Group of the UK. Having broken into the league of top five tractor manufacturers in the last four years, the company wants break new ground in the MUV market.

The MUV named RHINO has hit the Indian road in the late 2005. AmritSagar Mittal Vice-Chairman of International Cars and Motors Limited (ICML) who signed an MOU with MG Rover said, "Our research has indicated that there is a large market for MUV in India.

CHAPTER-2 INTODUCTION

ICML has also signed a MOU with Powertrain LTD of the UK to manufacture a new common rail diesel engine and six speed gearbox that would be used in the SUV. The SUV that was previously designed indigeniously will now have the technical backing of the famous UK’s largest car manufacturing Company that is part of the USD 3.5 billion Phoenix Venture holdings Limited. For the project, ICML has put in an investment of over Rs 200 crores and the plant is being set up at Amb in Himachal Pradesh. Mr. Mittal said that a state of the art assembly line is being set and the plant would have an annual capacity to manufacture over twenty-four thousand MUVs and SUVs per year. British Sports Utility Vehicles (SUVs) will soon hit the Indian market at a price that the Indian middle class can now afford.

International Cars & Motors Limited:-

Today with the changing times, the needs and expectations of the customer are changing. He is technically well aware and economically conscious. He is not only concerned about his own safety but also about the safety of the environment. He wants a multi utility product. A product with Power and Punch. Therefore, we, at International Cars & Motors Limited developed a team that is constantly working with the dreams that

Vehicles inspire.

Plant area details:

· Total plant area – 23 acres (93,000 Sq. M.)

· Total covered area – 10.5 acres (42,000 Sq. M.)

Major shop details :

· Press shop – 4,300 Sq. M.

· Body shop – 3,900 Sq. M.

· Paint shop (PT/CD & Top coat) – 5,400 Sq. M.

· Assembly shop – 6,440 Sq. M.

Press shop:

Sheet metal components are developed in-house using two giant hydraulic presses of 1200 and 600 T. Rapid prototyping facility with 5 axis laser cutting machine for automated cutting program and automated fixture designing & manufacturing that results in trimmed surface with no burr or bum marks. The press shop of I.C.M.L. located in I.T.L Hosiarpur, the area of press shop is 43, 00 sq. M.

Manufacturing Facilities:-

The manufacturing facility of ICML is located in Amb (Una District) in the picturesque Shivalik foothills of the Himalayas, about 38 Kilometers from the Group’s principal tractor manufacturing plant in Hoshiarpur. Being under tax free zone, the move to locate the plant in Amb is a major strategic move since the company will enjoy a distinctive cost advantage and will be able to deal with competitive business environment through aggressive price positioning for its products. Spread in a 56 acre plot and an investment of close to Rs. 200 Cr., and an installed capacity to produce 24,000 units per annum, the company has put in place a state-of-the-art globally integrated production facility which will employ all forms of modern production techniques and quality systems. This is India’s only completely pressurized automobile plant that will help to manufacture vehicles in total dust free and temperature & humidity controlled environment. The plant has built-in capacity strength for future expansion needs.

Torture Test Tracks:-

ICML vehicles that will roll out of the assembly line will be subjected to very stringent torture tests to withstand highly demanding road conditions prevalent in the country. Custom-built to international standards, the test track has sine wave, rumbles, rough road, corrugated pot holes, stone paved roads, gradient, water wading zone, under body inspection ramp and smooth road for long distance driving at different speeds. Testing on these different simulated road conditions for acceleration & braking, ride & handling, gradient test, body squeak noise & rattling test, under body inspection & leakage will make the end-product highly road wor Protection of environment:-The company rigidly adheres to the discipline of ‘respect for the environment’ and has established all standards that will help to protect the environment from industrial .

CUSTOMER EXPECTATIONS:-

· Price matters

· Easy and economic repairability

· Fuel economy is very important

· Comfort and seating capacity

· Easy finance

· Reliability

· Safe.

STRENGTHS:-

· Price positioning of RHINO is on highest volume and growth segment.

· Sitting comfort offered is best in its class.

· Our product operating expense is expected to be the minimum in the category.

· Vendors among the best in the country.

· Strong dealership network under stringent selection norms.

· All dealerships to project uniform and high quality corporate identity of ICML.

· ICML will undertake dealer sales/service manpower selection & training.

TERMS AND DEFINATIONS:

1) BLANK SIZE: - Total size of the sheet from which one component can be drawn is known as blank size. It is the minimum rectangular area of the sheet which for making the component and to be cut from the base sheet which of the size 2500 mm X 1250 mm.

2) VOLUME: - Volume is the area of the blank size of the sheet multiplied by thickness of the sheet i.e. the mass of the material.

3) ORIGINAL WEIGHT: - this is the weight of the component after the complete development. In it the weight of the waste material is not included.

4) SCRAP: - It is defined as the material that is left after the total processing of the component.

5) PROCESS COST: - The cost of all the processes that has been done to make a certain component is known as process cost. Several processes have been done to get the desired component. It is calculated as per tonnage capacity & per tonnage price.

6) SCRAP COST: - The cost of the scrap material is known as the scrap cost. It is the total weight of the scrap multiplied by the rate of the material of the scrap.

7) MATERIAL COST: - The material cost is the actual cost of material that is being used to obtain the desired component shape. It is in Rs. per kg.

CHAPTER-3 WELDING SHOP

FIG. 3.1 WELDING SHOP

3.1 BODY WELD SHOP

As the name suggests the shop in which the body or shell of Car is produced with the help of different types of welding, is known as BODY WELD