ACKNOWLEDGMENT

This is really a matter of pleasure for me to prepare a project report as it was included

in our course by the Manipal University.

It gave me the opportunity to learn things practically what we learnt enterprise and

their impact on the working of the company.

It really gives me pride to first thanks to the Workshop Manager of “Sangam Bajaj”

Mr. Anurag Thakur that gave me the chance to make analysis of “Bajaj Auto’s”

vehicle and he also guide me throughout my project. He give many Ideas,

Knowledge, Suggestions from his pool of knowledge and also by sharing his

valuable experiences in the field area.

1

AUTOMOBILE HISTORY

History of the automobile actually began about 4,000 years ago when the first wheel

wheel was used for transportation in India. Several Italians recorded designs for wind-

driven vehicles. The first was Guido da Vigevano in 1335. It was a windmill-type

drive to gears and thus to wheels. Vaturio designed a similar vehicle that was also –

never built. Later Leonardo da Vincide signed clockwork-driven tricycle with tiller

steering and a differential mechanism between the rear wheels.

In the early 15th century, the Portuguese arrived in China and the interaction of two

cultures led to a variety of new technologies, including the creation of a wheel that

turned under its own power. By the 1600s, small steam- powered engine models were

developed, but it was another century before a full-sized engine-powered vehicle was

created.

A Catholic priest named Father Ferdinan Verbiest is credited to have built a steam-

powered vehicle for the Chinese Emperor Chien Lung in about 1678. There is no

information about the vehicle, only the event. Since James Watt didn’t invent the steam

engine until 1705, we can guess that this was possibly a model vehicle powered by a

mechanism like Hero’s steam engine-a-spinning wheel with jets on the periphery.

Although by the mid-15th century the idea of a self-propelled vehicle had been put

into practice with the development of experimental vehicles powered by means of

springs, clockworks, and the wind.

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Nicolas-Joseph Cugnot of France is considered to have built the first true automobile in

1769. Designed by Cugnot and constructed by M.Brezin, it is also the first vehicle to

move under its own power for which there is a record. Cugnot’s three wheeled steam-

powered vehicle carried four persons and was meant to move artillery pieces. It had a

top speed of a little more than 3.2 km/h (2 mph) and had to stop every 20 minutes to

build up a fresh steam.

Evans was the first American who obtained a patent for “a self- propelled carriage.”

He, in fact, attempted to create a two-in-one combination of a steam wagon and a flat-

bottomed boat, which didn’t receive any attention in those days. During the 1830’s, the

steam vehicle had made great advances. But stiff competition from railway companies

and crude legislations in Britain forced the poor steam vehicle gradually out of use on

roads.

Automobile manufacturers in the 1930s and 1940s refined and improved on the

principles of Ford and other pioneers. Cars were generally large, and many were still

extremely expensive and luxurious; many of the most collectible cars date from this

time. The increased affluence of the United States after World War II led to the

development of large, petrol - consuming vehicles, while most companies in Europe

made smaller, more fuel-efficient cars.

3

INDIAN AUTOMOBILE HISTORY

India is the second largest manufacturer and producer of two-wheelers in the world. It

stands next only to Japan and China in terms of the number of two-wheelers produced

and domestic sales respectively.

The Indian two-wheeler industry made a small beginning in the early 50s when

Automobile Products of India (API) started manufacturing scooters in the country.

Until 1958, API and Enfield were the sole producers.

In 1948, Bajaj Auto began trading in imported Vespa scooters and three-wheelers.

Finally, in 1960, it set up a shop to manufacture them in technical collaboration with

Piaggio of Italy. The agreement expired in 1971.

In the initial stages, the scooter segment was dominated by API, it was later overtaken

by Bajaj Auto. Although various government and private enterprises entered the fray

for scooters, the only new player that has lasted till today is LML.

Under the regulated regime, foreign companies were not allowed to operate in India. It

was a complete seller market with the waiting period for getting a scooter from Bajaj

Auto being as high as 12 years.

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The motorcycles segment was no different, with only three manufacturers viz Enfield,

Ideal Jawa and Escorts. While Enfield bullet was a four-stroke bike, Jawa and the

Rajdoot were two-stroke bikes. The motorcycle segment was initially dominated by

Enfield 350cc bikes and Escorts 175cc bike.

The two-wheeler market was opened to foreign competition in the mid-80s. And

then market leaders - Escorts and Enfield - were caught unaware by the onslaught of

the 100cc bikes of the four Indo-Japanese joint ventures. With the availability of fuel

efficient low power bikes, demand swelled, resulting in Hero Honda - then the only

producer of four stroke bikes ( 100cc category), gaining a top slot.

The first Japanese motorcycles were introduced in the early eighties. TVS Suzuki and

Hero Honda brought in the first two-stroke and four-stroke engine motorcycles

respectively. These two players initially started with assembly of CKD kits, and later

on progressed to indigenous manufacturing. In the 90s the major growth for

motorcycle segment was brought in by Japanese motorcycles, which grew at a rate of

nearly 25% CAGR in the last five years.

The industry had a smooth ride in the 50s, 60s and 70s when the Government

prohibited new entries and strictly controlled capacity expansion. The industry saw a

sudden growth in the 80s. The industry witnessed a steady growth of 14% leading to a

peak volume of 1.9mn vehicles in 1990.

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The entry of Kinetic Honda in mid-eighties with a variometric scooter helped in

providing ease of use to the scooter owners.

In 1990, the entire automobile industry saw a drastic fall in demand. This resulted

in a decline of 15% in 1991 and 8% in 1992, resulting in a production loss of 0.4mn

vehicles. Barring Hero Honda, all the major producers suffered from recession in

FY93 and FY94. Hero Honda showed a marginal decline in 1992.

The reasons for recession in the sector were the incessant rise in fuel prices, high input

costs and reduced purchasing power due to significant rise in general price level and

credit crunch in consumer financing. Factors like increased production in 1992, due to

new entrants coupled with the recession in the industry resulted in companies either

reporting losses or a fall in profits.

India is one of the very few countries manufacturing three-wheelers in the world. It is

the world's largest manufacturer and seller of three-wheelers. Bajaj Auto commands

a monopoly in the domestic market with a market share of above 80%, the rest is

shared by Bajaj Tempo, Greaves Ltd and Scooters India.

The total number of registered two-wheelers and three-wheelers on road in India, as on

March 31, 1998 was 27.9mn and 1.7mn respectively. The two wheeler population has

almost doubled in 1996 from a base of 12.6mn in 1990.

6

HISTORY AND DEVELOPMENT OF BAJAJ Bajaj Group came into existence in 1926, during the turmoil and the heady euphoria

of India’s freedom struggle. Jamnalal Bajaj, founder of the group, was a close

confidant and disciple of Mahatma Gandhi, and was deeply involved in the effort for

freedom. The integrity, dedication, resourcefulness and determination to succeed which

are characteristic of the company today, are often traced back to its birth during those

long days of relentless devotion to a common cause.

Kamalnayan Bajaj, the eldest son of Jamnalal Bajaj, at the age of 27, he took over

the reins of business in 1942. Putting the Nation before business, he devoted himself to

the latter only after India achieved independence in 1947. and then after he was able to

give his full attention to the business. Kamalnayan Bajaj not only consolidated the

group, but also diversified into various manufacturing activities, elevating the group to

the status it enjoys till this day.

At present Chairman and Managing Director of the group, is Rahul Bajaj, took

charge of the business since 1965 and is recognized as one of the most outstanding

business leaders in India. As dynamic and ambitious as his illustrious predecessors, he

has been recognized for his achievement at various national and international forum.

Baja is currently India’s Largest Two and Three Wheeler manufacturer and one of

the biggest in the world. Under Rahul Bajaj’s leadership, the turnover of the Bajaj Auto

the flagship company has gone up from Rs.72 million to Rs.46.16 billion (USD 936

million), its product portfolio has expanded from one to and the brand has found a global

market. He is one of India’s most distinguished business leaders and internationally

respected for his business acumen and entrepreneurial spirit

7

GROUP COMPANIES

Bajaj Auto is the flagship of the Bajaj group of companies. The group

comprises of 27 companies and was founded in the year 1926. The companies in

the group are:

Bajaj Auto Ltd. Mukand International Ltd.

Mukand Ltd. Mukand Engineers Ltd.

Bajaj Electricals Ltd. Mukand Global Finance Ltd.

Bajaj Hindustan Ltd. Bachhraj Factories Pvt. Ltd.

Maharashtra Scooters Ltd. Bajaj Consumer Care Ltd.

Bajaj Auto Finance Ltd. Bajaj Auto Holdings Ltd.

Hercules Hoists Ltd. Jamnalal Sons Pvt. Ltd.

Bajaj Sevashram Pvt Ltd. Bachhraj & Company Pvt. Ltd.

Hind Lamps Ltd. Jeevan Ltd.

Bajaj Ventures Ltd. The Hindustan Housing Co Ltd.

Bajaj International Pvt Ltd. Baroda Industries Pvt Ltd.

Hind Musafir Agency Pvt Ltd. Stainless India Ltd. Bajaj Allianz General Insurance

Bombay Forgings Ltd. Company Ltd. Bajaj Allianz Life Insurance Company

- Ltd.

8

BAJAJ PLANT INFRASTRUCTURE

Bajaj has a main plant at Pune. Company produce all bike from its main plant by

assembling the parts which are purchased from different source and manufactured.

Bajaj Auto's have a three plants at Akurdi, Waluj and Chakan in Maharashtra, western

India.

Plant Location:

The Bajaj auto’s Three plant located at

1. Mumbai - Pune Road, Akurdi, Pune 411 035

2. Bajaj Nagar, Waluj, Aurangabad 431 136

3. MIDC, Plot No A1, Mahalunge Village, Chakan 410 501

Dist. Pune

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Plant as per its requirement. Generally company produces a Different Product/Bike in

different plant.

1. Akurdi:Geared scooters, ungeared scooters and Bajaj

Discover

2. Waluj:

Bajaj CT100, Bajaj Wind 125 and three wheelers

3. Chakan:

Bajaj motorcycles - Pulsar and Discover

Company produced 2,194,799 vehicles in 2004-05.

10

TECHNOLOGY TIE UP

Bajaj Auto has a technical tie-up with Kawasaki Heavy Industries of Japan to produce a

range of the latest state-of-art two-wheelers in India. Since the tie-up in 1986 Bajaj Auto

has launched KB100, KB RTZ, KB125, 4S, 4S Champion, Boxer, Caliber,

Caliber115, Wind125 and India's first real cruiser bike, the Kawasaki Bajaj Eliminator.

A Fortune 500 company with a turnover of USD 10 billion (Rs. 45,840 crore),

Kawasaki Heavy Industries has crafted new technologies for over a hundred years.

These technologies have redefined space systems, aircrafts, jet engines, ships,

locomotive, energy plants, construction machinery, and automation systems, apart

from a range of high quality, high reliability two-wheelers.

Kawasaki has given the world its legendary series of 600-1200cc Ninja and 1600

Vulcan bikes. Straight from Kawasaki design boards, the Kawasaki Bajaj Eliminator

redefines the pleasure of "biking" in looks as well as performance

Bajaj Have technology Tie-up with Kawasaki from

1988 to 2003.

11

MODELS OF BAJAJ AVENGER DTS-I

Technical specification

Engine : Five Speed, 4 Strock

220CC

Starting Sys : Kick start (Elec.

Start)

Tank : 14 Litter

Power : 16.5 BHP @8000rpm

ELIMINATORTechnical specification

Engine : Five Speed, 7 Port

Torque

Starting Sys : Kick start

(Elec. Start)

Max Speed : 110 kmph (solo)

Power : 15.2 BHP @8500rp

12

13

DISCOVER DTS-I PULSAR DTS-I

Technical specification Technical specification

Engine : Five Speed, 4 stroke, Engine : Five Speed, 4 stroke,

111.63 cc 150 cc / 178.60 cc

Starting Sys : Kick start Starting Sys : Kick start

(Elec. Start) (Elec. Start)Power : 7500rpm Power : 8000rpm (15 BHP)

Avg : 101 Km/L Avg : 55 Km/L

Fuel Tank Capacity: Fuel Tank Capacity:

10 Liters(2.3 Liters of 18 Liters(2.3 Liters of

Reserve Reserve

Suspension: (SNS) Spring inSuspension: Triple rate spring,

Spring with hydraulic shock Nitro Shock Observers

absorbersWeight : 137 Kg.

Weight : 117 Kg.Breaks : Drum 135 mm diameter

Breaks : Drum 130 mm diameter. Silencer : Exhaust TEC

COMPETITOR

Today competition is not only rife but also growing more intense every year. Competitors

are, the companies that satisfy the same customer need. It is a simple task for a company

to identify its competitors, once a company identifies its primary competitors, it must

ascertain their strategies, objectives, strengths and weaknesses and reaction pattern.

Whether competitors can carry out their strategies and reach their goal depends on their

resources and capabilities. Companies’ closest competitors are those seeking to satisfy the

same customers and need and making similar offer. A company should also pay attention

to latent competitors who may offer new or other ways to satisfy the same needs. Manager

needs to conduct a customer value analysis to reveal the company’s strengths and

weaknesses relative to competitors.

Bajaj’s competitors are:

· Hero Honda

· Honda

· LML

· Kinetic

· TVS

14

DEALERS

Bajaj Auto has a wide network in the country. Bajaj Auto have a more that one Show room

in each city. And dealers provide a vehicle to the customer as per its demand. The company

provide scheme to the dealers and dealers are very much active to attract customers by

providing more and more scheme and benefits to the customers.

The “Bajaj Auto” has a network of 498 dealers and over 1,500 authorized service

centers and 162 exclusive three- wheeler dealers spread across the country. Around

1,400 rural outlets have been created in towns with population of 25,000 and below.

The current dealer network is servicing these outlets.

Bajaj Auto is in the process of setting up a chain of retail stores across the

Country exclusively for high-end, performance bikes. These stores are called " Bajaj

Probiking". One such store has been opened in Pune.

15

GENERAL INFORMATION OF SANGAM

BAJAJ

Sangam bajaj is an authorized dealer and service station for Bajaj Auto Limited, situated

in Thakurdwara,palampur (H.P),established in 1990 initially it was only a authorized

dealer started with an initial investment of 1.5 lacs only. Mr. Vijay Khattar is the

EXICUTIVE DIRECTOR of the Sangam Bajaj, and his son Mr. Varun Khattar is the

branch manager. Sangam Bajaj have three outlets in District kangra and And one in

District mandi of himachal Pradesh.

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ORGANIZATIONAL STRUCTURE

Organization structure is the pattern of relationship among various components or

parts of the organization.

Since various persons hold the position, the organization structure is the relationship

among people of organization. Organization of Sangam Auto Sales is simple to

understand and can be studied looking at the chart shown below.

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EXECUTIVE DIRECTOR(VIJAY KHATTAR)

BRANCH MANAGER

(VARUN KHATTAR)

ADMIN HEAD

(D.M.PARMAR)-

SALES MGR

(ASEEM)

WORK SHOP MGR.

(ANURAG THAKUR)

SPM

(H.PANDIA)

PLANT LAYOUT

OIL SHOP ENGINE SHOP PAINT SHOP

SECURITY

PARK IN

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DELIVERY CELL

INVENTORY

W A I T I N

G

SHOWROOM AND OFFICE

G

PROCEDURE IN SERVICE CENTRE

Show room has its separate service center, Here at “SANGAM BAJAJ”

they also have a latest service center with all semi-automatic instruments.

Company maintain a unique and regular checking of each and every bike to increase a

satisfaction level of the customers.

Sangam Bajaj strictly watch and try to lesser the time of a customer while they give bike in to

service. Mostly Customer in “Sangam Bajaj” when come to give his bikes in service, the

service procedure of Automotive is very less and smallest so that customer will free within a 5

Minutes in Automotive.

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SERVICE PRODURE

WASHING THE BIKE

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MECHANICS/ENGINEER(BIKE WISE)

SPARE PART REQUICISION(IF REQUIRED)

SPARE PART DEPT.

FITTING OF SPARPARTS &COMPLETE FORTHERPROCESS

TESTING ONROAD

DELIVERE TO THE CUSTOMER

DIFFERENT EQUIPMENTS USED IN WORKSHOP

MOTORCYCLE SERVICE LIFT :-

This consists of a lift table, which has a facility of a sliding inbuilt support for parking the bike

on the ramps, a center stand & a vice is also provided to hold the center stand & front wheel of

the bike safely. This is supported by a power for energizing the cylinder in the lift table for up &

down movement suitably. The power pack has also got a very important feature of manual

operations which helps the operation of ramp manually at the time power failure.

AUTOMATIC CHAIN CLEANER MACHINE

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Automatic chain cleaner machine has gained wide appreciation for its International quality

standards. Provided with twin chamber type, one for cleaning and the other for greasing

enables two chains to be cleaned at the same time. Occupying less floor area (61cm x

38cm) the device adds life to the motorcycle chain during service. The greasing chamber

made of stainless steel sheet enables thermostatically controlled grease heating and

melting.

Features:

Total cleaning of chain in motorized movement with high pressure jets of kerosene or diesel (your choice) aided by set of built - in brushes to remove all dirt and grease efficiently

Twin chamber type - one for cleaning and the other for greasing - enables two chains to be worked at a time

Greasing chamber is of stainless steel sheet. Thermostatically controlled grease heating and melting

Dripping area leaves a smooth coat on the chain.

DIGITAL TYRE PRESSURE KITS

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Digital tyre pressure kits such as digital pressure gauge and analog pressure gauge are Rugged in

design,digital pressure gauge has microprocessor based automatic operation, for filling speed and

cut off at preset pressure.East to calibrate, the array of analog pressure gauge has marking in both

psi and kg/cm2.

Digital pressure gauge

Features:

Preset (desired) and Actual pressure indication in glowing digital 12 display at panel front.

Increase / decrease and actual pressure indication in glowing digital display at panel front.

Flat tyre key

Weather-proof

Analog pressure gauge

Features:

Markings both in psi and kg/cm2

Least count 1 psi and 1 kg/cm2

Big 6 to 18 inch dial (15 - 45cm)

Easy to calibrate

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ENGINE WORKSTATION

Designed with the assistance of our engineering excellence this workstation enables optimum

engine servicing at 3D X 360°, always at mechanic's eye level. Provided with overhead lighting

arrangement, the workstation has lockable cabinet for the safe-keeping of engine in service.

Features:

Choice of exploded view or special tool board at eye level

Pneumatic gun mounting bracket

Double airlines (lubricated and dry)

Lockable cabinet for safekeeping of engine in service

Drawer space for hand tools, drawing , service manuals

Overhead lighting arrangement

Custom - built jigs for every brand and model

Engine Jig

Nylon fixture for non - ferrous and polished parts

Valve spring compression holder

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GENERAL TWO-WHEEELER REPAIR EQUIPMENTS

POWER PACKS

Applications: wherever under pressure hydraulic fluid is necessary, such as molding machines,

machine tool clamps, lifting devices, furnace doors, hydraulic jacks etc.

Functions:

Depends on the drawings of party or as per customers require and need Pressure up to 315 kg /cm2

Power up to 100Kw.

WHEEL BALANCING MACHINE

The shaft of the balancing machine is fixed so that the wheel rotates freely on its own bearings.

This simulates exactly the assembly of the wheel on the motorbike and eliminates all the assembly

inaccuracies which are inevitable with traditional balancing machines for car wheels where the

adapter is put in rotation with the wheel.It permits dynamic balancing of motorbike wheels (that

is correction of unbalance on two planes), a very requested feature as a result of the diffusion of

wider tyres.The automatic measure of wheel distance and diameter makes quicker and more

accurate the detection of the data also with very wide alloy rims.

MIG WELDING MACHINE

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MIG welding machines, which are thyristor and inverter based with switch control. These

welding machines have separate as well as in-built wire feeder.MIG welding machines are

controlled by microprocessor where programs are controlled by single knob control ensuring

appropriate voltage for selected welding current. Separate control mode for current and voltage is

also available. MIG welding machines have easy-to-read and precise current/voltage scale.

Features:

Applicable for sheet metal applications as well as high-end fabrication

Excellent arc characteristics

Auto choke for the fine tuning of the welding arc

Excellent portability & mobility

Voltage preset switch

Standard ammeter and voltmeter

Modular and compact construction

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TECHNOLOGY USED IN BAJAJ AUTO

4 – VALVE TECHNOLOGY

Pulsar 135 LS is incorporated with World’s First DTSi 4 valve Engine –designed for better

performance than an equivalent capacity 2 Valve Engine.This engine has 2 intake & 2 Exhaust

valves compare to 1 intake & 1 Exhaust Valve of a 2 valve engine. These valves are smaller &

light weight compared to that of 2 valve engine. 4 Valves (2 Intake & 2 Exhaust valves) are

introduced to improve breathing means - intake & Exhaust process of engine.

A typical 2 valve engine has just 1/3 combustion chamber head area covered by the valves, but a

4 valve head increases that to more than 50% area. Because of this flow area of intake & Exhaust

port / passages leading to valves also get increased. This facilitates induction of more quantity of

charge (air-fuel mixture) and also evacuation of all burnt gases inside the combustion chamber

ensure faster, cleaner & more efficient combustion. The result is increased engine performance-

power, throttle response, pick up of all engine speeds.

Moreover the 4 valve engine can be revved up to much higher rpm easily, there by allowing the

rider to enjoy light sports bike performance.

DTS-I - DIGITAL TWIN SPARK IGNITION

Technology is a revolution in the modern motorcycling era in the country today and we are the

27

first to offer it to consumers. This technology offers phenomenal performance augmentation and

was introduced for the first time on the highly successful Pulsar twins. It is also being patented by

Bajaj Auto Ltd.

For faster and better combustion. Currently one spark plug at one end of the combustion chamber

is the conventional practice. The flame front created by the spark takes some time to reach the

farthest portion of the combustion chamber. This leads to slower burning of the air-fuel mixture

and creates limitations in optimizing the combustion chamber characteristics. Two spark plugs at

either ends of the combustion chamber help in faster and better combustion.

IGNITION WITH A DIGITAL C.D.I.

A Digital CDI with an 8 bit microprocessor chip handles the spark delivery. The programmed

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chip’s memory contains an Optimum ignition timing for any given engine rpm, thereby Obtaining

the best performance characteristics from the combustion chamber. Working together with the

Trics III system, it delivers optimum ignition timing for varying load conditions.

EXHAUSTEC

ExhausTEC is a device incorporated in exhaust system of ‘Pulsar DTS-i’ engine. ‘TEC’ stands for

‘Torque Expansion Chamber’. This world-first technology developed by Bajaj Auto improves the

‘scavenging’ process. The exhaust system has this revolutionary feature Incorporated, which

drastically improves engine torque at low revs without compromising anything at mid or high

engine revs. It has been extensively optimized to get the Maximum possible performance out of

the engine. The silencer also has a characteristic tonal quality to it. It gives out a pleasant sounding

low frequency ‘boom’ sound. While meeting the mandatory current noise norms, it gives the bike

an identity, which is different from any other bike, so as to make it very unique.

*Bajaj has been awarded patent for its innovation “ExhausTEC”, Patent

Number 231498

RIDE CONTROL SWITCH

This feature has been specifically introduced to enable the rider to have a non Distracting/non d

intrusive indication of an impending change between Economy zone cruising and Power zone

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cruising. The entire concept is based on Feel. Among the most sensitive parts for a Scooter rider,

his/her hands are the most sensitive.

The changes in effort required to open the throttle can also be felt very sensitively.

This forms the basis for the Ride Control Switch

Advantages of the Ride Control Switch

Once enabled, the throttle feel/force felt at the throttle will very immediately Inform the Rider that he is about to transgress the Fuel Economy zone. He does not have to look at the speedo console for speeds/rpms to be maintained, lights to glow or audible alarms to be heard.

There is absolutely no safety issue, as there are no visual or audible distractions like the other systems. The rider can concentrate on the road/traffic conditions ahead and modulate the throttle, instead of his attention getting diverted.

Being very simple and robust in design, there is virtually no chances of failure and it requires almost no maintenance.

BIBLOGRAPHY

http://www.bajajauto.com/

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7th ANNUAL REPORT “BAJAJ AUTO LTD.”- 2013-14

WIKIPEDIA

http://www.zigwheels.com/

http://overdrive.in/

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