daimler presentataion

Daimler India Commercial Vehicles Pvt. Ltd.

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INDUSTRIAL TRAINING REPORT (Duration -45 Days at PTI)


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Introduction

Focus area in assembly

Quality Feedback loops & Quality Gates

Quality inspection gates

Damage code purpose

Damage code architecture and comparison

Project description and methodology

Acknowledgement

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Training period : 5th Dec’13 To 17th Jan’14Trainer : Mr. Muralikrishna.P / Mr. Bhaskar.PProject : Damage codes

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Introduction

Well over a century ago, when horse-drawn modes of transport were the only known ways of mobility in the world, Gottlieb Daimler and Carl Benz came up with a revolutionary idea: motorized movement.

By combining an engine with a cab-over-chassis structure, the first truck was invented.

Our rich history of over 125 years of innovation is driven by excellence that continues into the 21st century. Numerous patents in automotive performance, safety and eco-friendly innovations, some of which are milestones in the history of the truck, are eloquent testimonies to our commitment to redefining mobility for the world.

As the inventor of the truck, Daimler assumes responsibility for their future. Our Road to Emission-free Driving stands for our commitment to securing sustainable mobility.

Our aim is to markedly reduce fuel consumption and emissions already today and to eliminate them entirely in the long term. To this end, we are developing a broad spectrum of state-of-the-art drive technologies that meet the specific requirements placed on today’s and tomorrow’s mobility in all modes of road transportation.

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Introduction

In DICV PTI shop , engine and transmission are assembled such as 170kw & 205kw HDT Engine

and G131, G85 & MO36 Transmission are assembled .

EURO 3 OM-906 LA G131 G85 MO36

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CRANKSHAFTCAM SHAFT

CYLINDER HEAD

CONNECTING ROD

CRANKCASE

ENGINE MAIN PARTS

Introduction


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INPUT SHAFT

COUNTER SHAFTMAIN SHAFT

TRANSMISSION MAIN PARTS

-1st gear -2nd gear -3rd gear -4th gear -5th gear -6th gear -Reverse gear -Gear hubs -Tapper roller

Bearing-Oil seal-Oil pipe-Circlip

-Tap roller gear-1st gear bracing-2nd gear bracing-3rd gear bracing-4th gear bracing-5th gear bracing-6th gear bracing-Twin gear

Introduction


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• Washing and cleaning cabinet•

•Torque analyser

PERFORMANCE TEST•SFC , Power and smoke Test

• Casting and forging material confirmation

• Tear down audit

•Geometrical parameters and indexing in gears

Focus area in engine and

transmission assembly

PART MATERIAL QUALITY PART CLEANLINESS

TORQUE INTEGRITY PRODUCT AUDIT

PART DIMENSIONAL QUALITY

Focus area in assembly


DICV Q-CONCEPT

Q means QUALITY

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The Q-Concept describes the functions ofthe QM and its relations to Production,Logistics, and Supplier Management. It willbe signed of by all Vice Presidents of DICV.Main contents are:Q-Methods, Standards, Product liabilityrequest, Q-Philosophy for Feedback loops,tasks and responsibilities etc.Supporting process descriptions are linkedto the operative documents e.g. checklist.T

Q-C

once

pt

Engine and transmission QSETTING UP QUALITY PROCESS THROUGH •Manufacturing PPAP•PFMEA•Control plan•Process study capability•Operator self certification•100% quality gates inspection•Section product audit•Process auditThe realization of this Q-concept is

monitored by QM during the project phase with a tool called “Q-Plan” and is the basis of Q-Release for process and product


Quality feedback loops 0-5

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Engine and transmission assembly quality gates


Quality inspection gates in engine assembly

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Quality inspection gates in transmission assembly

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Damage Code purpose

During the transportation chain when automobiles change possession they must be inspected immediately with any

damage or missing items being noted. The purpose of this manual is to provide a standard up-to date set of codes for

recording vehicle exceptions to all personnel responsible for handling vehicles throughout the transportation chain.

It is important the damage codes be accurately detailed. The codes are recorded manually on delivery receipts or in

portable data terminals for transfer into the manufacturers claims systems. Individual manufacturers may issue

manuals with photographs depicting several of the damage areas and types. Damage are of many types like

Broken , Broken off , Sheared off , Disengaged but continued to run , Engaged and overrun , Cracked , Torn, Torn

off, Burst , Sewing/thread fault etc.

Damage code helps in easy understanding of the damage part in the vehicle . If the customer complained about

any part then the customer care service centers will analyze that part and note down the damage in the vehicle in

the form of damage code and can send that vehicle to the company for damage reference . Every part has some

damage code from washer to crankcase.

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Damage code architecture

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Damage code concept comparison

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Project description

The purpose of this project is to provide a standard up-to date set of Damage codes for recording the defects in

the online concern tracking portal and MES usage .I have compared the Build sheet parts and the damage codes

available on the online portal and compiled the coded which were not available with the classification.

Current status - Total damage codes available in online portal for engine : 2041

- New damage codes compiled/developed : 645

- Gap between available & required : 645

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Damage code developed (SAMPLE)

Failure Type area

Digit 1

CONSTRUCTION GROUP 'DAMAGE

PARTDigit 2-3

LOCATION 'DAMAGE PART

Digit 4-6 DAMAGEPARTDESC

DAMAGE TYPE

Digit 7-8

REPAIR TYPEDigit 9

DAMAGE TYPE

Digit 10-11 DAMAGE TYPE DESCRIPTION

ASSEMBLED DAMAGE CODE

UPTO 11TH DIGIT

Q 03 201 Connecting rod 28 X 00 offset Q0320128X00Q 03 201 Connecting rod IA X 05 Material fault Q03201IAX05Q 03 201 Connecting rod 99 X 10 Damaged Q0320199X10Q 03 201 Connecting rod 42 X 00 Poor fit Q0320142X00Q 03 201 Connecting rod C8 X 00 Incorrect part Q03201C8X00

Q 03 301 Piston, Engine 28 X 00 offset Q0330128X00Q 03 301 Piston, Engine IA X 05 Material fault Q03301IAX05Q 03 301 Piston, Engine 99 X 10 Damaged Q0330199X10Q 03 301 Piston, Engine 42 X 00 Poor fit Q0330142X00Q 03 301 Piston, Engine C8 X 00 Incorrect part Q03301C8X00


Methodology followed

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Current data of online damage code available was reviewed I reviewed the main damage codes list available at DICV and compared it with all the parts used in assembly

line and listed all those parts which were not having damage codes.

Actual data collected After listed all the parts which were not having their damage codes , their construction group , location ,

damage type were collected from the DICV damage part codes list.

Gap analyzed Total 645 damage codes were not available in the DICV damage codes list .

Compiling the new damage codes

After collecting all the data ( construction group , location, damage type) then it were compiled in

according to damage code architecture .

Uploading the new file with developed existing damage code file.

Result

Total damage codes including new damage codes : 2686


Acknowledgement

I am highly grateful to Daimler India Commercial Vehicles Pvt. Ltd . for allowing me to do this project work. It is truly a matter of great pleasure me to express my sincere thanks and gratitude to Daimler India Commercial Vehicles Pvt. Ltd . for his supervision and encouragement throughout this project.

I am highly obliged to “ Bhaskar.P , Muralikrishna P, Sampath Kumar K ,Baraneedharan S , Jayakumar V , Arvind S ” for their guidance kind concern and encouragement throughout this project.

I am immensely indebted to “ Daimler India Commercial Vehicles Pvt. Ltd .” for the invaluable help that he rendered at every step of this project. It is a wonderful experience to be a part of “Daimler India Commercial Vehicles Pvt. Ltd . ” Where I work under brilliant minds. I owe my deep regards for the supporting and kind staff authorities who helped me in my lean patches during these 1.5 months.

The knowledge I gained throughout our studies have the practical implementation during this period. I am grateful to all the staff of “Daimler India Commercial Vehicles Pvt. Ltd . ”

YOURS OBEDIENTLY ANUBHAV GOEL

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