SHOWER LEAKAGE REDUCTION/ELIMINATION

REPORT

ON

SHOWER LEAKAGE REDUCTION

Submitted To- Submitted By- Yogesh Kumar Sardhana NAME-Hemant Kumar PantAssistance Manager Branch-MechanicalProduction College Name- UIT,Dehradun

HEMANT KUMAR PANT – UIT, DEHRADUN Page 1

SHOWER LEAKAGE REDUCTION/ELIMINATION

ACKNOWLEDGEMENT

This training would not have been useful to me without the utmost support and

guidance from many people in the TCF-1D Department of TATA MOTORS

LIMITED – SHOWER LEAKAGE REDUCTION PROJECT.

Firstly, I would like to thank Mr. A. N. Banerjee (Factory Head, TCF-1D shop)

who helped me throughout the training by sharing his knowledge and the lots of

experience he possesses, weathered over the years in the automotive industry, it was

indeed very precious working under you, Thank you Sir!

Secondly, I would like to thank Mr. Pramod Popale (Manager, TCF-1D shop) for

guiding me on the projects assigned to me, by helping me memorize all the minute

things that we tend to forget during the course of our work. Also, I appreciate the

guidance provided to me by Mr. Yogesh Kumar Sardhana (Assistant Manager,

Production, TCF-1D shop) who with his inspiring & innovative ideas, in a way, told

me how to stretch myself in order to increase the capacity to do work.

I am extremely grateful to Mr. Kamal Kishore Pandey who taught me about those

tiny, but absolutely important things in the TCF-1D Department which have given

finesse to my training.

I am grateful to Mr. Brijlal Arora (HR training coordinators) for letting me go

through the training, & making it altogether a diverse experience.

Last but not the least , I would like to thank the entire family of TATA MOTORS

LTD-Pantnagar Plant, who helped me in every sphere they could, and didn’t even let

me gauge how long or short 1 months can be. Thank you all!

HEMANT KUMAR PANT – UIT, DEHRADUN Page 2

SHOWER LEAKAGE REDUCTION/ELIMINATION

INDEX

S. No. Page No.Acknowledgement 2

1. World and Automobile 4

2. India and Automobile 5

3. Tata Group of Companies 7

4. Tata Motors Ltd. 9

4.1 Area of Business 10 4.2 Joint ventures, Subsidiaries and Associates 10 4.3 Research and Development 11 4.4 Location 12 4.5 Tata motors Hierarchy 13 4.6 Tata Motors Pantnagar 155. Shower Leakage Elimination 16

5.1 Wind shield leakage 20 5.2 Main harness leakage 22 5.3 LH/RH leakage 23 5.4 Head lamp joint Leakage 24 5.5 Sticker missed 256 Proposed Solution 26

6.1 Possible further aspect in Project 267 In Tata Motors 28

7.1 BIW 28 7.2 Paint shop 29 7.3 TCF shop 29 7.4 PDI shop 30 7.5 Powertrain shop 318 By the End of Training Period 31

9 Learning at Tata Motors 31

9.1 Kaizen 32 9.2 Just In Time Manufacturing 33 9.3 Just In Sequence 33 9.4 Just In Sequence is Just In time 33 9.5 Elimination of Waste 34 9.6 Bill of Material 35 9.7 Work Experience 36

HEMANT KUMAR PANT – UIT, DEHRADUN Page 3

SHOWER LEAKAGE REDUCTION/ELIMINATION

10 Bibliography 37

1) World & Automobile

During the 1670s, Father Ferdinand Verbiest (Flemish Jesuit missionary, China) designed the first ever self-propelled vehicle – many claim this as the world's first automobile but lack of evidence that it was actually built, in spite of its small size it could only operate for 12-15 minutes before running out of steam, and its

tremendous weight and poor balance made it very difficult to steer

The first car was built by Joseph Cugnot in 1769. It was powered by a steam engine and was very slow.

Notable Personalities of Past :

1 cylinder IC engine J.J. Étienne Lenoir

4 cylinder IC engine N. August Otto

1st 4-wheel automobile & v-slanted engine

Gottlieb Daimler (1886)

Automobile powered by IC engine Karl BenzOver 15 million Model Ts by 1927 Henry FordHybrid cars Since the 1900’s.

1st hybrid commercial truck in 1910

HEMANT KUMAR PANT – UIT, DEHRADUN Page 4

SHOWER LEAKAGE REDUCTION/ELIMINATION

2) India & Automobile

Automobile:o Public Transporto Personal Transporto War-fareo Law and ordero Tradeo Emergency Serviceso Public Hygiene o Sea Transporto Aero planes

Indian Automobile has 12 % share in Indian economy

AUTOMOBILE COMPANIES making the Dream Machines in India:

HEMANT KUMAR PANT – UIT, DEHRADUN Page 5

SHOWER LEAKAGE REDUCTION/ELIMINATION

GRAPH 2 GRAPH 3

HEMANT KUMAR PANT – UIT, DEHRADUN Page 6

SHOWER LEAKAGE REDUCTION/ELIMINATION

3) TATA GROUP OF COMPANIES

Tata Group, an Indian multinational conglomerate company, headquartered in the Bombay House in Mumbai, India, in terms of market capitalization and revenues, it is the largest private corporate group in India.

The Tata Group comprises 114 companies and subsidiaries in eight business sectors, 27 of which are publicly listed. 65.8% of the ownership of Tata Group is held in charitable trusts. The group takes the name of its founder, Jamsedji Tata, a member of whose family has almost invariably been the chairman of the group. The current chairman of the Tata group is Ratan Tata.

The Tata Group has operations in more than 80 countries across six continents and its companies export products and services to 80 nations.

TATA Group's 114 companies are held by its main Company Tata Sons. The 2009 annual survey included 600 global companies by the Reputation Institute ranked Tata Group as the 11th most reputable company in the world.

TATA GROUP of COMPANIES

Information technologies• CMC • Computational Research Labs • Nelito Systems • Tata Advanced Systems • Tata Business Support

Services • T ata Consultancy Services

• Tata Elxsi • Tata Interactive Systems • Tata Technologies • Comunication• Tata Communication• Tata Teleservices• Tata sky• Tata Net

HEMANT KUMAR PANT – UIT, DEHRADUN Page 7

Commercial VehiclesPassenger Vehicles

SHOWER LEAKAGE REDUCTION/ELIMINATION

• Nelco

• Automotive• Hispano Carrocera • Jaguar Land Rover • Tata AutoComp Systems • Tata Cummins • Tata Daewoo Commercial

Vehicle Company • Tata Motors • Tata Motors European

Technical Centre • Telco Construction

Equipments • Engineering• TAL Manufacturing Solutions• Tata Consulting Engineers• Tata Projects

• TRF• Voltas

• Metals• Hooghly Met Coke & Power• JAMIPOL • Jamshedpur Utilities and

Services • Mjunction services • NatSteel Holdings • Tata BlueScope Steel • Tata Metaliks

• Tata Sponge Iron • Tata Steel • Tata Steel KZN • Tata Steel Processing and

Distribution • Tayo Rolls • The Tinplate Company of India • TM International Logistics

• TRL Krosaki Refractories

• Hotels Property Developement• Indian hotel• Root Corp.• Taj Air• Tata

Housing Devlpmnt Co.• Tata Realty

&

infrastructure• Financial Services• Tata AIG General

Insurance • Tata AIG Life

Insurance • Tata Asset

Management

• T ala Capital • T ala Financial

Services • Tata Investment

Corporation

• Energy• North Delhi Power • Powerliks Transmission • Tata BP Solar • Tata Petrodyne • Tata Power & Tata Power Trading

• Consumer Product• Casa Decor • Infiniti Retail • Landmark • Tata Ceramics • Tata Global Beverages • Titan Industries • Trent • Westland

• Chemicals• Advinus Therapeutics • Rallis India • Tata Chemicals • Tata Chemicals Europe

HEMANT KUMAR PANT – UIT, DEHRADUN Page 8

SHOWER LEAKAGE REDUCTION/ELIMINATION

• Tata Chemicals Magadi • Tata Chemicals North America • Tata Pigments

• Other services• Drive India Enterprise Solution • Tata Industrial Services • Tata Quality Management Services • Tata Services • Tata Strategic Management

4) TATA MOTORS

Tata Motors Limited is a multinational automotive corporation. A part of the Tata Group, it was formerly known as TELCO (TATA Engineering and Locomotive Company).

Established in 1945 by J.R.D.Tata, Tata Motors' presence indeed cuts across the length and breadth of India. Tata Motors is India's largest automobile company, with consolidated revenues of Rs. 1, 23,133 crores ($ 27 billion) in 2010-11.

Through subsidiaries and associate companies, Tata Motors has operations in the UK, South Korea, Thailand and Spain. Among them is Jaguar Land Rover, the business comprising the two iconic British brands. It also distributes Fiat cars in India, and has an industrial joint venture with Fiat in India. With over 5.9 million Tata vehicles plying in India, Tata Motors is the country's market leader in commercial vehicles and among the top three in passenger vehicles. It is also the world's 4th largest truck manufacturer and 3rd largest bus manufacturer. Tata cars, buses and trucks are being marketed in several countries in Europe, Africa, the Middle East, South Asia, South East Asia and South America

HEMANT KUMAR PANT – UIT, DEHRADUN Page 9

4a) Areas of business: 

Tata Motors makes passenger cars, multi-utility vehicles and light, medium and heavy commercial vehicles.

Passenger cars: compact Tata Indica in 1998, the sedan Indigo in 2002 and the station wagon Indigo Marina in 2004. Tata Motors also distributes Fiat’s cars in India.

Utility vehicles: The Tata Sumo was launched in 1994 and the Tata Safari in 1998.

Commercial vehicles: The commercial vehicle range extends from the light two-tonne truck to heavy dumpers and multi-axled vehicles in the above 40-tonne segment.

Passenger buses: The Company also manufactures and sells passenger buses, 12-seaters to 60-seaters, in the light, medium and heavy segments.

4b) JOINT VENTURES, SUBSIDIARIES, ASSOCIATES

Tata Motors has joint ventures with MARCOPOLO, the Brazil-based maker of bus and coach bodies, and with FIAT-AUTO (to build a commercial vehicle at Fiat's facilities in Córdoba, Argentina).Other associates include:

Tata Daewoo Commercial Vehicle Co.: heavy commercial vehicles Tata Motors European Technical Centre: design engineering and

development of products. Telco Construction Equipment Company: construction equipment and

allied services. Tata Technologies: design services, product lifecycle management and

product-centric IT services. Tata Motors (Thailand): Tata Motors (70%) and Thonburi Automotive

Assembly Plant Co (30%).

Tata Cummins: manufactures high horsepower engines. HV Transmissions and HV Axles: make gearboxes and axles for

commercial vehicles. TAL Manufacturing Solutions: provides factory automation solutions

and provides machine tools. Hispano Carrocera: Spanish bus manufacturing company. Concorde Motors: retailing Tata Motors’ range of passenger vehicles Tata Motors Finance: the business of financing customers and channel

partners of Tata Motors

4c) Research & Development

The company’s Engineering Research Centre (ERC), in Pune (which has 1400

scientists and engineers), Tata Daewoo Commercial Vehicle Company Hispano Carrocera at Gunsan in Korea and Zaragoza in Spain.

These three facilities together enable the company to share and access knowledge and technology for designing and developing world-class products which are environment-friendly technologies in emissions and alternative fuels.

It was Tata Motors, which developed the first indigenously developed Light Commercial Vehicle, India’s first Sports Utility Vehicle Tata Indica, India’s first fully indigenous passenger car (India’s largest

selling car) Tata Ace, India’s first mini-truck.

The ERC in Pune, among whose facilities are India’s only certified crash-test facility and hemi-anechoic chamber for testing of noise and vibration has received several awards from the Government of India.

Some of the more prominent amongst them are: National Award for Research and Development Efforts in Industry in

the Mechanical Engineering Industries sector in 1999,

National Award for Successful Commercialization of Indigenous Technology by an Industrial Concern in 2000

CSIR Diamond Jubilee Technology Award in 2004.

Adopting the principle of Kaizen or continuous learning, versatile yet simple 5S approach to process improvement which helps to optimize various operations of the company and conserve precious resources is the way of life at Tata Motors.

The company introduced emission-friendly engines in its products in India even before such norms were made statutory. It ensures that its products are environmentally sound by reducing hazardous materials in vehicle components, developing extended life lubricants, fluids and using ozone-friendly refrigerants.

4d) Location

Tata Motors' plants are located at o Jamshedpur (eastern India),

o Pune and Sanand (western India),

o Lucknow and Pantnagar (northern India).

o Tata Motors and Fiat have a common manufacturing facility at

Ranjangaon, near Pune.being marketed in several countries

Europe, Africa, Middle East,South East Asia, South Asia and Australia

assembly operationsMalaysia, Kenya, Bangladesh, Ukraine, Russia, Spain and Senegal..

4e) TATA Motors Hierarchy

Board of Directors

Mr. Ratan N. Tata (Chairman)

Mr. Ravi Kant Mr. Nusli N. Wadia Mr. S. M. Palia Dr. R. A. Mashelkar Mr. Nasser Munjee

Mr. Subodh Bhargava Mr. V. K. Jairath Mr. Ranendra Sen Dr. Ralf Speth Mr. Carl-Peter Forster Mr. P. M. Telang

Senior Management

Mr. Carl-Peter Forster Managing Director & Group CEO

Mr. P. M. Telang Managing Director - India OperationsMr. C. Ramakrishnan Chief Financial OfficerMr. Ravi Pisharody President (CVBU)

Dr. Tim Leverton Head (Advanced and Product Engineering)Mr. S. B. Borwankar Senior Vice President (Mfg Operations-CVBU)

Mr. Prabir Jha Senior Vice President (Human Resources)Mr. R. Ramakrishnan Vice - President (Commercial - PCBU)

Mr. Girish Wagh Head (Passenger Car Operations - PCBU)Mr. R. T. Wasan Head (International Business - CVBU)

Mr. Johnny Oommen Head (International Business - PCBU)Mr. H. K. Sethna Company Secretary

FIG. 2: Fuel type- Diesel, Gasoline and CNG

4f) TATA MOTORS (Small Car Division) Pantnagar This plant came into existence in 2007. TATA MOTORS LTD. Pant Nagar has four shops for manufacturing of vehicles.

DESCRIPTION OF SHOPS

ASSEMBLY SHOP –

Also known as TCF Shop(TRIM CHASSIS FITTING). In this shop all the assembly works like Engine,Suspension, Tyres, Lights, Dashboard etc. fitting is carried out.

WELD SHOP –

Also known as BIW Shop(BODY IN WHITE) .Here the different parts are welded together and the whole structure of the car is built.

POWER TRAIN SHOP –

o This shop is divided into Power Train and Engine shop. Here various operations related to Engine, Gear Trains etc. are performed.

PAINT SHOP –

The TAIKISHA paint shop is the beauty parlors of the car plant. This shop paints the car in various shades. It takes 18 steps spread over less than 10 hours to accomplish the task.

CKD(COMPLETE KNOCK DOWN)BIW-1A

GEAR ASSEMBLY

BIW-1CBIW-1B

TATA MOTORSS UMMER INTERNSHIP P ROJECT (SIP)

SHOWER LEAKAGE ELIMINATION IN TATA ACE ZIP & TATA MAGIC IRIS

5)Shower test

The shower test is used for checking the leakage of water into the vehicle. It is also known as water testing.

The nozzles spray the water on both right hand and left hand side of the vehicle at a pressure of 1.3 bar ( greater than the atmospheric pressure i.e. 1.01325bar).

The pressure in the nozzle is controlled by the flow regulating arrangement.

The following tests are conducted on the shower.

Windshield leak

Head lamp moist/ bezzle leak

Air vent leak

Canopy leak

Door pad leak

Weather strip leak

Floor leak

Tail lamp leak

Corner trims

Roof leak

Door seal leak

Window glass run leak

HMSL leak

STG gear grommet leak

Fire wall grommet leak

Repeater lamp leak

Shower defect monitoring sheet

Defects 4JuneA B

5JuneA B

6juneA B

7juneA B

8juneA B

9juneA B

total

1.wind shield leakage 4 3 3 6 5 12 3 2 5 5 4 1 53

2.main harness leakage 8 5 7 6 4 4 9 7 8 4 6 7 75

3.LH/RH door leakage 3 7 11 13 9 15 7 10 9 14 6 7 111

4.dome nut leakage 6 5 5 0 1 2 3 1 2 5 5 13 48

5.cabin joint leakage 0 4 0 7 0 3 0 5 0 9 0 6 34

6.head lamp joint leakage 6 3 4 6 3 3 3 3 5 6 5 9 56

7.head lamp grommet leakage

4 3 1 6 0 1 3 2 4 3 2 4 33

8.rear glass leakage 2 0 2 1 2 3 0 6 4 9 6 4 39

9.sticker missed 2 0 2 2 2 2 5 5 7 8 6 12 5310.LH/RH fender leakage 4 6 3 7 4 5 2 1 4 2 1 2 41

Total vehicle tested 57 44 44 50 50 61 51 41 51 39 39 48Ok vehicle after test FSO-

15FSO-17 FSO-30 FSO-32 FSO-18 FSO-16

Major shower leakages

Wind shield leakage-53

Main harness leakage-75

LH/RH leakage-111

Head lamp joint leakage-56

Sticker missed-53

5.1)Wind shield leakage

Glass- it has two layers which are fabricated by adhesive such as poly vinyl beautyl (PVB).the thickness of glass is generally taken about 4.56mm and the adhesive is 0.76mm.

The glass can be used in wind shield leakage is of two types.

a) laminatedb) tempered

laminated- the laminated glass is cheaper and having cost about 200rs. It has the property not to create sharp edges when it breaks so that it will not harm the driver during accident.

Tempered- the tempered glass is manufactured by heating it above re- crystalization Temperature and hold it for some time and cooled in some cooling medium. It has the property not to scatter when it breaks. It is costlier than laminated glass about 5times i.e. 1000Rs.

Robot timing- The sealant, used to make the surface nonporous is provided by the robot from the sealant drums. The process is repeated in about 2min.

Problem concerning with robot-

a) priming- when the air stuck between the sealant pipes. It does not allow the sealant to flow by creating an air pressure head.

b) Voltage fluctuation- if the fluctuation of light takes place in very short period of time, the robot does not sense it and the sealant flow rate vary that creates problem like porosity, leakage etc.

S.No.

Wind shield leakage

Causes Remedies

1. Fender leakage B.I.W , human, welding error.

Automation and precise machinery

2. Profile leakage Human, robotic and manufacturing problem.

Advanced manufacturing processes, training of workers

5.2)main harness leakage-

It is the leakage due to improper tightening of grommet.

S. No.

Harness leakage Causes Treatment

1. Grommet leakage Improper tightening Inspection

2. Fitting leakage Improper sealing or fittings

Testing and inspection

The leakage is due to improper size of grommet and imperfection in fitting. This can be eliminated by the providing a washer there.

5.3)LH/RH Door leakage

It is the leakage in the right hand and left hand door of the vehicle due to some misalignment and improper fitting of glasses.

This is the major leakage in the shower test, so it must be eliminated by overcome the above problems.

S. No.

Door leakage

Causes Remedies

1. Door pad leakage

Misalignment of fittings. Testing and inspection.

2. Fitting leakage

Improper fittings of doors and rubber pads.

Hammering the door.

In door pad, membrane is used.

5.4)Head lamp joint leakage-

It is the leakage in head lamp portion of the vehicle due to improper fittings and some BIW problem.

The bezel gap must be within certain limit of range so that proper fitting and no leakage can be achieved.

S. No.

Head lamp leakage

Causes Remedies

1. Bezel gap leakage

manufacturing inaccuracy(bezel gap must be controlled)

Precise machinery

2. Fitting leakage

Due to improper fitting ,human error

Testing and inspection

5.5)sticker missed-

sticker is used to prevent leakage due to some unwanted holes.

It has the property to sustain the high pressure at high speed (80km/hr).

Precaution-

a) sticker must be placed effectively.

b) It must have high plasticity.

6) Proposed Solution:

Here at TCF-1D, I was trained by the Line-supervisor to identify the shower leakage which can be reduced by proper functioning during fitment process.

During fitment due to human error or by some other way in trim section, shower leakage can occour.so proper care need to be to eliminate it.

Hence I observed that:

Testing and inspection should be carried out at every quality gate.

Tightening of nut and bolt should be proper.

By using automation and precise machinery.

The assembly parts should be manufactured by advanced manufacturing processes in vendor company.

The training and motivating policy should be applied to workers.

Kaizen should be applied.

Job rotation policy should be applied.

6.1) Possible further aspects in the project:

“WHAT CAN GO WRONG ANALYSIS”: By doing this one can also find the root cause of the untraceable line problems and take suitable steps towards its elimination and thus TML TCF-1D shop can assure nearly perfect fitment for the car .

CONCLUSIONS

After analyzing the problem, in the trim section (magic iris and tata

ace) the leakage can be eliminated within accepted limit of standards.

So, the leakage is eliminated as well as quality is also improved.

1) The quality of vehicle is obtained within accepted limit of

standards.

2) The leakage will be eliminated.

3) Rating of vehicle will be improved.

4) As the fouling is eliminated, the life will be improved.

5) Due to reduction in leakage , engine work properly and heat

loss will be minimum.

7) In TATA MOTORS:

7a) BIW

This shop plays very important role in framing the body shell of Nano. The press panels are transported from Bhuj and Pune plant.

It has three main assemblies, which includes-UB(under body), ML(Main line or main frame) and MF(metal finish) where different welding processes of

Projection welding Stud welding Spot welding

CO2 welding MIG welding

are done and after that the parts are attached to the main assemblies

9b) PAINT shop:

MANUFACTURING

PRODUCTION SYSTEM

BIW(Body in white)

PAINT

TCF(Trim chassis fitment)

PDI (Pre-Delivery Inspection)

POWERTRAIN

MATERIAL SUPPLY (JIT,KAIZEN,JIS)QUALITY MANAGEMENT

MES(Manufacturing execution system)SAP

PRODUCTION PLANNING

UNDER BODY LINE

SUB ASSEMBLIESSUB ASSEMBLIES

MAIN FRAME

LINE

SUB ASSEMBLIESSUB ASSEMBLIES

METAL FINISH LINE

PAINT SHOP

Here in Paint shop: Colour and appearance Covering of gaps between the weld joints Corrosion resistance Smoothening of sharp corners

SHOP LAYOUT:

7c) TCF (Trim Chassis Fitment) shop:

SHOP LAYOUT:

WELD BODY

ELECTRODEPOSITIONPRETREATMENT

UNDER COAT

INTERMEDIATE COAT (I/C)

TOUCH UP AND

INSPECTION

ED OVEN

SOL SEALING(UB)

SEALANT

UNDERCOAT OVEN

COOLING

DRY SANDINGI/C OVEN

COOLING

DRY SANDING

TOP COAT (T/C)

T/C OVENTCF

ROLL AND BRAKE TEST

CANOPY TEST

REWORK PRE DISPATCH INSPECTION (PDI)

NOK OK

PAD

UNDER BODY LINE(UB1, UB2, UB3, UB4)

To costumer

TRIM LINE(TR1, TR2)

MECHANICAL LINE

WHEEL ALIGNMENT

7c) TCFShop

It is the biggest of all the shops in TML,Pantnagar.

Here the painted chassis delivered from the Paint shop is accessorized from scratch to a finish car ready for dispatch and also tested.

The car delivered by the TCF shop is completely checked with reference to product’s utility quality and manufacturing quality. After several inspections made by line operators for operational conformance and ethical looks the Car is permitted to be dispatch from TCF shop by the assurance of Line supervisors and operators.

The cart dispatched from the TCF shop is delivered, through drive test to the PDI (Pre-Delivery Inspection) shop where final touching to looks is given and the conformance of working of all the accessories is done.

7d) PDI Shop:

PDI is the final quality check, in this the overall checking of the vehicle takes place, in this the fitment is not done, only the outward checking is completed. The final QA OK of the vehicle is done here and after this the vehicle is sent for dispatch.Parts which are checked are mentioned below:

1.       Brake, Brake oil. 21.   Inner handle.

2.       Carpet fitment. 22.   Instrument cluster.

3.       Central lock 23.   Keys.

4.       Coolant filling 24.   RH front door.

5. Dents 25.   Roof lamp.

6.       Door pad 26.   Roof lining.

7.       Drive shaft 27.   Rear bumper.

8.       Engine oil . 28.   Rear door LH, RH.

9.       Engine wiring harness. 29.   Rear door lock LH

10.   Front bumper. 30.   Rear door lock RH.

11.   Front door LH 31.   Rear seat

12.   Front door lock LH 32.   Seat. Belt

13.   Front door lock RH 33.   Spare wheels

14.   Front seat 34.  Scratches on whole body

15.   Fuel. 35.   Steering wheels.

16.   Gear shifter. 36.   Tail lamp.

17.   Head lamp. 37.   Washer jet.

18.   Hood LH. 38.   Window glass.

19.   Hood RH 39.   Wind shield washer.

20.   Horn 40.   Wiper.

7e) POWERTRAIN shop:

It consists of Engine Assembly Shop Transaxle Assembly Shop Engine Dressing Line

In Engine assembly the various components of the Engine are assembled into a single unit and sent for the various tests.

8) By the end of training period:

If this plan can be implemented then there is considerable change in the trim line. With kind consultation and guidance of authority, department managers and Line supervisors I was able to analyze the remedies of shower leakage reduction.

9) Learning’s at Tata Motors

Being one of the most technically sound and having few of the costliest technologies among the Asian automobiles, the culture in the Tata Motors is free, motivating and appreciative.

Here the culture of Equality is fully nurtured all the people operator to senior level are given equal respect through all the possible manner like same Canteen facility, same transportation facility, same uniform among various levels.

The lesson of “Time is Money” & “Creativity is thinking up new things Innovation is doing new things.” is taught from day 1 to all employees. The lesson of “Appreciate your colleague’s work” is well taught from senior level manager to all the man-force in TML, Pantnagar.

Other nice and unique things which I observed in the Plant were:

9.1KAIZEN

The Japanese refer to Kaizen as a simple parts-movement system that depends on cards and boxes/containers to take parts from one work station to another on a production line.

The essence of the Kaizen concept is that a supplier or the warehouse should only deliver components to the production line as and when they are needed, so that there is no storage in the production area.

Within this system, workstations located along production lines only produce/deliver desired components when they receive a card and an empty container, indicating that more parts will be needed in production.

In case of line interruptions, each work-station will only produce enough components to fill the container and then stop. In addition, Kaizen limits the amount of inventory in the process by acting as an authorization to produce more inventories.

ADVANTAGES OF THE KAIZEN PROCESS:

A simple and understandable process Provides quick and precise information Low costs associated with the transfer of information Provides quick response to changes Limit of over-capacity in processes Avoids overproduction Is minimizing waste Control can be maintained Delegates responsibility to line workers

9.2 JUST IN TIME MANUFACTURING

JIT is a philosophy of continuous improvement in which non-value-adding activities (or wastes) are identified and removed for the purposes of:

Reducing Cost Improving Quality Improving Performance

Improving Delivery Adding Flexibility Increase innovativeness

JIT is not about automation. JIT eliminates waste by providing the environment to perfect and simplify the processes.  JIT is a collection of techniques used to improve operations. It can also be a new production system that is used to produce goods or services.

9.3 JUST IN SEQUENCE (JIS):

JIS is an inventory strategy that matches Just In Time and complete fit in sequence with variation of assembly line production. Components and parts arrive at a production line right in time as scheduled before they get assembled. Feedback from the manufacturing line is used to coordinate transportation to and from the process area.. JIS is mainly implemented with automobile manufacturing.JIS is sometimes called In-Line Vehicle Sequencing (ILVS).

9.4 JUST IN SEQUENCE IS JUST IN TIME

Just in Sequence (JIS) is just one specialized strategy to achieve JIT.

The process concept of JIT sees buffers at the production line as waste in capital bound. The aim is to eliminate buffers as much as possible at expense of stability when disturbances arise.

Just in Sequence is one of the most extreme applications of the concept, where components arrive Just In Time and sequenced for consumption.The sequencing allows companies to eliminate supply buffers as soon as the quantity in component part buffers necessary is reduced to a minimum. If not sequencing according to scheduled variety of production, all required components must be stocked in buffers.

For flexible production lines, as here in Tata Motors, a modern automotive assembly line, the variety is an option to produce directly on customer orders. As soon as the

next order arrives at the work centre, the scheduler distributes the supply orders in line with the production sequence of the final production line.

With JIS the buffer quantities are displaced upward in material flow to the components suppliers. It is a misinterpretation of JIS to assume that all buffers will be eliminated. Hence just the cost for buffer inventory becomes re-allocated to the producers of the supplies. Sequencing eliminates buffers in the final assembly line by consolidating all similar components into distributed and sequenced buffers, which partly reside on the paths of transportation to final assembly. This strategy thus reduces the line-side inventory buffer. However, the effect is worse when the sequence does not get not correctly scheduled upwards or when the transportation line gets congested.

9. 5 Elimination of Waste:

JIT usually identifies seven prominent types of waste to be eliminated:

Waste from Overproduction Waste of waiting/idle time

Transportation Waste Inventory Waste

Processing Waste Waste of Motion

Waste from Product Defects

9.6 BILL OF MATERIAL:

A Complete formally structured list of the components that make up a product or subassembly

Here the bill of material is a complete, formally structured list of the components that make up a product or assembly

The list contains the item number of each component, together with the quantity and unit of measure.

The Internship program was quite beneficial for me. It helped me in improving my various technical skills and enhanced my knowledge in new areas.

I gained new knowledge in the various issues involved and mechanisms to tackle them in automobile industries.

By studying and analyzing the contents, I also learnt that how database, products and operations are all mingled up and how they function in coordination with each others.

What are the various issues one need to be aware of while looking for Data Management and Problem tracing for solutions.

Automobile is an ever-green and vast field and through the internship I got some insight into a how it looks like in world market.

I was working on an analysis topic for the first time and I got introduced to this area and various methods employed.

9.7 Work Experience:

My internship was quite satisfactory in terms of work environment.The team, I worked with, was very friendly and helped me a lot in all my problems. New experiences include:

TeamworkIn this project I worked with line operators in order to understand the workin process thus providing enough opportunity for proper teamwork and coordination. This was a good experience for me as the team was very cooperative and understanding.

Communication Working along with the lower level operators and making them understand the process and also getting the valuable information out of them in a way that is comfortable to them not making them feel that they are inferior.

Responsibility and keeping commitmentsThe importance of honouring commitments and time of others was an important thing, which I learnt as a Summer Intern. Especially, while working as a team it is very important to keep these points in mind.

10) BIBLOGRAPHY

1. www.google.co.in 2. www.wikipedia.com3. www.tatamotors.com

4. http://www.acmainfo.com/pdf/Status_Indian_Auto_Industry.pdf (Graphs 2009, 15, 20).

5. http://www.imaginmor.com/automobileindustryindia.html (Pi charts)

6. http://www.tatamotors.com/know-us/milestone.php 7. http://www.tata.com/businesses/sectors/index.aspx?

sectid=aZ72PXPwpaI=#Informationsystemsandcommunications (Tata Group of Companies)

8. http://www.exampleessays.com/viewpaper/17379.htm (1800 1st automobile)