Project Report

PROJECT REPORT ON SUMMER TRAINING IN

TATA MOTORS, LUCKNOW

SUBMITTED BY ADITYA JAIN

MECHANICAL ENGINEERING DEPARTMENT WALCHAND INSTITUTE OF TECHNOLOGY SOLAPUR, MAHARASHTRA.

PROJECT REPORT TATA MOTORS, LUCKNOW 14th JUNE-3th JULY, 2010.

PROJECT ON

TIME STUDY OF SUB TRIM LINE (COWL LINE) & REMOVAL OF UNNECESSARY PROCESSES IN SUB TRIM LINE Submitted by

ADITYA JAIN Mechanical Engineering Department WIT SOLAPUR

Under the Guidance of

Mr. VARUN KAINTH (Manager, Sub-trim Line)

CONTENTS

 Declaration  Acknowledgement  TATA MOTORS- An Introduction  TATA Journey-Year by year  Telco (Lucknow Plant)  Organization Structure  Vehicle Classification  Eastern complex  Detailed Study of cowl line of TCF trim line  Projects: 1.

TIME STUDY OF SUB TRIM LINE (COWL LINE)

2.

REMOVAL OF UNNECESSARY PROCESSES IN SUB

TRIM LINE  Summary

DECLARATION

I hereby declare that the project work entitled: 1. TIME STUDY OF SUB TRIM LINE (COWL LINE). 2. REMOVAL OF UNNECESSARY PROCESSES IN SUB TRIM LINE. is an authentic record of my own work carried out at TATA MOTORS,

LUCKNOW as

requirements of three week summer project , under the guidance of MR. VARUN KAINTH (Manager, SUB-TRIM LINE) , during 14th JUNE 2010 to 3th JULY, 2010.

ADITYA JAIN B.E 3rd Year Date: 3rd July,2010

Certified that the above statement made by the student is correct to the best of our knowledge and belief.

Mr. Varun Kainth (Manager, Sub-trim line)

ACKNOWLEDGEMENT Industrial training is a crucial period in engineering curriculum since it exposes a student to the real world which he or she is going to enter after the completion of the graduation. This is the period during which an engineer actually becomes an engineer by gaining the Industrial experience. I am very thankful to God who has given me the opportunity to get training in TATA MOTORS, LUCKNOW one of the most renowned organization of India. I would like to express my deep gratitude to my Project Head MR. VARUN KAINTH (MANAGER, SUB-TL) for having provided me with the wonderful & conductive environment to work in and realize what really industry is, he has been ever helpful and supportive. Last but not the least I would like to thank MS. JASNEET RAKHRA (Asst. Manager HR) for providing me the opportunity to add a new dimension to my personality. I will remain indebted to her for her generous ways of dealing with industrial trainees.

ADITYA JAIN, B. E, 3rd YEAR, WIT SOLAPUR.

TATA MOTORS- AN INTRODUCTION Established in 1945, Tata Motors is India's largest and only fully integrated automobile company. Tata Motors began manufacturing commercial vehicles in 1954 with a 15-year collaboration agreement with Daimler Benz of Germany. Since 1969, the company's products have come out of its own design and development efforts. Today, Tata Motors is India's largest commercial vehicle manufacturer with a 59 per cent market share and ranks among the top six manufacturers of medium and heavy commercial vehicles in the areas of business Tata Motors' product range covers passenger cars, multi-utility vehicles as well as light, medium and heavy commercial vehicles for goods and passenger transport. Seven out of 10 medium and heavy commercial vehicles in India bear the most trusted TATA mark.

CV Unit Commercial Vehicle Business unit. The company has over 130 models of light, medium and heavy commercial vehicles ranging from two tones to 40 tones, buses ranging from 12-seaters to 60-seaters, tippers, special purpose vehicles, off-road vehicles and defense vehicles.

Passenger Car Unit The Company’s passenger car range comprises the hatchback Indica, the Indigo sedan and the Marina, its station wagon variant, in petrol and diesel versions. The Tata Sumo, its rural variant, the Spacio and the Tata Safari (the country's first sports utility vehicle) are the company's multi-utility offerings. The Tata Indica, India's first indigenously designed and manufactured car, was launched by Tata Motors in 1999 as part of its ongoing effort towards giving India transport solutions that were designed for Indian conditions. Currently, the company's passenger cars and multi-utility vehicles have a 16-per cent market share. In addition to the growth opportunities in the buoyant domestic market, the company is pursuing growth through acquisitions (it acquired Daewoo Commercial Vehicles, Korea, in 2004) and alliances (it has entered into a tie-up with MG Rover, UK, to supply 1, 00,000 Indicas to be budged as City Rover) in other geographies.

Research and Development Tata Motors invests up to 1.3 per cent of its annual turnover on research and development, with an emphasis on new product / aggregates development and technology up gradation. Its Engineering Research Center in Pune employs over 900 scientists and engineers and has India's only certified crash-test facility and hemi-anechoic chamber for testing of noise and vibration. The company also draws on the resources of leading international design and styling houses like the Institute of Development in Automotive Engineering, SPA, Italy and Stile Bertoni, Italy. The company has also been implementing several environmentally sensitive technologies in manufacturing processes and uses some of the world's most advanced equipment for emission checking

and

control.

Environmental Responsibility Tata Motors has led the Indian automobile industry's anti-pollution efforts through a series of initiatives in effluent and emission control. The company introduced emission control engines in its vehicles in India before the norm was made statutory. All its products meet required emission standards in the relevant geographies. Modern effluent treatment facilities, soil and water conservation programs and tree plantation drives on a large scale at its plant locations contribute to the protection of the environment

Exports Tata Motors' vehicles are exported to over 70 countries in Europe, Africa, South America, Middle East, Asia and Australia. The company also has assembly operations in Malaysia, Bangladesh, Kenya, South Africa and Egypt.

Associates With an aim to expand its business horizons, Tata Engineering has always sought opportunities to form alliances with business leaders. In a world driven by specialization, this policy adopted by Tata Engineering has ensured overall business control and an edge over competition. The joint ventures that Tata Engineering has formed over the years were guided by the contemporary technologies of the partners. Tata Engineering entered into a joint venture with Cummins Engine Company, USA, in 1992 – long before emission control norms were prevalent in India. Cummins was the leading name in manufacturing engines that used emission control technologies. This alliance was the result of Tata Engineering’s foresight and concern for the environment. It is a business practice at Tata Engineering to make strategic investments. These investments provide technologies, markets and capabilities to strengthen the company's existing businesses. Tata Engineering is India's largest exporter of engineering goods. Tata Engineering invests in opportunities that can enhance and reinforce its presence in the corporate world. The Company has numerous subsidiary companies, Foreign Collaborations, Technical Collaborations and Financial Collaboration. Tata Motors has made substantial investments in building associate and subsidiary companies that complement and support its business activities. These include:

Tata Daewoo Commercial Vehicle Company manufactures heavy trucks ranging from 15T GVW to 45T GVW. Tata Motors acquired this company in March, 2004HV Transmissions, supplies gearboxes for the company's medium and heavy commercial vehicles. TAL Manufacturing Solutions manufactures painting systems, welding lines, material handling systems and robotics. It also develops factory automation solutions and provides consultancy services in the field of manufacturing processes and factory layouts. Concorde Motors (India): Retails Tata Motors' range of passenger vehicles.

Tata Precision Industries, Singapore and Tata Engineering Services, Singapore, are engaged in the manufacture of high precision tooling and spare parts, and warehousing, respectively. Nita Company, Bangladesh, is engaged in the assembly of Tata vehicles for Bangladesh market.

Locations

Corporate Head LUCKNOW

SANAND

JAMSHEDPUR PUNE

MUMBAI

Quarters :Mumbai

Manufacturing Plants : Jamshedpur

DHARWAD

Pune Lucknow Dharwad Sanand Pantnagar

Tata Motors has manufacturing plants at Jamshedpur, Pune, Lucknow, Sanand, Pantnagar and Dharwad as well as a well-integrated national sales, service and spare parts network that is focused on providing users with easy access service solutions.

BUSINESS AREAS: The activities of the enterprises promoted by the Tatas are classified in 11 sectors: 1.

Metals and associated Industries

2.

Automobiles

3.

Energy

4.

Engineering

5.

Chemicals and Pharmaceuticals

6.

Consumer products

7.

Services

8.

Agro Industries

9.

Information Technology and Communication

10. Exports and Overseas Operations 11. Finance

JOINT VENTURES Tata Cummins Limited (TCL)

During the year TCL supplied 6,207 engines to the Company. Turnover for the 18month period ended March 31,1999 was Rs.288.47 crores. (Previous year ended September 30,1997 Rs.233.57 crores). The Company proposes to eventually switch over from its existing range of engines for H/MCV s to those manufactured by TCL in collaboration with Cummins Engine Co. Inc. USA.

Mercedes-Benz India Limited (MBIL) with a further increase in the capital of MBIL from Rs.450 crores to Rs.600 crores, the Company's holding in MBIL has been diluted to 14%. This is in keeping with its decision not to invest any amounts over its initial investment of Rs.84 crores in MBIL. MBIL's sales during 1998-99 were 1,006 "E" class cars, which included exports of 502 units. Turnover during the year was Rs.212.6 crores (Previous year Rs.332.7 crores).

Tata Holset Limited (THL)

In the year 1998-99, THL produced 6,525 turbochargers and sold 6,888 turbochargers. Net sales turnover for the year was Rs.8.17 crores. (Previous year Rs.4.13 crores). THL, which supplies the turbochargers to TCL for fitment on its engines, would also see a marked improvement in performance once the volumes for TCL build up.

Concorde Motors Limited (CML) CML was appointed as the Company's dealers for passenger vehicles in Delhi, Mumbai, Ban galore, Hyderabad, Chennai, Lucknow and Ludhiana. It has also acquired the dealership of Mercedes-Benz India Ltd. in Mumbai. During the year, CML sold 1,934 cars and achieved an overall turnover of Rs.126.82 crores for the year 1998-99. With sales of the Tata Indica expected to be much higher in the current year, CML should be able to consolidate its position in the car retailing market.

Joint Ventures Abroad Tata Precision Industries

For the year ended December 31, 1998, Tata Precision Industries (TPI), Singapore, achieved a turnover of Singapore $2.4 million (1997- Singapore $5.0 million). This was mainly due to the fact that business in general was influenced by the economic

crisis that befell almost all countries in the ASEAN region. TPl's business was particularly affected due to the drop in consumer demand for electronic items. Due to the loss of Singapore $2.20 million (1997-loss of Singapore $0.35 million), no dividend was paid for the year. With present indications of improved business, including substantial orders from a new: customer, TPI expects to wipe out its losses over the next two years.

Nita Company Limited The Company's joint venture in Bangladesh which assembles TATA vehicles for the Bangladesh market, sold 881 vehicles to yield a turnover of Tk 600.7 million (approximately Rs.49.1 crores) for the year 1997-98 and declared a dividend @ 15%. The dividend amount of $44,344 was paid to the

Company in March 1999. Sales in 1998-99 were lower at 580 nos. With the automobile market in Bangladesh showing signs of recovery, the performance during the current year is expected to be better.

SUBSIDIARY COMPANIES: Telco Construction Equipment Company Limited (TELCON) As reported earlier, the CEBU of the Company was transferred to TELCON on March 30, 1999. The consideration received by the Company for the transfer of the CEBU was Rs.416.46 crores. The Company has invested Rs.4.50 crores in the capital of TELCON during the year making it a 90% subsidiary. The first financial year of TELCON will be from December 30, 1998 to March 31, 2000 and, consequently, the annual accounts of this company have not been included in this Annual Report.

Tata Technologies (India) Limited (TTIL)

In addition to looking after the Company's on-going IT requirements, TTIL also provides services for SAP implementation; CAD/CAM based design, as well as E-Commerce to customers in India and abroad. For the year ended March 31, 1999

TTIL achieved a turnover of Rs.51.26 crores (Previous year Rs.23.37 crores) and earned a Profit After Tax (PAT) of Rs.2.84 crores (Previous year Rs.1.97 crores). The Board of Directors of TTIL has proposed a dividend of year Rs.l.97 crores). The Board of Directors of TTIL has proposed a dividend of Rs.8/- per share for the financial year 1998-99 (Previous year Rs.7/- per share).

Sheba Properties Limited (Sheba)

During the year, the Company subscribed Rs.51.60 crores to the increase in the share capital of Sheba, its 100% investment subsidiary. For the year ended March 31, 1999 Sheba recorded a gross income of Rs.54.06 lakhs (Previous year Rs.307.22 lakhs) and earned a PAT of Rs.23.93 lakhs (Previous year Rs.9.27 lakhs). No dividend has been, proposed for the year.

Telco Dadajee Dhackjee Limited (TDDL)

TDDL formerly called Matruchhaya Capital and Finance Limited acquired a showroom at Worli, Mumbai in June 97. The premises are undergoing structural repairs and renovation, which is expected to be completed by February 2000. TDDL is expected to commence operations immediately thereafter. In the interim, the funds have been

MARKET SHARE: Tata Engineering and Locomotive Company Ltd (Telco), the Tata group flagship company, is the leader in the commercial vehicle segment with 63% market share in Light Commercial Vehicle (LCV) and 66% market share in Medium & Heavy Commercial Vehicle (M&HCV). In addition, Telco has a market share of 26% in the utility vehicle (UV) segment and 9% in the passenger car industry. Being the oldest

company in the business, Telco has a wide-ranging product portfolio to match customer requirements.

MILE STONES: 1945- Incorporated as a Public Ltd. Company with a factory at Jamshedpur for manufacturing steam locomotives1954- Collaboration with Daimler-Benz AG, Germany, for manufacturing MCVs at Jamshedpur - Introduced commercial vehicle with 5T payload1959-

Research & Development Centre set up at Jamshedpur1961- Collaboration with M/s. Pawling & Harnischfeger (P&H), USA, for manufacturing cable type excavators and cranes1964- Introduced 7.5T payload CV1966- Acquisition of Investa Machine Tool Company and setting up of Machine Tool Division at Pune1967- Engineering Research Centre set up at Pune1970- Last locomotive manufactured1976- First commercial vehicle produced in the second plan at Pune1983 - Introduced HCV, including articulated vehicles1984- Collaboration with M/s. Hitachi Construction Machinery Co. Ltd., Japan for manufacturing hydraulic excavators1985 - First hydraulic excavator manufactured - Collaboration with Niigata Engineering Co., Japan, for NC/CNC Horizontal Machining Centres and with Nachi-Fujikoshi Corpn. Japan, for NC/CNC In-line Machining Centre and Flexible Manufacturing Systems 1986- First indigenously-developed 4T (407) Light Commercial Vehicle meeting fuel efficiency norms specified by the Government manufactured1987- Indigenously developed high-end 6T (608) Light Commercial Vehicle manufactured1989- Sophisticated LCV Tatamobile Pick-up (206) introduced - Collaboration with M/s. Kloth Senking Metal, West Germany, for manufacturing know-how of aluminium castings - Collaboration with Hitachi, Japan, to manufacture new generation EX-series hydraulic excavators 1990- First EX model hydraulic excavator produced - Indigenously-designed Front End Wheel Loader TWL-3036 introduced 1991Introduction of first Multi-Axle 2416 Vehicle - Introduction of indigenously-designed cars - Tata Sierra & Tata Estate - TAC-20 crane produced - One millionth vehicle 1992- Production commences in third plant at Lucknow1993-

Technical collaboration with Cummins, USA for joint venture company, Tata Cummins Private Ltd., to manufacture highly-efficient diesel engines for HCVs & MCVs - Introduction of popular 2213 Multi-Axle Vehicle 1994- Popular Multi-Utility Vehicle, "Tata Sumo", introduced - Collaboration with Mercedes Benz AG, Germany, for manufacturing E-class cars in India by setting up a joint venture company – Mercedes Benz India Ltd. 1996 - First Cummins-powered vehicle introduced - Tata Sumo Deluxe launched 1997 - Tata Sierra Turbo launched - The 100,000th Sumo rolled out - LPT 909 (1st intermediate commercial vehicle launched) 1998- Two millionth vehicle - Tata Safari launched Tata Indica car launched 1999- Record 115,000 fully paid bookings for Tata Indica2000- 50,000th

Tata Indica sold in 12 months since commencement of deliveries - Entire passenger car and multiutility vehicle range becomes Euro II compliant - Two distinct Commercial Vehicles Business and Passenger Cars Business Units formed - Indica 2000 launched.

TATA JOURNEY –YEAR BY YEAR: 1868: Jamsetji Nusserwanji Tata starts a private trading firm, laying the foundation of the TATA group. 1874: The Central India Spinning, Weaving and Manufacturing Company is set up, marking the Group's entry into textiles. 1902: The Indian Hotels Company is incorporated to set up the Taj Mahal Palace and Tower, India's first luxury hotel, which opened in 1903. 1907: The Tata Iron and Steel Company (now Tata Steel) is established to set up India's first iron and steel plant in Jamshedpur. The plant started production in 1912. 1910: The first of the three Tata Electric Companies, The Tata Hydro-Electric Power Supply Company, (now Tata Power) is set up. 1911: The Indian Institute of Science is established in Bangalore to serve as a centre for advanced learning. 1912: Tata Steel introduces eight-hour working days, well before such a system was implemented by law in much of the West.

1917: The Tatas enter the consumer goods industry, with the Tata Oil Mills Company being established to make soaps, detergents and cooking oils.

1932: Tata Airlines, a division of Tata Sons, is established, opening up the aviation sector in India. 1939: Tata Chemicals, now the largest producer of soda ash in the country, is established. 1945: Tata Engineering and Locomotive Company (renamed Tata Motors in 2003) is established to manufacture locomotive and engineering products. Tata Industries is created for the promotion and development of hi-tech industries. 1952: Jawaharlal Nehru, India's first Prime Minister, requests the Group to manufacture cosmetics in India, leading to the setting up of Lakme. 1954: India's major marketing, engineering and manufacturing organization, Voltas, is established. 1962: Tata Finlay (now Tata Tea), one of the largest tea producers, is established. Tata Exports is established. Today the company, renamed Tata International, is one of the leading export houses in India. 1968: Tata Consultancy Services (TCS), India's first software services company, is established as a division of Tata Sons.

1970: Tata McGraw-Hill Publishing Company is created to publish educational and technical books. Tata Economic Consultancy Services is set up to provide services in the field of industrial, marketing, statistical and techno-economic research and consultancy. 1984: Titan Industries - a joint venture between the Tata Group and the Tamil Nadu Industrial Development Corporation (TIDCO) - is set up to manufacture watches. 1991: Tata Motors rolls out its millionth vehicle. (The two-million mark was reached in 1998 and the third million in 2003.) 1995: Tata Quality Management Services institutes the JRD QV Award, modelled on the Malcolm Baldrige National Quality Value Award of the United States, laying the foundation of the Tata Business Excellence Model. 1996: Tata Tele services (TTSL) is established to spearhead the Group's foray into the telecom sector. 1998: Tata Indica - India's first indigenously designed and manufactured car – is launched by Tata Motors, spearheading the Group's entry into the passenger car segment. 1999: The new Tata Group corporate mark and logo are launched.

2000: Tata Tea acquires the Tetley Group, UK. This is the first major acquisition of an international brand by an Indian business group. 2001: Tata-AIG - a joint venture between the Tata Group and American International Group Inc (AIG) - marks the Tata re-entry into insurance. (The Group's insurance company, New India Assurance, was nationalized in 1956). The Tata Group Executive Office (GEO) is set up to design and implement change in the Tata Group and to provide long-term direction. 2002: The Tata Group acquires a controlling stake in VSNL, India's leading international telecommunications service provider Tata Consultancy Services (TCS) becomes the first Indian software company to cross one billion dollars in revenues. Titan launches Edge, the slimmest watch in the world. Idea Cellular, the cellular service born of a tie-up involving the Tata Group, the Birla Group and AT&T, is launched. Tata Indicom, the umbrella brand for telecom services from the Tata Tele services stable, starts operations. 2003: Tata Motors launches City Rover – Indicas fashioned for the European market. The first batch of City Rovers rolled out from the Tata Motors stable in Pune on September 16, 2003. 2004: Tata Motors acquires the heavy vehicles unit of Daewoo Motors, South Korea. TCS goes public in July 2004 in the largest private sector initial public offering (IPO) in the Indian market, raising nearly $1.2 billion. 2005: Tata Steel acquires Singapore-based steel company NatSteel by subscribing to 100 per cent equity of its subsidiary, NatSteel Asia. 2009: Tata Motors launched Tata Nano, world’s cheapest family car.

TELCO (LUCKNOW PLANT): Year of commencement:

1991

Plant Area:

600 acres

Number of employees

835

Divisions

Assembly

Training

TATA MOTORS Lucknow Works is a third manufacturing unit of Tata Engineering and Locomotive Company. This unit covers an area of 600 acres. In this unit the assembly of chassis and spare parts takes place. On 14th January 1992 the recruitment of operators started in Lucknow plant. On 25th June induction of

Engineers (first phase) started which also included ITI's and Occupancy of administration office of assembly shop in September 1992. First vehicle rolled out from Lucknow plant on 20th October 1992 which was LP 1210 52. Construction of MRS finished on 6th January 1993. It took approximately 9 years since the conception of the plan and to rollout the first vehicle from this latest manufacturing facility of Tata Motors.

ORGANIZATION STRUCTURE (Lucknow Plant)

There are three divisions in TATA Motors Lucknow: Training division The Training Center at the Lucknow plant aims at providing high quality Apprenticeship Training. In addition, the Centre provides both internal and external training, support to operators, supervisors and managers in areas like special skills and technology, safety, personnel practices etc. The Lucknow plant, after a major restructuring exercise, executed a smooth transition from function-based to process-based structure. By this structure, process owners are required to meet stretched targets, and in order to do so, are required to encourage individual learning and development of employees. A structured process is being followed to establish and reinforce an environment that encourages innovation.

Assembly division Lucknow Plant started with the assembly of Medium Commercial Vehicles (MCVs) to meet the demand in the Northern Indian market. However, in 1995, the unit started manufacturing bus chassis of Light Commercial Vehicles (LCVs) and SUMOs. The facilities for manufacturing the spare parts were set up and started supply of Crown wheel & pinion (CWP) in 1994. Subsequently, G-16 & G-18 Gear Parts started in 1998. With the availability of G-16 gear parts manufacturing facility, the Plant also started assembly of G-16 Gear Box to meet in-house requirement for SUMO vehicles in the year 2000.Now TATA Motors Lucknow has started assembling of CNG MCV`s to meet the consumers demand. TATA Motors is also producing Rear Engine CV`s.

Manufacturing Division In TATA Motors Lucknow Crown Wheel and Pinion are manufactured by various gear cutting process. Machining (grinding and heat treatment) of Gear Box parts is also done here. These gears are used in gear boxes or as spares. Now TATA Motors is assembling Gear Box of ACE (Newly launched small –CV) in Lucknow itself. The Manufacturing unit of Tata Motors at Lucknow is the latest manufacturing facility of Tata motors and is located towards East of Lucknow plant.

There are five factories in Tata Motors, Lucknow: - CV-CX (Commercial Vehicle) Factory - Transmission Factory - TATA MARCOPOLO MOTORS Limited - Integral Bus Factory (IBF) - RECON Factory Departments in TATA Motors Lucknow are:  Planning  Technical services  Central tool room  Central procurement  Dispatch  Central logistics  Factory logistics group-CV  Factory logistics gear-transmission  Factory logistics Gr-sumo  SQIG  Engineering services  Central maintenance  FPIG - CV factory  FPIG-transmission factory  Central quality (CQ)  Area office, Lucknow  Regional sales office (Lucknow)  Service deptt., Lucknow works  Plant head office

 Manufacturing head office  Human resources  Get training

 Business excellence  Finance  Internal audit  ERC Lucknow  Administration  Construction

COMMERCIAL VEHCILES – CENTER OF EXCELLENCE Over the last fifty years, Tata Engineering has built up an impressive line up of commercial vehicles that can match international benchmarks. Today Telco is India’s largest and among the world’s top ten commercial vehicles manufactures. They have over 130 models and variants of vehicles designed to transport almost anything. Their commercial vehicles can haul loads ranging from 2 tonnes to 40 tonnes. They have mini buses that can seat 12 people and bushes that can accommodate as many as 60.Tippers, tractors trailers, and 4x4off road vehicles. In Telco Lucknow assembly of commercial vehicles (CV) and assembly of MUV’s are done. With the increasing demand assembling of CNG buses are in full vogue Telco Lucknow has also started assembling of Rear Engine models and export quality buses.

Different models of CV assembled in Lucknow plant are: 1. 207 DI-MOBILE 2. SFC 407 (Semi Forward Control) CLB/COWL 3. SFC 407 F/L (27 & 31 WB) 4. SFC 709 5. LP 709 (Laden Passenger) 6. LPT 709 (Laden Passenger Truck)

7. LP/LPT 407 8. LP 407(TT)(Twin Tyre) 9. LP 407 CNG 10. LPO1512 TC (Laden Passenger Overhung- Tata Cummins Engg.) 11. LPT 1613 TC

12. LPT 1613 CMVR (CMVR Engines) 13. LPO 1520 CNG 14. LPT 2515 TC Ex 15. LPT 3118 TC BS II 16. RE 1615 SLF (Semi Lower Floor) 17. LPO 1510 CNG 18. LP 1510 TC/CMVR 19. LPO 1510CMVR 20. SE 1613 CMVR 21. LPO 1616(EURO 1, EURO 2 & PNEU. SUSP.) 22. LPO 1651 ULF (HCBS) 23. LPO 1623 ULF (HCBS)

Abbreviations used  VIN – Vehicle Identification Number  CNG – Compressed Natural Gas  HLA – Head Lamp Aimer  FIP – Fuel Injector Pump  PLC – Programmable Logic Controller  R/B test – Roll and Brake Test  ABS – Anti Locking Brake System  CMVR – Common Motor Vehicle Rules  FA – Front Axle  R/T Axle – Rear/Tandem Axle  HCBS – High Capacity Buses Service  TMML – Tata MARCOPOLO Motors Ltd.

 BIW - Body In White  TML – TATA MOTORS LTD.

ABOUT VEHICLE CLASSIFICATION In the Commercial Vehicle Business Unit, the models are classified on the basis of GVW as under: HCV:

Heavy Commercial Vehicles

MCV:

Medium Commercial Vehicles.

LCV:

Light Commercial Vehicles.

The HCV segment can be further classified into three segments based on gross vehicle weight as follows:  ICV:

Intermediate Commercial Vehicle with GVW of 8 to 10 ton.

 MCV:

Medium Commercial Vehicle with GVW of 10 to 15 ton.

 HCV:

Heavy Commercial Vehicle with GVW of 16 ton and above.

MCV & HCVs can also be classified into two categories depending on their usage as Trucks and Buses. Buses are passenger carriers. Trucks include goods carriers along with specialized vehicles like dumpers, tractor-trailers etc. the ICVs fall in the load category of 8 to 10 ton GVW and are often substituted for medium or heavy commercial vehicles in trunk routes or cities. EICHER Motors and SWARAJ MAZDA are two manufacturers operating in this segment.

Some important definitions:  Gross Combined Weight (GCW): The total weight of a vehicle, including all its cargo, plus the weight of a trailer and its entire contents.  Gross Combined Weight Rating (GCWR): The maximum allowable weight of the GCW as specified by the manufacturer. Exceeding this limit compromises safety. What you need to know: Vehicles that operate above the GCWR are a potential safety hazard because the engine, frame, suspension,

Brakes and tires are not designed for weight above the rating the manufacturer has set.  Gross Vehicle Weight (GVW): Maximum legal weight at which a vehicle can be operated. The total weight of a vehicle with driver and passengers, cargo, fuel, coolant, any dealer or aftermarket installed accessories, and tongue weight if towing.

 Gross Vehicle Weight Rating (GVWR): It is the maximum permissible total weight of the vehicle that may not be exceeded, as designated by the manufacturer. GVWR is identified on the manufacturer's label, which is

usually located on the driver's door or door jam. What you

need to know: Vehicles that operate above the GVWR are a potential safety hazard because the engine, frame, suspension, brakes and tires are not designed for weight above the rating the manufacturer has set.  Curb Weight: The weight of an empty vehicle, without cargo and driver and passengers, but including maximum amounts of fuel, oil, coolant and standard equipment, including the spare tire and tools.  Payload: The maximum amount of weight, including driver and passengers that can be carried in the truck's bed and cabin. Basically, the payload is the GVWR minus the Curb Weight.

Naming conventions: Any Bus/Truck will always be named by its classification. The last two digits multiplied by 10 indicate the Brake Horse Power (BHP) rating of the engine. The digits prior to last two digits indicate the Gross Vehicle Weight (GVW)

GVW = payload +

vehicle weight

That is:

607 : GVW = 6 Tonnes , 7 * 10 = 70 BHP. 4018 : GVW= 40 Tonnes, 18 * 10 =180 BHP. LP

stands for full forward control bus model.

LPT stands for full forward control truck model. LPK stands for full forward control tipper. LPO stands for full forward control with extra overhang SFC stands for semi forward control.

EASTERN COMPLEX:

TATA Motors Ltd. Lko, has total plant area of 600 acres of which 280 acres are covered in the Western Part called the Western Block which has a present production capacity of 120 vehicles per

day and now they have planned to increase its daily production capacity to 520 vehicles by extension which is already going in the form of eastern complex on the other side of ‘Dewa’ road covering the remaining 320 acres. The production capacity of this new assembly plant will expected to be 320 vehicles per day. The eastern complex would have longest conveyor line of India i.e. 375 meters. This eastern complex will have two conveyers formed by the combination of single chain conveyor and double chain slat conveyor. These conveyors are named as ‘Line-2’ and ‘Line-3’ (Line-1 is the name given to the conveyor at western complex). There is also a provision of a future expansion in form of ‘Line-4’ and ‘Line-5’ and two more trim lines to cater their cowl/cab needs.Line-2’ and ‘Line3’ will be composed of 30 stations of 12.5 meters each in comparison to the 19 stations in the existing line.

The complete assembling activity for the vehicle chassis will be done in these 30 stations. The assembly of cowl/cab will be catered by the two trim lines, which will be composed of 34 and 40 stations respectively.

Apart from this, it would also have the biggest paint shop, which will be dedicated for the painting of cowls and cabs along with the BIW (Body in White) shop. Presently the cowls are being received from the Jamshedpur which carries a lot of extra transportation charges will now be seized with the start of Eastern Complex. Moreover in the Eastern Complex there are many other changes made for the efficient working on the line. Firstly the line will accommodate the assembling of chassis of various types of MCV`s and HCV`s up to the upcoming model WORLD TRUCK of TATA. All the equipments and tools etc. will operate over-head so as to make the more floor surface available and reducing hindrance on the shop floor. Platforms for accommodating different types of over-head equipments and machines are hanged to the top with various beams and hangers. Also the aggregates which are the heavy parts required during the chassis assembly (Engine, Axles, and Cab etc.) will now be moved from storage to the fitment station through EMS (Electric Monorail System) which will freeze the movement of fork-lifters on the shop floor. Moreover the docking stations are built aside the wall to dock the material from outside in front of the station in which that part will go to the assembly line directly. Above all the main thing is that the flow of work is made in efficient & systematic way to enhance the productivity with the increased safety.

CAB AND COWL AT TRIM LINE: At TRIM LINE of TATA MOTOR’S EASTERN PLANT, LKO cabs and cowls of trucks of following models has to be prepared-

CABS:

COWL:

LPK 2516 (NON SLEEPER CAB)

LP 2515

LPS 4018 (SLEEPER CAB)

LP 3118

TRIM LINE

COWL LINE

CAB LINE

LPS 4018 SLEEPER CAB

LPK 2516 NON SL CAB

LP 2515 COWL

MY WORK AS A TRAINEE I joined TATA Motors as a summer trainee in the session 14th of June to 3rd of July, my duty as a summer trainee firstly was to feel what the real industry is, starting from the BIW Shop where the cowl welding was done then to the paint shop where the cowl and cab were automatically painted by highly efficient and precise robots, the paint shop is fully automatic and is claimed to be the Asia’s largest paint shop. Followed by that the trim line was to be viewed in detail where I had spent my more than two weeks inspecting processes as well as calibrating new things and methods. Further was the central quality checking department which inspects each truck and find out the fault prior to delivery As a trainee I was given the sub trim line where painted cowl of models 2515 and 3118 were dropped and all the fixing was done in required time. As well as I was also asked to cut down the useless processes and shorten the time for cowl line and reduce the number of stations.

DETAILED STUDY OF COWL LINE ( SUB TRIM LINE)

Station 1( Dropping of Cowl)    

Description:-assembly bare cowl Validity:-1 Tool/ gauges:- tackle Quick check:- No dent , No run down on face  Guidelines:- Cowl Properly sit on pot.

Station 2 (Fitment of Mascot)    

Description:- Assembly TATA Mascot Validity:-1 Tool/ gauges:-Templet Quick check:- Poor adhesion of mascot/Mascot letters broken/chipped off  Guidelines:- Mascot firmly adhered to face

Station 3 (Pasting of Heat Insulation)    

Description:-Assembly Insulation Validity:-1 Tool/ gauges:- N/A Quick check:- No Damaged / cracked Adhesive not proper  Guidelines:- pads Properly pasted on cowl.

 Station 4 (Fitment of Flange Pipe)  Description:- Assembly flange pipe  Validity:-1  Tool/ gauges:- 10 mm Socket & Runner  Quick check:- No Damage, Bend, Thread damage, Scratches  Guidelines:- Flange pipe to be properly tightened.

Station 5 (Assembly of Service Indicator)  Description:- Service indicator  Validity:-1  Tool/ gauges:- 14mm open end spanner  Quick check:- Broken/No crack.  Guidelines: - proper Tightening.

Station 6(Fitment of DTV)  Description:- Assembly DTV  Validity:-1  Tool/ gauges:- 10 mm socket , Nut runner  Quick check:- Loose , No washer deform  Guidelines:- Proper Tightening

Station 7(Fitment of engine hood beading)    

Description:- Sealing rubber Validity:-1 Tool/ gauges:- Brush /Spray gun Quick check: - Loose adhesion of beading with cowl.  Guidelines:- Beading properly seated in cowl channel.

Station 8 (Fitment of hand brake valve & Low pr. Switch)    

Description:- Main switch Validity:-1 Tool/ gauges:- Screw driver Quick check:- No scratches /No damage  Guidelines:- Properly tightened

Station 9(Fitment of Clutch fluid container)    

Description:- Assembly clutch container Validity:Tool/ gauges:- M10 socket. Quick check:- No Damaged , Filter missing.  Guidelines:- Properly tightened .

Station 10 (Fitment of TATA letter)    

Description:- Assembly ''T & A'' letters Validity:-2 Tool/ gauges:- Nylon hammer Quick check:- Letters not self-locking, Letters broken, crack  Guidelines:- Letters to lock properly on panel

Station 11 (Fitment of T-emblem)    

Description:- Assembly T-emblem Validity:-1 Tool/ gauges:- 8mm Socket Quick check:- Emblem broken,Scratches,crack on emblem  Guidelines:- Properly tighten.

Station 12 (Routing of main cable set)    

Description:- W/H MAIN Validity:-1 Tool/ gauges:- N/A Quick check:- Wire slit/cut, Fuse box cover damaged  Guidelines:- Proper tightening of fuse box to clamp

Station 13 (Fitment of wiper motor)    

Description:- Wiper motor Validity:-1 Tool/ gauges:- 13mm socket Quick check:- Bracket rusty, Connection wrong, Bolts loose  Guidelines:- Bolts to be properly tightened

Station no 14 (Fitment of Plastic Cover for Wiper Motor)     

Description:- Wiper Motor Cover Validity:-1 Tool/ gauges:- 12 mm Spanner Quick check:- No scratches, No cracks Guidelines:- Cover to be fitted without crack and no fouling with other parts

 Station 15 (Beeper unit and connection)     

Description:- Beeper alarm unit Validity:-1 Tool/ gauges:- M10 socket Quick check:- Beeper not working Guidelines:- Checking of proper functioning of beeper

Station 16(Fitment of engine lamp)  Description:- ASSY ENGINE LAMP (12V,21W,W/BLB)  Validity:-1  Tool/ gauges:- Bit (Size-2)  Quick check:- Engine lamp hole out, Bulb mismatch  Guidelines:- holes to be match with cowl

Station 17 (Fitment of dome and H/L (LH and RH))    

Description:- LH/RH H/L dome & Lamp 12V,21W, Validity:-1 Tool/ gauges:- bit 2 Quick check:- Dome crack, Parking bulb connection loose/L crack  Guidelines:- Dome to be fitted properly without crack

Station 18 (Fitment of LH RH blinker and H/L)    

Description:- Blinker lamp LH&RH Validity:-1 Tool/ gauges:- bit 2 Quick check:- Blinker crack, Wrong connection with main W/H  Guidelines:- Connection tightly done, Blinkers fed on trolley only

Station 19 (Fitment of horn)    

Description:- HORN 12V W/O RIS Validity:-1 Tool/ gauges:- M16 socket Quick check:- Connection with main W/H  Guidelines:- Connection with W/H made tightly

Station 20 (Fitment of accelerator pedal and stopper bolt with retainer plate)  Description:- Accelerator pedal  Validity:-1  Tool/ gauges:- M10 socket, M17 spanner, pneumatic nut runner  Quick check:- Accelerator pedal loose/rubber cover on stopper bolt/Retaining plate loose  Guidelines:- properly tightened

Station 21 (Fitment of driver seat)    

Description:- Assy driver seat Validity:-1 Tool/ gauges:- M13 socket Quick check:- Hole mismatch,Seat not sliding smoothly,Seat up/down lever not working  Guidelines:- Smooth functioning of up/down lever

Station 22 (Fitment of Air filter bracket)     

Description:- Air filter mounting bracket Validity:- 1 Tool/ gauges:- 16mm socket/Nut runner Quick check:- No scratches /No damage Guidelines:- Proper handling

Station 23 (Fitment of air intake pipe)    

Description:- Air intake pipe Validity:- 1 Tool/ gauges:- M13 & M11 socket Quick check:- Elbow crack, Clamp loose, Flange pipe cover not removed  Guidelines:- Flange tube cover removed before fitment of air intake pipe

Station 24 (Fitment of air filter)    

Description:- Air filter Validity:-1 Tool/ gauges:- M14 ,M13 & M11 socket Quick check:- Rusty strap, Rubber strap short in length, Air filter damage  Guidelines:- Proper alignment of assembly strap with air filter groove

Station 25(Connection and fitment of instrument panel)    

Description:- Instrument cluster Validity:-1 Tool/ gauges:- 13mm socket Quick check:- Scratches on panel/ cluster ,Gauges/piano switch crack, Wrong wiring  Guidelines:- Line diagram of connections should be displayed

Station 26 (Fitment of steering column)    

Description:- Assembly steering column Validity:- 1 Tool/ gauges:- M16 socket Quick check:- Rust marks on column, CD hole out, Welding finishing poor  Guidelines:-N/A

Station 27 (Fitment of combi switch on steering column)    

Description:- Assembly combi switch Validity:-1 Tool/ gauges:- Screw driver Quick check:- Combi switch crack, Combi switch not working  Guidelines:- Checking of proper functioning of combi switch

Station 28 (Fitment of steering wheel)    

Description:- Steering wheel Validity:-1 Tool/ gauges:- M 32 socket Quick check:- Spindle thread damage, Nut free, Steering wheel crack/scratch  Guidelines:-proper alignment

Station 29 (Electrical testing of all electrical accessories)    

Description:- Battery Validity:-1 Tool/ gauges:-N/A Quick check:- working of Electrical accessories, Fuse missing/blown, Wrong/loose connection  Guidelines:- All electrical parts to be

OK

Station 30 (Inspection)  Description:-inspection of prepared cowl  Validity:-1  Tool/ gauges:-N/A  Quick check:- All fitments to be OK, Dent on face, Paint run down, Welding not done  Guidelines:- All attributes to be OK before rollout

sr no NAME OF OPERATOR 1 Sriraj 2 aniruddha kumar singh 3 prabhakar yadav 4 prabhakar yadav 5 prabhakar yadav 6 jitendra kumar 7 ramdiksh 8 satya prakash 9 satya prakash 10 satya prakash 11 arvind tiwari 12 amrash kumar yadav 13 amrash kumar yadav 14 mithunjay pratap singh 15 manish kumar 16 mohd mosin 17 mohd mosin 18 mohd mosin 19 suryadev rai 20 ranjeet singh 21 santosh jaiswal 22 jitendra singh 23 jitendra singh 24 ajit kumar 25 satya prakash 26 satya prakash 27 satya prakash 28 satya prakash

OPERATION

TIME TAKEN

lifting of cowl 1.50 min fitting of mascot 20 sec pasting heat insulation 2.16 sec fitting of flange pipe 1 min 25 sec service indicator 1 min 36 sec DTV 4 min engine hood beading 2 min 30 sec hand break 2 min 45 sec wiper motor 1 min 35 sec beeper indicator 2 min clutch fluid container 2 min 13 sec fitment of TATA 3 min fitment of t emblem 1 min 40 sec reflector tape 1 min 22 sec routing of main cable 5 min 35 sec fitment of engine lamp 2 min fitment of head lights 5 min 10 sec fitment of indicators 3 mins fitment of horn 2 mins 5sec accelerator pedal 1 m 10 sec driver seat 5 min 35 sec air filter bracket 2 min 51 sec air intake pipe 1 min 15 sec air filter 1 min 50 sec connection fitment inst panne 15 min combi s/w on steering 20 sec steering fitment 2 min 52 sec fitment of steering 5 min 38 sec

OPERATION SEQUENCE REMARK yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes no no yes yes yes yes yes yes

unavailability of runner sequence wrong

In order to remove the unnecessary processes as stated in the cowl line a list is prepared as follows with station according to the above table with cycle time chart.

Station 1 Station 2 Station 3 Station 4 Station 5 Station 6 Station 7 Station 8 Station 9 Station 10

:- Dropping of cowl :- Mascot fitment + Reflector Tape :- Air Duct :- Pasting heat Insulation + TATA Emblem + TATA Letters :- Service Indicator + Engine hood Beading :- Hand Break + Wiper motor :- Routing of main cable :- Routing main cable + DTV :- DTV + beeper indicator :- engine lamp + clutch fluid Container + horn

Station 11 Station 12 Station 13 Station 14 Station 15 Station 16 Station 17 Station 18

:- Instrument panel + indicator :- Instrument panel + Acc. pedal :- driver seat + filter bracket :- filter tightening + head lamps :- steering fitment + head light :- combi St. s/w + St. fitment :- remaining task + inspection :-Inspection and lifting of cowl

Time chart recalculated

time taken in seconds 400 350 300 250 200

time taken in seconds

150 100 50 0 0

5

10

15

Station number

20

.

SUMMARY The sole motive of this three week’s vocational training is to give an idea what a real industry is all about and getting training in such an esteemed organization is definitely a thing to be proud of. I got the chance to learn much more than I expected before I came here. During my training I learnt how to plan the activities regarding different work and develop the techniques to solve the problem. I also learnt the power of team work that how onerous tasks can be accomplished easily with the help of team work. Apart from the allotted projects, I also learnt a lot about Organizational Culture. Working with people from different areas taught me a lot of managerial as well as personal skills that are definitely very helpful for my future. I also learnt different protocols that are being followed at different levels of Organizational hierarchy. My experience in TATA motors has been really enriching and has provided me a stepping stone for a prospective bright future in the industrial Sector. I wish that every engineer get a chance to get associated with such a giant and reputed group.