Top Banner
PROJECT REPORT ON SUMMER TRAINING IN TATA MOTORS, LUCKNOW SUBMITTED BY ADITYA JAIN MECHANICAL ENGINEERING DEPARTMENT WALCHAND INSTITUTE OF TECHNOLOGY SOLAPUR, MAHARASHTRA.
45
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Page 1: Project Report

PROJECT REPORT

ON SUMMER TRAINING IN

TATA MOTORS, LUCKNOW

SUBMITTED BY

ADITYA JAIN MECHANICAL ENGINEERING DEPARTMENT

WALCHAND INSTITUTE OF TECHNOLOGY

SOLAPUR, MAHARASHTRA.

Page 2: Project Report

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)

Page 3: Project Report

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

Page 4: Project Report

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)

Page 5: Project Report

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.

Page 6: Project Report

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.

Page 7: Project Report

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.

Page 8: Project Report

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.

Page 9: Project Report

JAMSHEDPUR

LUCKNOW

PUNE MUMBAI

DHARWAD

SANAND

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

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.

Corporate Head

Quarters :Mumbai

Manufacturing

Plants :

Jamshedpur

Pune

Lucknow

Dharwad

Sanand

Pantnagar

Page 10: Project Report

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 18-

month 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).

Page 11: Project Report

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

Page 12: Project Report

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).

Page 13: Project Report

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-

Page 14: Project Report

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 1991-

Introduction 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

Page 15: Project Report

Tata Indica sold in 12 months since commencement of deliveries - Entire passenger car and multi-

utility vehicle range becomes Euro II compliant - Two distinct Commercial Vehicles Business and

Passenger Cars Business Units formed - Indica 2000 launched.

Page 16: Project Report

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.

Page 17: Project Report

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.

Page 18: Project Report

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.

Page 19: Project Report

ORGANIZATION STRUCTURE (Lucknow Plant)

Page 20: Project Report

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.

Page 21: Project Report

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

Page 22: Project Report

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

Page 23: Project Report

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.

Page 24: Project Report

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 after-

market installed accessories, and tongue weight if towing.

Page 25: Project Report

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

Page 26: Project Report

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 ‘Line-

3’ 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.

Page 27: Project Report

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

CAB LINE COWL LINE

LPS 4018

SLEEPER CAB

LPK 2516

NON SL CAB

LP 2515

COWL

Page 28: Project Report

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.

Page 29: Project Report

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

Page 30: Project Report

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.

Page 31: Project Report

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

Page 32: Project Report

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

Page 33: Project Report

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

Page 34: Project Report

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

Page 35: Project Report

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

Page 36: Project Report

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

Page 37: Project Report

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

Page 38: Project Report

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

Page 39: Project Report

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

Page 40: Project Report

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

Page 41: Project Report

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

Page 42: Project Report

sr no NAME OF OPERATOR OPERATION TIME TAKEN OPERATION SEQUENCE REMARK

1 Sriraj lifting of cowl 1.50 min yes

2 aniruddha kumar singh fitting of mascot 20 sec yes

3 prabhakar yadav pasting heat insulation 2.16 sec yes

4 prabhakar yadav fitting of flange pipe 1 min 25 sec yes

5 prabhakar yadav service indicator 1 min 36 sec yes

6 jitendra kumar DTV 4 min yes

7 ramdiksh engine hood beading 2 min 30 sec yes

8 satya prakash hand break 2 min 45 sec yes

9 satya prakash wiper motor 1 min 35 sec yes

10 satya prakash beeper indicator 2 min yes

11 arvind tiwari clutch fluid container 2 min 13 sec yes

12 amrash kumar yadav fitment of TATA 3 min yes

13 amrash kumar yadav fitment of t emblem 1 min 40 sec yes

14 mithunjay pratap singh reflector tape 1 min 22 sec yes

15 manish kumar routing of main cable 5 min 35 sec yes

16 mohd mosin fitment of engine lamp 2 min yes

17 mohd mosin fitment of head lights 5 min 10 sec yes

18 mohd mosin fitment of indicators 3 mins yes

19 suryadev rai fitment of horn 2 mins 5sec yes

20 ranjeet singh accelerator pedal 1 m 10 sec yes

21 santosh jaiswal driver seat 5 min 35 sec no unavailability of runner

22 jitendra singh air filter bracket 2 min 51 sec no sequence wrong

23 jitendra singh air intake pipe 1 min 15 sec yes

24 ajit kumar air filter 1 min 50 sec yes

25 satya prakash connection fitment inst panne15 min yes

26 satya prakash combi s/w on steering 20 sec yes

27 satya prakash steering fitment 2 min 52 sec yes

28 satya prakash fitment of steering 5 min 38 sec yes

Page 43: Project Report

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 :- Dropping of cowl

Station 2 :- Mascot fitment + Reflector Tape

Station 3 :- Air Duct

Station 4 :- Pasting heat Insulation + TATA

Emblem + TATA Letters

Station 5 :- Service Indicator + Engine hood

Beading

Station 6 :- Hand Break + Wiper motor

Station 7 :- Routing of main cable

Station 8 :- Routing main cable + DTV

Station 9 :- DTV + beeper indicator

Station 10 :- engine lamp + clutch fluid

Container + horn

Station 11 :- Instrument panel + indicator

Station 12 :- Instrument panel + Acc. pedal

Station 13 :- driver seat + filter bracket

Station 14 :- filter tightening + head lamps

Station 15 :- steering fitment + head light

Station 16 :- combi St. s/w + St. fitment

Station 17 :- remaining task + inspection

Station 18 :-Inspection and lifting of cowl

Page 44: Project Report

Time chart

recalculated

Station number .

0

50

100

150

200

250

300

350

400

0 5 10 15 20

time taken in seconds

time taken in seconds

Page 45: Project Report

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.