Pulkit Shikhar Report

8/15/2019 Pulkit Shikhar Report

1/81

1|P a g e

A

Final pr oject Report

on

General Motors India Ltd.

Submitted by:

Name : Bhardwaj Varun Ashok University Roll No. :- 90361126349

Class Roll No.:-4117

Batch: 2009

Group : M2G2

Guru Gobind Singh College Of Engineering & Technology,

Talwandi Sabo, Bathinda.

Punjab Technical University,

Jalandhar ,Punjab.

Mentor: Rajkumar Taneja

Mr. Ashok kumar mougil PEM- PE

Dy Manager -PE


2/81

2|P a g e

INDEX

1. Acknowledgements....................................................................................................................04

2. Preface........................................................................................................................................05

3.Introduction &&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&.06

4.Birth of GM &&&&&&&&&&&&&&&&. &&&&&&&&&&&&&&&&07

5.Chronological of GM &&&&&&&&&&&&&&&&&&&&&&&&&&&&..10

6.Company Brands &&&&&&&&&&&&&&&&&&&&&&&&&&&&&&12

7. Global Partners of GM &&&&&&&&&&&&&&&&&&&&&&&&&&&..15

8. GM before independence &&&&&&&&&&&&&&&&&&&&&&&&&&..15

9. Various arms of GM &&&&&&&&&&&&&&&&&&&&&&&&&&&&.17

10. Product portfolio &&&&&&&&&&&&&&&&&&&&&&&&&&&&&.19

11.Introduction to GMI &&&&&&&&&&&&&&&&&&&&&&&&&&&&.21

12. GMI Halol &&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2213.Integrated Management System &&&&&&&&&&&&&&&&&&&&&&&&24

14. GMI Products &&&&&&&&&&&&&&&&&&&&&&&&&&&&&&...27

15. Various departments of GMI &&&&&&&&&&&&&&&&&&&&&&&&..32

16. Product Engineering Department &&&&&&&&&&&&&&&&&&&&&&&.34

16.1 Product definition &&&&&&&... &&&&&&&&&&&&&&&&&&&&&34

16.2 Current Product Engineering &&&&... &&&&&&&&&&&&&&&&&&&..35

16.3Testing before launch of new vehicle &... &&&&&&&&&&&&&&&&&&&..37

16.4Localization &&&&&&&&&&.. &&&&&&&&&&&&&&&&&&&&..37

16.5Testing and validation &&&&&&.. &&&&&&&&&&&&&&&&&&&&..37

16.6Product Engineering- Document Con...trol &&&&&&&&&&&&&&&&&&&38

16.7Roles and Responsibilities &&&&&.. &&&&&&&&&&&&&&&&&&&&38

17.Localization &&&&&&&&&&&.. &&&&&&&&&&&&&&&&&&&&40

18. Statement Of Requirement &&&&&.. &&&&&&&&&&&&&&&&&&&&41


3/81

3|P a g e

19. Projects &&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&.43

19.1Inter ior and exter ior functions &&&&&&&&&&&&&&&&&&&&&&&43

19.1.1 Project no. 1 . Door latch &&&&&&&&&&&&&&&&&&&&&&&&&43

19.1.2 Projects no.2: Front Door Squeaks noise &&&&&&&&&&&&&&&&&&&46

19.1.3 Project no.3 Cargo door dent issue &&&&&&&&&&&&&&&&&&&&&.4819.1.4Project No.4Check Link stopper fouling with rear door inner panel &&&&&&&&...50

19.2 Chassis function &&&&&&&&&&&&&&&&&&&&&&&&&&&&.52

19.2.1 Project no.5 Brake line fouling with steering shaft &&&&&&&&&&&&&&&.52

19.2.2Project no.6 Brake Line Clips &&&&&&&&&&&&&&&&&&&&&&&..55

19.3Heat Ventilation and Air Conditioning function &&&&&&&&&&&&&&&57

19.3.1Project no.7 Radiator Fan fouling with shroudBS-3 &&&&&&&&&&&&&&&57

19.3.2Project no.8 radiator Fan Fouling with Shroud-BS4 &&&&&&&&&&&&&&...59

19.3.3Project No. 9 Coolant Hose Fitment problem &&&&&&&&&&&&&&&&&..61

19.3.4Proect no.10 Intercooler hose length short &&&&&&&&&&&&&&&&&&..64

19.4Noise Vibration And Harness &&&&&&&&&&&&&&&&&&&&&&&.66

19.4.1Study the basics of NVH &&&&&&&&&&&&&&&&&&&&&&&&&.66

19.4.2project no.11 Pass by Noise test &&&&&&&&&&&&&&&&&&&&&&..68

19.4.3Project no.12 Ultrasonic Leak Detection &&&&&&&&&&&&&&&&&&&.75

19.4.4Project no. 13 Incabin Noise Test &&&&&&&&&&................................................78


4/81

4|P a g e

1.ACKNOWLEDGEMENT

Success is the manifestation of inspiration, motivation, diligence, perseverance, and

innovation. For completion of any task triumphantly, it requires not only help and support of many but, also a constant source of inspiration. The task of executing the project would not have

been possible without the amount of support that I received from the managers and executives at

General Motors, India. It therefore makes the task of acknowledging the role that each one of

them played in encouraging me to learn how things work in a corporate set-up like that of GMI

even more challenging. I hope that I will be able to do justice to all them here.

I express deep gratitude to Mr.Rajkumar Taneja, Senior Divisional Manager, Product

Engineering for providing me an opportunity to work in the Product Engineering Department at

GMI.

I immensely thank Mr. Ashok Kumar Moudgil, Deputy Manager, Product Engineering

under whose guidance I have worked for my entire stint. I am grateful to him for motivating me

persistently, supportive temperament and guiding me in each and every step for my entire work

term in GMI and without whose support I couldn t have accomplished my work term.

I would like to thank Mr . Rakesh Mehta , Director HR for providing me an

opportunity for training at GMI.

I would like to thank Mr . Rohan lele, Miss Aditi Dureja and Mr. Amit Atalia,

Training HR for providing me an opportunity for training at GMI.I express my profound gratitude to Mr . Gurpr it Singh Tuteja, Manager PE Workshop,

Product Engineering.

My mid term training report will be incomplete without the invaluable support and

guidance of Mr.Gnana shekar, Mr. Sandeep Vansia, Mr. Senthil Ganpathy, Mr . Lalit

Vishwakar ma, Mr . Nirav Modi, Mr . Nayan Solanki & Mr. Pr itpal Singh, Mr .Ronak Shah,

&Mr . Chandrakant Parmar . Their constant Spresence is keeping me more motivated and

eager to learn more and absorb the experience in order to make myself a better individual.

I would be failing my duty if I forget to acknowledge the Personnel of the PE Workshop

specially Mr. Anil Tank and Mr. Nirav Panchal for their patient replies to all my queries.


5/81

5|P a g e

2.PREFACE

Technical innovations certainly do not come about automatically. They have to be invented,

planned, initiated and implemented in a way that will make educational practice more adequately

geared to the changing needs of industries. It is Industrial training bridges the gap between the

theoretical and practical knowledge of a student. It helps a student to narrow down the gap

between his institute, workshop and the industry. The main purpose of the training is to expose

an individual to the industrial environment, which is not possible merely by means of classroom

study.

Unique challenges arise during the development phase of a product s life cycle. Product

development has been identified as one of the most important business process. This is mainly

due to increased competition and changes in customer expectation, which has led to improved

performance of the product, in terms of high reliability, timely introduction, low cost, and high

quality. In current scenario manufacturers are facing stiffer global competition. So productdevelopment plays a more vital role in the successful manufacturing of products.

I have worked in Product Engineering Department at GMI. This gave me an opportunity to learn

more about the Engineering processes involved in the development of a product. The training

helped me in the view of implementing theoretical knowledge to the actual industrial

requirements. The training is definitely going to play an important role in developing an aptitude

for hard work and self-confidence necessary to build a successful carrier.

Six months industrial training is a crucial aspect of a engineering student s life. At Guru Gobind

Singh College of Engineering & Technology, B. Tech Mechanical Engg. programme under the

aegis of Punjab Technical University, Jalandhar-Punjab, six months internships aim to give the

students an opportunity to actually put their theoretical knowledge into practical use.

Undergraduate students with no or minimal experience also get a chance to feel the processes,

systems and functions at a corporate level. The students get an exposure to the workings of a

corporate organization. This would further help the student to understand their level of creativity

and assist them to choose a field in which they would like to pursue specialization in future.

In this final project report prepared by me at GMI Halol, I have presented my understanding of the working of Product Engineering unit which is one of the major players in the automobile

industry in India and the World.


6/81

6|P a g e

3.INTRODUCTION:

Ø General Motors Corporation, also known as GM, is the world's largest car manufacturer.

Founded in 1908, in Flint, Michigan, GM today employs about 280,000 people around

the world. With global headquarters at the 300 Renaissance Centers in Detroit , Michigan,

USA, GM manufactures its cars and trucks in 33 countries.

Ø

GM

cars and trucks are sold globally under the following brands: Buick , Cadillac, Chevrolet, GMC,

Daewoo (now sold under the Chevrolet and Suzuki brands in the United States, Europe and in

some other countries), Holden, Hummer, Oldsmobile (now defunct), Opel, Pontiac, Saab, Saturn,

Vauxhall. GM operates a finance company, GMAC Financial Services, which offers automotive,

residential and commercial financing and insurance. GM's On Star subsidiary is a vehicle safety,

security an information service provider. GM is the majority shareholder in GM Daewoo Auto &

Technology Co. of South Korea, and has product, power train and purchasing collaborations with


7/81

7|P a g e

Suzuki Motor Corp. and Isuzu Motors Ltd. of Japan.

Ø GM also has advanced technology collaborations with Toyota Motor Corporation of

Japan, DaimlerChrysler AG and BMW AG of Germany, and vehicle manufacturing

ventures with several automakers around the world, including Toyota, Suzuki, Shanghai

Automotive Industry Corporation of China, AutoVAZ and Avtotor of Russia and

Renault SA of France.

Ø GM Parts and accessories are sold under the GM, GM Performance Parts, GM Good

wrench and ACD elco brands through GM Service and Parts Operations, which supplies

GM dealerships and distributors worldwide. GM engines and transmissions are marketed

through GM Power train. GM's largest national market is the United States, followed

by China, Canada, the United Kingdom, and Germany.

General Motors Company, wasformerly incorporated(until 2009)asGeneral Motors

Corpor ation, is an Americanmultinationalautomotivecorporation headquartered in Detroit,

Michigan.

4.THE BIRTH OF GM

1897- Olds Motor Vehicle Company, Inc. is organized by Ransom E. Olds and the first

Oldsmobile is produced.

1903 May 19 - Buick Motor Company, founded by David Dunbar Buick is incorporated.


8/81

8|P a g e

1904 November 1 - William Crapo ("Billy") Durant of Durant- Dort Carriage Company, Flint,

Michigan, takes control of Buick Motor Company.

1908 Sept 16 - Under Billy Durant's leadership, General Motors Company is organized

incorporating the Buick Motor Company.

1908 Nov. 12 - Oldsmobile becomes the second company to join General Motors when Olds

Motor Works is sold to GM.

1862 - Adam Opel founded Opel in Russelsheim, Germany to manufacture high-quality sewing

machines in volume.

1885 - The company began selling bicycles. When Adam Opel died in 1895, they were making 2,

000 bicycles a year and were leading Europe in sewing machine sales.


9/81

9|P a g e

1899 - Adam Opel's 5 sons with their mother partnered with engineer Friedrich Lutz Mann to

produce Opel's first motorcar the "Opel-Patent- Motorwagen System Lutz Mann ,

1929 Opel joined the General Motors family of cars and trucks and since then has spread

to be a global maker of high quality automobiles.

1909 - With the help of a well known race car driver Louis Chevrolet, William Durant came up

with the car design for introduction to the public

1911 -Establishment of the Chevrolet Motor Car Company

1912 - Chevrolet launched its "Classic Six" - a large 5-passenger touring sedan that could reach

the top speed of 65 miles per hour

1914 -The Chevrolet "bowtie" logo appears for the first time

1918 -First Chevrolet truck sold. Chevy joins GM Corporation.


10/81

10|P a g e

1927 - Chevrolet outsold Ford in the US by topping 1 million units for the first time.

1965 - First to build over 3 million cars and trucks in a single year.

1979 - A momentous year as Chevrolet rolled out its 100 millionth car.

1979 To date, Chevy is now part of the global landscape. Selling more than 150 million cars it

now enjoys iconic status in many countries and is one of the most recognized brands worldwide.

5. Chronological of GM History

Sept 16. 1908 - General Motors is organized incorporating the Buick Motor Company

Nov 12. 1908 - Oldsmobile becomes the second company to join GM

Jan 20. 1909 - GM owns half of Oakland Motor Co, following summer GM has full ownership.

1932 Oakland name dropped and Pontiac becomes the division name

July 29, 1909 GM purchases Cadillac.

1909 - GM acquires Rapid Motor Vehicle Company and Reliance Motor Truck Co.


11/81

11|P a g e

July 22, 1911 - General Motors Truck Company (later known as GMC) is organized to handle

sales of GM's Rapid and Reliance products.

November, 1911 - Chevrolet Motor Company is established.

1918 - Chevrolet joins GM

1925 - Vauxhall Motors Ltd. of England is acquired.

1929 - Adam Opel A. G. Germany is acquired by GM.

1931 - General Motors - Holden's Ltd. is formed through merger of Holden s Motor Body

Builders Ltd. and GM (Australia) Pty. Ltd.

1971- GM acquires a portion of Isuzu Motors Limited.

1972 - GM and Shinjin Motor Co. of Korea, form a J. V. It is named General Motors Korea

Company, Ltd. renamed to Saehan Motor in 1976.

1982 - Daewoo Group assumes managerial control and renames it Daewoo Motor Co. Ltd. GM

retains 50% stake until 1992.

1985 - Saturn Corporation created as a separate subsidiary to make a new family of sub- compact

cars

1987. GM purchases a small share in Suzuki.

1989 GM purchases 50 percent of Saab Automobile AB of Sweden.

1999 - General Motors enters into a M.O.U to acquire exclusive rights to the Hummer

automotive brand from AM General Corporation.

2000 - Increases share to 20 percent, Increases equity to 100% and Buys the share of FIAT

2002 - GM acquires bulk of Daewoo Motor's automotive assets and new co. GMDAT is formed.


12/81

12|P a g e

6.Company Brands:

1. Buick:

It is a premium brand ofGeneral Motors(GM).Buick models are sold in the United

States, Canada, Mexico, China, Taiwan, and Israel, with China being its largest market. Buick

holds the distinction as the oldest active American make. Many current Buick models are shared

with other GM global subsidiaries.

2. Cadillac:

Cadillacis an American luxury vehiclemarqueowned byGeneral Motors(GM).

Cadillac currently sells vehicles in 37 countries, with its primary market being North America.

Cadillac is currently the second oldest American automobile manufacturer behind fellow GM

marqueBuick and is among the oldest automobile brands in the world.

3. GMC:


13/81

13|P a g e

GMCis a manufacturer oftrucks,vans,military vehicles, andSport utility vehicles

marketed inNorth Americaand theMiddle EastbyGeneral Motors .

4. Chevrolet:

Chevrolet is an American brand of vehicle produced byGeneral Motors(GM). Founded

byLouis Chevroletand ousted GM founderWilliam C. Duranton November 3, 1911,[1]General

Motors acquired Chevrolet in 1918. In North America, Chevrolet sells and produces a wide

variety of automobiles, fromsubcompactcars to medium-duty commercial trucks, whereas in

Europe, the brand name is used on automobiles produced in Korea by General Motors.

5. Opel:

Adam Opel AG(Opel) is a Germanautomobilecompany founded byAdam Opelin 1862.Opel has been building automobiles since 1899, and became anAktiengesellschaftin 1929. The

company is headquartered inRüsselsheim, Germany. It became a majority-stake subsidiary of the

General Motors Corporationin 1929 and has been a wholly owned subsidiary since 1931.

6. Vauxhall:


14/81

14|P a g e

Vauxhall Motorsregistered nameGeneral Motors UK Limited)is a British automotive

manufacturing company owned byGeneral Motors(GM) and headquartered inLuton. It was

founded in 1857 as a pump and marine engine manufacturer, began manufacturing cars in 1903

and was acquired by GM in 1925. It has been the second-largest selling car brand in the UK for

over two decades.

7. Holden:

GM Holden Ltdis anautomakerthat operates in Australia, based inPort Melbourne,

Victoria. The company was founded in 1856 as asaddlery manufacturer. In 1908 it moved into

the automotive field, before becoming asubsidiaryof the U.S.-basedGeneral Motors(GM)automotive group in 1931. After becoming a subsidiary of GM, the company was namedGeneral

Motors-Holden's Ltd.

8. Hummer:

Hummer was a brand of trucks and SUVs, first marketed in 1992 when AM General began

selling a civilian version of the M998Humvee. In 1998, General Motors (GM) purchased thebrand name and marketed three vehicles: the original Hummer H1, based on the Humvee; and theH2 and H3 models that were based on smaller, civilian-market GM platforms


15/81

15|P a g e

7.Global Partners of GM

Fiat Auto Spa of Italy, Fuji Heavy Industries Ltd., Isuzu Motors Ltd. and Suzuki Motor Corp. of

Japan, In addition, GM is the largest shareholder in GM Daewoo Auto & Technology Co. of

South Korea. GM also has technology collaborations with BMW AG of Germany and Toyota

Motor Corp. of Japan Vehicle manufacturing ventures with many companies including Toyota,

Suzuki, Shanghai Automotive Industry Corp. of China, A VTOVAZ of Russia and Renault SA of

France founded in 1908 has been the global automotive sales leader since 1931. Manufacturing

operations in 32 countries and its vehicles are sold in more than 190 countries. In 2002, GM sold

more than 8.6 million cars and trucks, nearly 15 percent of the global vehicle market with

turnover of 192 billion dollars. Global headquarters is at the GM Renaissance Center in Detroit.

Non automotive products also include Locomotives, Diesel engine, Gas turbines, DefenseEquipment Financial Products Information management & communication

Chevrolet brand has been part of the Indian landscape before our Independence. These cars were

imported or assembled at a plant of General Motors India which was opened in 1928. The first

car plant in India! Many of the cars are still running the roads in India.

8. GM in India before Independence

Chevrolet brand has been part of the Indian landscape before our Independence. These cars wereimported or assembled at a plant of General Motors India which was opened in 1928. The first

car plant in India! Many of the cars are still running the roads in India.

100 % subsidiary of General Motors Corporation USA, State of the art plant at Halol Gujarat &

Start of sales on June 27, 1996


16/81

16|P a g e

ASIA PACIFIC OPERATION [APO]

The General Motors Group worldwide consists of the various car newly acquired partly or

fully owned subsidiaries

· Fiat Auto Spa (20% market share

· Fuji Heavy Industries Ltd.

· Isuzu motors Ltd.

· Suzuki Motors Corp.

· Daewoo Auto & Technology Co (DAT)-now known as GM-DAT

ORGANIZATIONAL STRUCTURE

Pr esently its arms are divided as per the decentralization policy of GMC into various

geographic regions:

· GMC, Corporate Affairs

· NAO, North America Operations

· LAO, Latin America Operations

· GME, General Motors Europe

· APO, Asia Pacific

Brief Information

1. GMC, Corporate Affair s : Detroit


17/81

17|P a g e

2. NAO, North America Operations

3. LAO, Latin America Operations: Brazil, Argentina

4. GME, General Motors Eur ope : Poland, Germany, Egypt, South Africa,

Hungary, Czech Republic.

5. APO, Asia Pacific Oper ations HQ: Singapore, Indonesia, Japan, China, Hong Kong,

Philippines, India, Australia, Malaysia, South Korea,

Thailand.

9. VARIOUS ARMS OF GM

Delphi Automotive Systems (DELPHI)

Ø Delphi is the world s most diverse supplier of automotive systems and components.

Ø Operating in 37 countries, Delphi offers expertise in the areas of chassis, interior, lighting,

electric, energy and engine management, and steering and thermal systems.

North American Operations (NAO)

Ø With a focus on offering its customers precisely targeted products, GM-NAO designs,

engineers, manufactures and markets vehicles for Chevrolet/ GEO, Pontiac - GMC,

Oldsmobile, Buick, Cadillac and Saturn.

Electro Motive Division (EMD)

Ø In the 1930 s, Electro-Motive changed the rail industry when the Zephyr diesel

locomotives run in more than sixty nations, and EMD still leads the way with AC

technology.

Ø EMD also supplies power for marine propulsion, offshore and land based drilling rigs,

Vehicle Sales, Service, & Marketing

Group

Warren Michigan,

Luxury car group Los Angeles , California + Mexico & Canada sales

offices.


18/81

18|P a g e

stationery generators and off-road vehicles.

Allison Transmission Division (ALLISON)

Ø Allison transmission is the world s leading designer, manufacturer and seller of themedium and heavy-duty commercial automatic transmissions.

Ø Founded in1915, Allison built its reputation in the aviation industry in the early 20s.

Ø In 1946 the company produced its first automatic transmission, and 1996 marks its 50th

year in the business.

Hughes Electronic Corporation (HUGHE S)

Ø Hughes designs, manufactures and markets advanced technology electronic systems,

products and services for the automotive electronics, telecommunications and space, and

aerospace and defense industries worldwide.

9.1 General Motors International Operations (GMIO)

Ø GMIO meets the demands of customers outside North America with vehicles designed,

engineered, manufactured and marketed under the name Opel, Vauxhall, Holden, Isuzu

and Saab nameplates.

9.2 General Motors Acceptance Corporation (GMAC)

Ø GMAC provides a broad range of financial servicing including vehicle and dealer

financing, car and truck mechanical service agreements, vehicle and home comers

insurance, and residential and commercial mortgage services in the United States and 27

other countries throughout the world.

9.3Corporate Affairs

Ø Corporate affairs provides the business sectors those common services that are most

efficiently delivered centrally; provides counsel in special areas of expertise as enablers

of strategy and policy development; and furnishes a single point of contact for consistent

communication and policy exchange with external entities.

9.4WWP World Wide Purchasing


19/81

19|P a g e

Ø The company has various arms for control and functioning. The arm, which controls the

Purchasing, is known as WWP World Wide Purchasing.

Located at: Warren, Michigan

Headed by: Harold R. Kutner

9.5Main Functions:

Ø To match costs with each currency sphere. Have global procurement. Reduce car

platforms to seven, with various model series arising from these platforms so that the

major components can be used identically without compromising on the individuality of

the car/truck. Help suppliers go global.

10. PRODUCTS PORTFOLIO

Ø Vehicles:

§ Passenger cars, Commercial vehicles - trucks, vans, buses & Sports

§ Vehicles. Vehicle Development & Technical Operations Group - Warren,

§ Michigan.EL1 - the first electric motor driven car launched in 1996 in USA by

§ DELCO motors a subsidiary of GMC.

Ø Locomotives, diesel engines, gas tur bines:

§ Electro Motive Division (EMD) est. 1930: LaGrange, Illinois. - Provides

§ Zephyr diesel locomotive engine used in over 60 countries, AC technology,

§ Stationary + vehicle loaded generators, marine propulsions, offshore + land based drilling

rigs.

Ø GM power tr ain Group - Pontiac, Michigan.

§ Delphi Harrison Thermal Systems - Lockport, New York.

§ Delphi Energy and Engine - Flint, Michigan

§ Delphi Interior and Lighting System - Warren, Michigan

§ Delphi Packard Electric Systems - Saginaw, Michigan.


20/81

20|P a g e

Ø Heavy-duty automatic transmissions

§ Allison Transmission Division (1915) - Indianapolis, Indiana.

§ Financial products - car finance, property mortgage etc.

§ Defense equipment

§ Delphi Chassis System

§ Hughes Aircraft Company - Los Angeles, California.

§ Information management and communication

§ Delco Electronics Corporation - Kokomo, Indiana.

§ Hughes Electronic Corporation providing solutions in telecom, space and aerospace as

well as for the defense industries worldwide.

§ Apart from these

§ GMAC / MIC - Human Resources - Detroit, Michigan


21/81

21|P a g e

11.INTRODUCTION TO GM INDIA:

2.1 Company Profile

Ø Manufacturing Plants

(1) Talegaon Plant Capacity: 200000 cars per annum

(2) Halol Plant Capacity: 85000 cars per annum

§ Plant Land area - 695000 m2

§ Total plant size - 44000 m2

A Shift: 6 am to 4 pm (6 working days)

B Shift: 4 pm to 2:00 am (6 working days)

General shift : 8:30 am to 5:30 pm (6 working days)

Ø Gurgaon, Haryana§ Marketing Head Office

§ North Zone OfficeØ Regional Sales / after sales Offices:

" Mumbai, Chennai & Calcutta

Ø R & D- Technical Centre, Bangalore


22/81

22|P a g e

12. GMI- HALOL

General Motors India Ltd. incorporated on 15th August 1994, is 100% subsidiary of General

Motors Corporation (GMC). GMC provides technology transfer in the following areas:

Product specifications, Designs, Information, Part list with drawings / Releases Product

modification and engineering changes for Indian conditions, Test methods and procedures,

Vendor assessment/cert ification and development and persuade OE suppliers for tie ups.

" Site area : 172 Acres

" Plant area : 65,000 m2

" Total plant size : 44000 m2

" Utilized area : 27000 m2

" Star t of Pr oduction : June 1996

" Capacit y : 85,000 unit / year

(Expansion underway)

" Shift : 3 shift, 6 days / week

" Management systems : GM Global Manufacturing System

: ISO 9001

: ISO 14001

" Automation level : Medium


23/81

23|P a g e

ABOUT THE ORGANIZATION:

GM VISION

§ Be the world leader in transportation products and related services.

§ We will earn our customers enthusiasm through continuous improvement driven by

the integrity, teamwork & innovation of GM people

GM MISSION

§ To profitably sell 2, 00,000 vehicles in 2010 and to be the Preferred brand of choice with

all our products in top 2 ranking of J.D. Power.

GM Core Values

§ Customer Enthusiasm

§ Integrity

§ Team Work

§ Innovation

§ Continuous Improvement

§ Individual Respect and Responsibility

GM Cultu ral Pr ior ities

§ Enhance our Product and Customer Focus

§ Act as One Company

§ Embrace Stretch targets

§ Move with a sense of urgency


24/81

24|P a g e

QUALITY POLICY

§ General Motors India is committed to manufacture and deliver automobiles that conform

to GM global quality standards which will exceed the changing requirements of our

customers.

§ Continual improvement of our products processes and services will be achieved through

employee, dealer and supplier involvement.

§ Focus on customer satisfaction will drive our efforts to be a quality leader in our field

ENVIRONMENT POLICY

§ GMI is committed to protecting human health, natural resources & the local & global

environment.

§ GMI will continually improve its environmental performance.

§ GMI will comply with all applicable environmental laws and regulations.

§ GMI will practice effective pollution prevention by giving top priority to waste

prevention at the source, elimination or reduction of wasteful practices, and recycling.

13. INTEGRATED MANAGEMENT SYSTEM

Quality, the environment, and health and safety are all unified by the concept of risk.

Using three separate management systems within one organization is clearly time-consuming

expensive and inefficient.

By integrating your management systems, you can minimize duplication align your

objectives and reduce costs. An integrated management system (IMS) describes severalpreviously separate management systemsgrouped together to form a single system. For example,

it could combine ISO 9001:2000 (quality) certification with ISO 14001 (environment)

certification. A management system is integrated when at least two out of three possible systems

(quality, environment and health and safety) are integrated. The different possibilities are:

· Quality + Environment


25/81

25|P a g e

· Quality + Health & Safety

· Environment + Health & Safety

· Quality + Environment + Health & Safety

The aim of an integrated system is to streamline processes even further and avoidduplication. However, just because a system is integrated does not mean less attention is paid to

auditing individual systems. The system must conform to the requirements of the individual

standards, in order to maintain a high level of credibility and effectiveness.

Implementing Integrated Management System (IMS) requires preparing integrated

QMS/EMS and documenting procedures required by ISO 9001:2008 / ISO 14001:2004.

IMS(IntegratedManagementSysytem)

QMS (Quality

ManagementSystem)

EMS(Environmental

ManagementSystem)

GMS(Global

manufacturingSystem)

(i.) QMS(Quality Management System) :

Aquality management system(QMS) can be expressed as the organizational structure,

procedures, processes and resources needed to implementquality management. QMS has tended

to converge withsustainabilityandtransparencyinitiatives, as both investor and customer

satisfaction and perceived quality is increasingly tied to these factors. Of all QMS regimes the

ISO 9000andISO 14000series are probably the most widely implemented worldwide - theISO

19011auditregime applies to both, and deals with quality and sustainability and their integration.


26/81

26|P a g e

(ii.) EMS (Environmental Management System):

Environmental management system(EMS) refers to the management of an organization's

environmental programs in a comprehensive, systematic, planned and documented manner. It

includes the organisational structure, planning and resources for developing, implementing and

maintaining policy for environmental protection. The term can also refer to software systems for

organizational environmental management.

An Environmental Management System (EMS):

o Serves as a tool to improve environmental performance

o Provides a systematic way of managing an organization s environmental affairs

o Is the aspect of the organization s overall management structure that addresses immediate

and long-term impacts of its products, services and processes on the environment

o Gives order and consistency for organizations to address environmental concerns through

the allocation of resources, assignment of responsibility and ongoing evaluation of practices, procedures and processes

o Focuses on continual improvement of the system

(iii.) GMS (Global Manufacturing System) :

GMS is a set of standards which describe the what, why and how to organize our

manufacturing operations in order to eliminate waste. Within GMS, waste is defined as

anything that our customers are not willing to pay for. Elimination of waste is the only way

to survive as a company.

The structure of GMS is organized around five principles

o People Involvement,

o Built-in Quality,

o Standardization,

o Short Lead Time

o and Continuous Improvement.

Within each of these principles are several unique operating concepts named Elements

which define particular ways to accomplish a particular part of our manufacturing effort. Intotal, there are 33 Elements, each one belonging to one of the 5 Principles. The most

important thing to understand about the Principles and Elements is that it takes ALL of them

to form GMS.


27/81

27|P a g e

14.GM INDIA PRODUCTS

CHEVROLET OPTRA

It is a masterpiece of contemporary automobile design. It has a Total Noise Reduction System

(TNRS), which leads to total sound-proof interior and an All-Wheel Independent Suspension

(AWIS) which gives a velvet smooth ride. Its engine is amazing with 16-valve, D-Tec, 1.8L,

High-compression DOHC engine with 32-bit ECM pumps out 115 PS of power. With its high-

tension steel safety-cage , SRS airbag, crash bars, crumple zones, collapsible steering, disc

brakes and three-point safety belts for every occupant, the Optra s safety standards are without

doubt world class.

CHEVROLE T TAVERA

The new Chevrolet Tavera is designed to make every moment on the road, absolute & delightful.

It has an Advanced Suspension Setup, which is specially designed to increase the comfort of its

plush interior, while giving it unmatched ruggedness. Its Amazing Insta-Torque Engine is the 2.5

L Direct Injection turbo diesel power plants, which eliminate turbo-lag. It responds eagerly with

instant torque the moment you press the accelerator, which means, no loss of power, no idling

and certainly no waiting after start and before shut down. It has and excellent low-end torque

due to which you need not to change gears frequently in city traffic conditions. It is also

equipped with Triple Row Air-conditioning System, which gives the facility of individual A.C.

for each row.


28/81

28|P a g e

CHEVORLE T AVEO

This is designed to enjoy the driving on the fast track. It is having some advanced features and it

was made to have the customer of urban areas in mind.


29/81

29|P a g e

CHEVORLE T U-VA

This is a small segment car. This car is seducing to all type of customer whether they are from

metros, urban or village area particularly of because it s low area.

CHEVROLE T SPARK

There are three models of Chevy spark in the market namely LS,LT & Base. The Four cylinder

S-Tech design is said to provide a very flat torque curve, and exceeds most performance

expectations. With the refined engine the spark provides you greater power for a more relaxing

drive at sustained higher speeds for longer journeys. With the completely new pedal box design

and durable plastic molded pedals and a noise-insulating material between the engine

compartment and the dashboard, improves the sound insulating effect. Chevrolet claims fuel

figure as 17.85kpl with a top speed of 156 Kmph.


30/81

30|P a g e

CHEVROLET CAPTIVA

Captiva was launched in January, 2008. The SUV has a 1991cc, 4-cylinder, 16 valve, VCDi

diesel engine which outputs maximum power of 150ps@4000 rpm and torque of 320Nm@2000

rpm. The Rs.17.73 lakh (ex-showroom, Delhi) Captiva is available in five colors.


31/81

31|P a g e

CHEVROLE T SAIL

Sail was launched in November, 2012 in india. Moreover, On 11 January 2010, Shanghai-GM

introduced the all-new Chevrolet Sail. [12] The car was designed and engineered by the Pan Asia

Technical Automotive Center (PATAC). A 1.2-liter S-Tec2 64kW engine and a 1.4-liter 76kW

S-TEC III engine are available. The transmission options include a five-speed manual and a five-

speed electronic manual transmission (EMT). Airbags, central locking, AUX in / USB input and

power steering are standard equipment


32/81

32|P a g e

15. VARIOUS DEPARTMENT OF GMI

1) Global Pur chasing and Supply Chain

§ Global Purchasing and Supply Chain is the organization responsible for acquiring

parts for vehicles, equipment for plants and products and services used globally by

General Motors.

§ Because GM operates in four global regions, suppliers are able to do business in

unprecedented volumes and have the opportunity to become global players.

§ GPSC the name was changed from Worldwide Purchasing/Order to Delivery in

March 2005 is an integral part of GM.

§ GPSC activities touch all aspects of the business, including Research and

Development, Engineering, Manufacturing and Sales and Marketing

2. Manufacturing Depar tment:

Ø GMI Manufacturing department does not fabricate any component of the car and is only

responsible for assembling various components of the car supplied by the purchase

department to bring final product, the car.

Ø Manufacturing department consists of body shop, paint shop and assembly line.

3. Finance Department:

Ø Finance Department looks after all the monetary transactions and is responsible for

budgeting.

4. Product Engineering:

Ø The department is responsible for getting the localized parts only those, which confirm

the GM specifications.

Ø Even though, this department does not involve in designing of the parts, it tries account

for the value-engineered proposals put forward by the employees in order to improve the

part efficiency.

5. Quality Department:

Ø Quality department ensures the best quality to be delivered to customers.

Ø Quality department audits vehicles right from body shop till final buyoff of the vehicle.


33/81

33|P a g e

6. Maintenance Department:

Ø The maintenance department at General Motors India has a lot of responsibilities to be

taken care of.

Ø This department deals with the maintenance of all GMI equipments in manufacturing

departments. All the team members are trained to solve the problem immediately if

something is malfunctioning and that affects the production.

7. Human r esources depar tment:

Ø It deals with the training of the employees & recruitment of new persons .It also takes

care of facilities available for team members. It also takes care of the employees

relationship.

Ø Human Resource management includes (1) conducting job analyses, (2) planning

personnel needs, and recruitment, (3) selecting the right people for the job, (4) orientingand training, (5) determining and managing wages and salaries, (6) providing benefits andincentives,(7) appraising performance, (8) resolving disputes, (9) communicating with all

employees at all levels. Formerly called personnel management.

Human Resource management includes various sub functions such as:

Ø Training Function.

Ø Recruitment Function.

Ø Payroll Function.

Ø Industrial Relation.

Ø Safety & Security.

Ø Administration.


34/81

34|P a g e

16.PRODUCT ENGINEERING DEPARTMENT

General Motors India is mainly a manufacturing unit of General Motors Corporation for the

Completely Knocked down (CKD) vehicles. The vehicle produced by GM India are designed &

developed by the different engineering centers of GM Corporation [e.g. International Technical

development Centre ( ITDC), Opel, Germany or GM Do Brazil or GM Daewoo Auto &

Technology Co ( GMDAT), South Korea ] or by its alliance partner company ( example, Isuzu

Motors Limited, Japan).

In order to fulfill (i) the local regulatory requirements or (ii) the facilitation of the localization (

due to local supplier s process and technology ) or (iii) the product improvement based on the

field / customer feed back, if any design change becomes essential, Product Engineering co-

ordinate and approve the required design changes.

The activities of Product engineering can be broadly classified in the following areas:

· New Project and Product Description related activities.

· Engineering activities for product development, current product improvement and

localization.

· Testing & validation of products.

· Certification and compliance with applicable CMVR regulations.

16.1 PRODUCT DEFINITION

Based on the customers requirements input given by Marketing Department of GMI, product-engineering work together with the relevant engineering center of GM Corporation, to define

the technical specification of the vehicle and its engineering part list. Specific Product

developments are carried out by the responsible Engineering Centre to adopt the original

vehicle to Indian regulatory, environmental and customer specific requirements. During the

phase from program approval to Start of Production (SOP), stages like Alpha, Beta, Gamma,


35/81

35|P a g e

Pilot etc. vehicle builds are carried out under the supervision of GMI-PE (along with the

support of responsible engineering center) for:

§ Engineering Prototype vehicles- Alpha build.

§ Confirmation of the required engineering part list -Beta builds.

§ Verification of the manufacturing suitability & readiness- Gamma & Pilot build.

§ Making prototype vehicle available and testing to check the suitability of the product

designed and adopted by GM International design centre for local conditions.

§ Lead the resolutions of the product build problems. PE also supports marketing and after

sales for making the owner's manuals supplied with the vehicles.

§ PE maintains the technical library containing documents of external origins, like

engineering drawing (in hard copy or in micro-film i.e. aperture cards), material

specification, standards for test methods and other engineering related technical literature.

PE also maintains documents from GM engineering centers or different international

standards and internally originated documents like statements of Requirements etc. On

request in the specified format, PE issues the copies of the required documents to the

requester.

§ Any engineering change in the component is communicated by PE through Engineering

Change Order (ECO). ECO is released by the PE, after verifying whether the content of

the ECO is approved by the responsible engineering center and relevant functions within

GM India.

16.2 CURRENT PRODUCT ENGINEERING

· Problems reported in priority lists are reviewed, analyzed and resolved by problem

resolution teams (CPIP and IRT). Lead role and Coordination of CPIP is done by CPE as

per their procedure.· Current Product Engineers represent PE in In-plant / field product problem resolution

teams (CPIP and IRT) and takes lead role in resolving problems related to Engineering

through detailed analysis and by co-ordination with other Product Engineers and ECs of

GM and its alliance partners.

· Service Alerts raised by product problem resolution team (CPIP) is reviewed and


36/81

36|P a g e

approved by Current Product Eng.

· Engineering Deviation Requests (EDR) related to the on going productions are reviewed

and approved by Current Product Engineering in consultation with other product

engineers and ECs of GM.

· Special assistance in resolving critical customer complaints are provided by Current

Product Engineers.

· Various types of assistance to ECs of GM worldwide are provided by Current Product

Engineers in product improvement process.

16.3 Testing before Launch of new vehicle

· Before launching a new vehicle in-country testing in different pre-determined routes as

specified by the responsible engineering center is carried out. PE conducts the vehicle

testing & monitors the checkpoints as per the directives given by Engineering Center

(EC).

· Vehicle testing is also conducted to verify the functional performance of the various

localized components.

· PE is also involved in the analysis of any problem faced by manufacturing department

during the regular production of vehicles, and helps in resolving the problem.

· PE is also involved as a key member of the cross-functional team for the resolution of the

field problems referred by marketing and after sales to PE.

· Moreover as a part of Continuous Improvement Process, PE, as per request made in

Global Product Instrument Panel (GPIP), co-ordinates with EC's to implement specific

product changes (if required).


37/81

37|P a g e

16.4 Localization

· Localization of a component of the vehicle is a cross-functional activity in GMI. Purchase

and Supply Department plays a lead- role in the localization activities. PE plays a

supportive role in this process, starting from specifying the technical requirements of the

component to verify whether the localized component is

· Fulfilling the specified requirements, to obtain engineering approval as a part of Product

Part Approval Process (PPAP).

· In the process of localization, if there are any deviations to the specified design, PE co-

ordinates with EC to get an approval of that deviation.

· During the introduction of new variants of an exiting vehicle, certain components are

newly required, which are non-functional. PE consults with engineering centers. And in

those cases, PE handles the development of the items if full responsibility is given by

engineering centers.

16.5 Testing and Validation

· Once the activity related to the launching of vehicles such as Prototype / Pilot build are

finalized with the coordination of Project Engineering, planning and preparations parts

for the in-country testing and validation.

· Similarly as and when the outlook for the availability of localized test parts are available

through Localization Engineers, planning and preparations start for the in-vehicle testing

and validation.

· Test requirements for the vehicle validation and component validation are defined by

Project Engineering or by Localization Engineers or by Current Product Engineers or by

representatives of EC of GM worldwide or alliance partners.

· Test and Validation team executes the durability tests and validation as defined and

provides the test incident details and other reports to relevant people time to time to

facilitate periodical reviews and end of test decision-making.

It has a facility that acts as the service point and also testing point for all the vehicles. The


38/81

38|P a g e

components or parts that undergo design changes and are to be validated later, and are fixed

here. In the validation of a particular car, the vehicle is driven in the pre-defined test track /

route and periodical checking of certain parameters are conducted to determine the functional

performance and durability on the Indian road conditions against the mileage. Also the time

interval of refilling / replacement of the different consumables like coolant, air or fuel filers,

engine belts, spark plugs, gearbox oil etc. are checked. During the validation of the vehicle, if

any squeaking or rattling noise is noticed, the root cause analysis of the same is done here.

16.6 Pr oduct Engineer ing- Document Control

All the engineering data, drawings are maintained in this section. The component drawing or

installation drawings are kept in micro-films. These are called aperture cards.

The entire engineering and part list related manuals, files, and different specifications and test

methods for vehicle components adopted by General Motors are maintained in the technical

library. In a word this is the technical data bank for all the information to build the vehicles

and their servicing.

16.7 Roles and Responsibilities

Approval of parts by signing off of Approval Documents (ADs), whenever the AD specifies

that approval by GM India Product Engineering is allowed. The approval is done on the basis

of the parts recommendation.

16.8 Responsibilities of a Product Engineer

A Product Engineer is responsible for preparation of Statement Of Requirements (SOR),

release of SOR to purchase executives, taking part in technical reviews, discussing the

engineering changes proposed by sub-contractors with the EC s, conveying the agreed

/approved engineering changes by EC to sub-contractors, raising Engineering Work Order

(EWO) request for the engineering changes and for the change from imported components to

local components at appropriate time.

· Responsibility for clarifying approval requirements to the sub-contractor, freezing the


39/81

39|P a g e

testing plan and testing time plan with the sub contractor, monitoring the testing, planning

the vehicle validation and executing it by giving proper inputs to the validation group.

· Responsibility to convey the test incident reports to the sub-contractor.

· Responsibility to get the Test Incident Report (TIR) from the sub-contractor and for

scrutinizing the submissions for approval made by sub-contractor, compile these with

GMI internal documents and submit the recommendation for approval.

· Responsibility for making the local drawing of the part.

· Responsibility for releasing engineering changes.

· Responsibility for approving their respective parts after proper checking and validation

with the SQA department.

17.LOCALIZATION


40/81

40|P a g e

Localization is a process of making car components locally available in order to ensure cost

reduction and to optimize the procurement activity.

Localization of a component of the vehicle is a cross-functional activity in GMI. Purchase and

Supply Department plays a lead- role in the localization activities. PE plays a supportive role in

this process, starting from specifying the technical requirements of the component to verify

whether the localized component is fulfilling the specified requirements, to obtain engineering

approval as a part of Product Part Approval (PPAP).

17.1 NEED OF LOCALIZATION

Localization is a cost efficient strategy, which is being used by almost all the car-manufacturing

companies in India. It is essential for a Multi National Company to localize the parts of its

product in order to cut down on the manufacturing cost and importing costs. The procurement is

done from local suppliers who are potentially sound in quality, service, technology and

competitive pricing. With the help of localization the company will be able to manufacture

quality cars at low affordable prices, in order to meet the demand of the customers and to survive

in the highly competitive automobile segment.

17.2 LOCALIZ ATION PROCEDURE

1. For localization Product Engineering gives the engineering input (validation time & cost)

to Finance / Purchase / Product Planning & Program Management to decide the

business case on whether a part to be taken into localization or not.

2. To start the localization, Product Engineering releases the Statement of Requirement

(SOR).

18.STATEMENT OF REQUIREMENT (SOR)

18.1 NEED FOR SOR:


41/81

41|P a g e

The Statement of Requirement (SOR) is provided to assist potential suppliers in quoting for

development, tooling including checking gauges, prototyping, manufacturing and testing of parts

listed.

It provides the following information to the supplier:

Ø Who is the Responsible Engineer for the concerned part?

Ø Part Description: Part Description is provided for the supplier, where exactly the part, which

is being localized, is assembled on the vehicle.

Ø In the SOR the Key Product Characteristics (KPC) were defined. For example, the supplier

must meet the required dimensions and tolerances strictly which are mentioned on the drawing.

Ø List of Engineering Drawings: The Engineering Drawing list provides the list of main

drawings and child drawings needed for making the part.

Ø Specifications: In this Specification table, the specifications, which are to be followed while

making a part by the supplier, are listed. The specifications are strictly according to the

Engineering Daewoo Standards or Automotive Industry Standards or Japanese Industrial

Standards.

Ø Supplier Part Testing: The supplier must perform all the tests specified on the drawing and

any additional tests as specified by the General Motors India Private Limited in this SOR.

Ø GMI Testing: The localized components must undergo validation testing in accordance with

the time plan developed by the supplier.

18.2 SOR RELEASE PROCESS:


42/81

42|P a g e

Design Release Engineer (DRE) to write the SOR taking into consideration of:

Ø Applicable drawings and specifications

Ø Generic Template of the SOR Check list

Approval of the SOR is done by signing off by relevant approval authority (DIRECTOR, PE).

Ø After getting the approval of the SOR, corresponding DRE communicates the SOR release to

purchase and to PE-Document controller by sending the soft copy of the SOR by electronic mail.

19. PROJECTS:

19.1 INTERIOR AND EXTERIOR FUNCTION:

19.1.1 PROJECT ON DOOR LATCH: PROJECT NO.1


43/81

43|P a g e

ISSUE: After certain particular of cycles the door is unable to unlock.

TYPE OF ISSUE: Warranty issue.

IPTV(INCIDENT PER THOUSAND VEHICLES):10

CPV (COST PER VEHICLE): 7.21

CASES REPORTED: 10

DESCRIPTION:

DOOR: A door is a movable structure used to open and close off an entrance, typically consistingof a panel that swings on hinges or that slides or spins inside a space. A vehicle door is a

partition, typically hinged, but sometimes attached by other mechanisms such as tracks, in frontof an opening which is used for entering and exiting a vehicle. A vehicle door can be opened to

provide access to the opening, or closed to secure it. These doors are similar to doors used inbuildings.

DOOR LATCH: A door latch is defined as a device or mechanism that is to close and open thedoor, it is also used to lock and unlock the door.

PROBLEM (ISSUE): After the vehicle has manufactured at plant successfully, there is no

problem but when the customer has purchased the vehicle and after the vehicle has covered

certain thousands of kilometres the customer faces difficulty to unlock the door.

This is a warranty issue and we have collected a lot of door latches at our warranty department.

PREVIOUS DESIGN OF DOOR LATCH (WARRANTYPART): As you note from the below picture

there is a slot at the door latch which can move upward &downward.

In the new design wen have deleted the slot & we have fixed that point (pivot).


44/81

44|P a g e

PROPOSED DESIGN FAILED AT PRODUCTION TRAIL RUN (PTR): The door latch below failed

because the adjustable clip (highlighted) was fouling with glass run channel.

Slot

Rod can

reciprocate up

& down.


45/81

45|P a g e

PROPOSED DESIGN PASSED AT PRODUCTION TRAIL RUN (PTR): As shown below this

modified part passed in PTR because we have removed the slot and made the point to be fixed (

hinged).

Adjustable clip is

provided in place of

slot.


46/81

46|P a g e

19.1.2FRONT DOORS SQUEAKS / ABNORMAL NOISE: PROJECT NO.2

ISSUE: Squeak noise comes at the time of opening and closing of front door.

TYPE OF ISSUE: Field issue

DESCRIPTION OF PROBLEM: We have observed that the vehicle does not face any problem

after production but when the vehicle ran about 4000Kms (approx.)the rubber tends to get wear

and also get displaced inside the door as a result of that the dust particles and foreign particles

introduced into the door and causes the metal to metal contact between the door link and the door

and the squeak noise prevails.

TASK PERFORMED: We have fixed the dust preventing rubber to the door link.

Previous case


47/81

47|P a g e

After 4000Kms

New part introduced.

PART NOT


48/81

48|P a g e

After fitment


49/81

49|P a g e

19.1.3 CARGO DOOR DENT ISSUE: PROJECT NO.3

ISSUE: Dent and Waviness are observed at the cargo door near the garnish plate.

TYPE OF ISSUE: Plant issue, Global Customer Audit issue.

CASES REPORTED: Almost in every vehicles.

PPH: 100% (approx.)

DESCRIPTION OF PROBLEM: Vehicles investigated at Global Customer Audit (GCA) is

being captured with a dent and waviness at the Cargo door near the garnish plate and it is

concerned with the Mutilation factor, moreover these dents and waviness is being created during

the manufacturing processes.

ROOT CAUSES:

1. Trolley at which vehicle is loaded is transferred from one station to another station manually,

due to which sometimes the cargo door bangs on the handle of the trolley and results into the

dent on the cargo door.

2. Most of the cargo doors are defected through the supplier end only.

3. Due to transportation dents were created on the cargo door.

4. Due to lack of knowledge of the team members, they are transferring the car body by pushing

it from cargo door results in the form of dent.

PROPOSED SOLUTIONS:

1. Properly handle the car body.

2. To use the structural patch behind the cargo door.

ACCEPTED SOLUTION:

we have used two structural patch on Cargo door at two location.


50/81

50|P a g e

STRUCTURAL PATCH


51/81

51|P a g e

19.1.4 CHECK LINK STOPPER PLATE FOULING WITH REAR DOOR INNER PANEL:

PROJECT NO.4

ISSUE: Check link fouls with inner panel which results in abnormal noise.

TYPE OF ISSUE: Plant issue, Global Customer Audit issue Field issue.

CASES REPORTED: Almost in every vehicles.

PPH: 100% (approx.)

DESCRIPTION OF PROBLEM: Due to various Mutilation factors during the manufacturing

time check link starts to foul with inner panel and which creates an abnormal noise at the rear

door.

ROOT CAUSES:

Root causes has not been found yet.

PROPOSED SOLUTIONS:

1. manually grind the panel of the rear door upto 2.5mm to 3mm.

2. correction should be done at the tool level.

PROPOSAL ACCEPTED

Done correction at tool level to reduce reinforcement trim height by 2.5 to 3 mm to maintain 3

mm gap in-between check link stopper plate & door reinforcement at vehicle level.

STATUS: Under Implementation


52/81

52|P a g e


53/81

53|P a g e

19.2 CHASSIS FUNCTION:

19.2.1 BRAKE PIPE FOULING WITH STEERING SHAFT: PROJ ECT NO.5

ISSUE: Brake pipe fouling with steering shaft. This problem is observed at Global Customer

Audit (GCA) department

TYPE OF ISSUE: Global Customer Audit issue.

STEERING SHAFT: 1) Steering shaft.

OBSERVATIONS:

· Brake pipe fitted in trim line and it is tightened at the chassis line in under body station.

· Before tightening the flaring nut of the brake pipe there was a gap observed between pipe

and shaft around 15 to 20mm.

· When we were tightened the nut the gap reduced to 10-15mm

· Torque used in order to tightening the nut is 15.7-16mm.· The pipe got twisted after tightening the nut & it fouls with steering shaft.

TASKS PERFORMED:

· We have done the tool calibration & it had found correct.

· As it was a design issue, I have changed the design manually in order to get more gap.

· Trail done on vehicle & found no problem.

CURRENT SITUATION:

· Sample has sent to Design Release Engineer in order to confirm that whether the part is

OK regarding the design point of view.


54/81

54|P a g e

Regular part

So to avoid that situaton

Break pipe

We have changed the dimensions of the gap which

is highlighted in the picture and it has reduced

from

Regular part Manual sample


55/81

55|P a g e

R eg ular part Manual part

The g ap between the brake p ipe and the steering shaft increases from 10mm to 30mm.


56/81

56|P a g e

19.2.2 BRAKE PIPE CLIPS: PROJECT NO.6

ISSUE: Brake pipe clip falls.

TOTAL NUMBER OF CASES: 5 cases is reported at Global Customer Audit (GCA)

ISSUE DESCRIPTION:

· Brake pipe clip falls in plant during the fitment due to less grip of the clip,

· Brake pipe outer diameter =5mm

· Inner diameter of w-shaped clip=5 to 5.7mm

· In order to hold the brake pipe very firmly & tightly inner diameter of the clip < 5mm.

· As the inner diameter of the clip is not less than 5mm clip mounting location on the

brake pipe &position are not consistent.

· After fasten the rake pipe flaring nut in chassis, the pipe get twisted &causes the clip to

come out from its locking position.

STEPS TAKEN IN ORDER TO SOLVE THE ISSUE:

We have changed the design of the clip previously we were using the W shaped clip but now

we are using M-shaped clip with inner diameter =4.5 to 4.6mm

As the inner diameter of the newly introduced clip is less than 5mm, therefore it holds the brake

pipe very firmly & strongly.

W-SHAPED: M-SHAPED:

PERFORMANCE OF M- SHAPED CLIP


57/81

57|P a g e

19.3HEAT VENTILATION AND AIR CONDITIONINGFUNCTION

PERFORMANCE OF W- SHAPED CLIP


58/81

58|P a g e

19.3.1 RADIATOR FAN FOULING WITH SHROUD: BHARAT STAGE 3: PROJ ECT

NO.7

ISSUE: The clearance between the radiator shroud and fan is less & as a result radiator fan fouls

with shroud.

TYPE OF ISSUE: Plant issue and field issue.

IPTV: 100% (APPROX)

CASES REPORTED: 6

DESCRIPTION:

RADIATOR FAN: Radiators are used for cooling internal combustion engines mainly in

automobiles or any similar use of such an engine. By passing a liquid called engine coolant

through the engine block where it is heated, then through the radiator itself where it loses heat tothe atmosphere, and then back to the engine in a closed loop. Engine coolant is usually water-

based, but may also be oil. It is common to employ a water pump to force the engine coolant to

circulate, and also for an AXIAL FAN to force air through the radiator.

Radiator fan

Shroud


59/81

59|P a g e

ROOT CAUSES: In this case we found the following causes:

1) The radiator hole dimension and location in 2D and initial 3D data are not identical.

2) The holes for the radiator mounting on the deflector panel had a variation of 5mm between the

drawing of supplier and CAD.

FIGURE:

Solutions: Shift the Shroud holes by 5mm in negative z direction so that the shroud shall mount

on the radiator which will increase the gap between shroud and fan.

As a result the gap increases from 20.5mm to 23.5mm

19.3.2 RADIATOR FAN FOULING WITH SHROUD: BHARAT STAGE 4 : PROJECT

NO.8


60/81

60|P a g e

ISSUE: The clearance between the radiator shroud and fan is less & as a result radiator fan fouls

with shroud.


IPTV: 100% (APPROX)

CASES REPORTED: Almost in every vehicle

DESCRIPTION: In BS-4 vehicles radiator fan is fouling with shroud as it is loose at its fitment

as there is less griping between the lugs on the shroud and the deflector panel. As a result of it

pushes out of the deflector panel or radiator and start to foul with radiator fan.

ROOT CAUSES:

1.The lug comes out of the radiator as we were unable to maintain the Warpage of the shroud. As

the result of that there was a fitment problem.

PROPOSED SOLUTIONS:

Shroud with Lug


61/81


62/81

62|P a g e

ISSUE: Fitment problem arises during the assembly of radiator outlet hose into the power train

integration hose due to which there is the issue of coolant leakage in an engine compartment.


IPTV: 100% (APPROX)


DESCRIPTION: As a process the radiator outlet hose is inserted in the power integration hose.

At the mating portion is clamped with the worm clamp but due to change in the cross sectional

area (i.e. outer diameter) of the radiator hose the rubber hose of PTI get slipped and as a result of

that coolant starts leaking.

ROOT CAUSES:

1.The change in the cross sectional area of the radiator outlet hose causes the PTI hose to slip.2.There is a bulging at the starting of the radiator outlet hose instead of the uniform cross

sectional area.

CONTAINMENT:

1.Wipe out the coolant from the opening of the hose as coolant acts as a lubricant during the

fitment of the hose. The Radiator outlet pipe will go hard in the Rubber hose as compared to

coolant in it. This will avoid the slippage of the Metal pipe on tightening the clamp.

2.White mark has been provided on the radiator hose pipe, so as to fit the PTI hose upto that

extend.

3.Use the Wire Clamp instead of Worm Clamp.

Wire Clamp Radiator outlet hose Wire Clamp Radiator outlet hose


63/81

63|P a g e

OK PART NOT OK PART

Leakage not observed Leakage observed

PROPOSED SOLUTIONS:

5. To change the design of the radiator outlet hose, one should maintain the uniform cross

sectional area of the radiator outlet hose throughout its length.

6. Provide one more flaring at the end of the bulge.

7. PTI hose should be made up of metal.

ACCEPTED SOLUTION:


64/81

64|P a g e

We have ordered the supplier of the radiator outlet hose to provide one more flaring at the end of

the bulge.

Flaring provided at the end of the bulge

19.3.4 INTERCOOLER HOSE LENGTH SHORT: PROJECT NO.10


65/81

65|P a g e

ISSUE: Rubber intercooler hose length has become short when it is assembled between the two

metallic hoses of the intercooler.


PPH: 100% (APPROX)


DESCRIPTION: As per CAD specification there should be 40mm overlap between the rubber

hose and intercooler hose, but practically rubber hose has become short during assembly which

results in improper fitment of the intercooler hose.

If we fit the rubber hose from one side at an overlap of 40mm then we are getting the overlap of

only 20mm at the other side, but as per specification we should meet the overlap of 40mm.

ROOT CAUSES:

1. Both the intercooler hoses are not in the same plane.

2. Both the hoses are not collinear.

3. During the manufacturing processes the inter distance between the two hoses can be

changed.


66/81

66|P a g e

ANALYSIS DONE ON RUBBER HOSE:

CONTAINMENT:

1. We will going to provide the Washer at the bottom of intercooler, so that the intercooler

will shift upwards and as a result the inter distance between the both the pipes will

decrease and we will attain the proper overlapping as per specification.


67/81

67|P a g e

19.4 NOISE, VIBRATION AND HARNESS FUNCTION:

19.4.1 STUDY ON THE BASICS OF SOUND AND NOISE:

WHAT IS SOUND?

Sound may be defined as any pr essure var iation (in air, water or other medium) that thehuman ear can detect.

The most familiar instrument for measuring pressure variations in air is the barometer. However,

the pressure variations which occur with changing weather conditions are much too slow for the

human ear to detect and hence do not meet our definition of sound. But, if variations in

atmospheric pressure occur more rapidly at least 20 times a second they can be heard and

hence are called sound. (A barometer cannot respond quickly enough and therefore cannot be

used to measure sound). The number of pressure variations per second is called the frequency of

the sound, and is measured in Hertz (Hz).

WHAT IS NOISE?

Yet, too often in our modern society, sound annoys us. Many sounds are unpleasant or unwanted

these are called noise. However, the level of annoyance depends not only on the quality of the

sound, but also our attitude towards it. The sound of his new jet aircraft taking off may be music

to the ears of the design engineer, but will be ear-splitting agony for the people living near the

end of the runway. But sound doesn't need to be loud to annoy. A creaking floor, a scratch on a

record, or a dripping tap can be just as annoying as loud thunder.

Worst of all, sound can damage and destroy. A sonic boom can shatter windows and shake

plaster off walls. But the most unfortunate case is when sound damages the delicate mechanism

designed to receive it the human ear.

TYPES OF NOISES:-

When measuring noise, we need to know the type of noise so that we can choose the parameters

to measure, the equipment to use, and the duration of the measurement. Often we need to use our

ears to pinpoint the annoying features of the noise, before making measurements, analysing and

documenting them.

CONTINUOUS NOISE

Continuous noise is produced by machinery that operates without interruption in the same mode,

for example, blowers, pumps and processing equipment. Measuring for just a few minutes with

hand-held equipment is sufficient to determine the noise level. If tones or low frequencies are

heard, the frequency spectrum can be measured for documentation and further analysis.

INTERMITTENT NOISE

When machinery operates in cycles, or when single vehicles or aeroplanes pass by, the noise

level increases and decreases rapidly. For each cycle of a machinery noise source, the noise level


68/81

68|P a g e

can be measured just as for continuous noise. However, the cycle duration must be noted. A

single passing vehicle or aircraft is called an event. To measure the noise of an event, the Sound

Exposure Level is measured, combining level and duration into a single descriptor. The

maximum sound pressure level may also be used. A number of similar events can be measured to

establish a reliable average.

IMPULSIVE NOISE

The noise from impacts or explosions, e.g., from a pile driver, punch press or gunshot, is called

impulsive noise. It is brief and abrupt, and its startling effect causes greater annoyance than

would be expected from a simple measurement of sound pressure level. To quantify the

impulsiveness of noise, the difference between a quickly responding and a slowly responding

parameter can be used. The repetition rate (number of impulses per second, minute, hour or day)

should also be documented.

18.4.2 PASS BY NOISE TEST: PROJECT NO.11


69/81

69|P a g e

Ø OBJECTIVE: :- To Study and understand the pass by noise levels for various cost Saving

Proposals.

Ø 1) Proposal of removing the Hood insulation.

Ø 2) Proposal of removing the fender insulation.

INTRODUCTION:

Ø A pass by noise test is carried outPass by noise test is a standard which specifies the

method for measuring the external noise emitted by road vehicles in moving condition.

Ø Pass by noise levels are defined as a noise generated by vehicle in moving condition.

Ø It is a noise that person listens whenever a vehicle moves or passes through him.

Ø It is very important to measure & control the pass by noise to save our preciousenvironment from noise pollution.

Ø Excessive noise causes various health problems such as hearing deficiency, high blood

pressure headache etc.

TEST SITE AND PREPARATION OF THE VEHICLE

APPARATUS REQUIRED:

The apparatus used for measuring the noise level shall be a sound-level meter of the type

described in IS 9779 or the equivalent and the measurements shall be carried out using thefast response of the sound-level meter and the 'A' weighting curve which are also

described in that publication. The frontal mode of operation of the sound-level meter shall be

used. At the beginning and end of each set of measurements, the sound-level meter shall be

calibrated according to the instructions given by the manufacturer of the instrument, by means

of an appropriate sound source such as piston phone. The test shall be considered invalid, if

the sound-level meter errors registered during these calibrations exceed 1db

CONDITION OF MEASUREMENT:-


70/81

70|P a g e

TEST SITE:

The test site shall consist of a central acceleration section surrounded by a substantially flat test

area. The test acceleration section shall be level; the track surface shall be dry and such that

rolling noise remains low. The test site shall be such that the variations in the free sound field

between the sound source at the centre of the acceleration section and the microphone are within1 dB (A). These conditions shall be deemed to have been met, if there are no large sound-

reflecting objects such as fences, rocks, bridges or buildings within 50 metres radius of the centre

of the acceleration section. There shall be no obstacle that affects the sound field within the

vicinity of the microphone and no person shall stand between the microphone and the sound

source. The observer carrying out the measurement shall so position himself as not to affect the

readings of the measuring instrument.

TEST SURFACE DESIGN:-


71/81

71|P a g e

AREA:-

When designing the test track layout it is important to ensure that, as a minimum requirement,

the area traversed by the vehicles running through the test strip is covered with the specified test

material with suitable margins for safe and practical driving. This requires a width of at least 3 mand length of the track extended beyond the lines AA' and BB' by at least I0 metres at either end.

Figure 3 shows the plan of a suitable test site that indicates the minimum area which, shall be laid

and compacted by a machine with the specified test surface material.

DESIGN REQUIREMENTS FOR THE SURFACE:-

The test surface shall comply with the following four design requirements:

a) It shall be of dense asphaltic concrete;

b) The maximum chipping size shall be 8 mm (tolerance value between 6.3 and 10 mm);

c) The thickness of the wearing course shall be greater than or equal to 30 mm;d) The binder shall be a straight penetration grade bitumen without any modification.

As a guide to the test surface constructor, an aggregate grading curve which shall give desired

characteristics is shown in Fig. 4. In addition, Table 2 gives some guidelines in order to obtain

the desired texture and durability. The grading curve fits the following formula:

P (percent passing) - 100 (d 'h l d ~ a x ) where

d = square mesh sieve size, in mm; and d ~ a x= 8 mm for the mean curve, 10 mm for the lower

tolerance curve, 6.3 mm for the upper tolerance curve.

In addition to the above, the following recommendations shall also be considered:

Ø The sand fraction (0.063 mm


72/81

72|P a g e

METEOROLOGICAL CONDITIONS:-

The measurement shall not be made in adverse weather conditions such as rain, storm and heavy

winds that would affect noise, instruments and test results

PREPARATION OF THE VEHICLE:-

1. The vehicle shall conform in all its parts, components and systems to the design and/or

production series as applicable.

2. Prior to test, the vehicle shall be run-in as recommended by the manufacturer.

3. The vehicle's tyres shall be of the type normally fitted to such vehicles by the manufacturer.

Tyres that have covered only 10 percent or less of their expected life shall be fitted on the vehicle.

4. The tyres shall be inflated to the appropriate pressure(s) for the load condition prescribed for

the test as specified by the vehicle manufacturer.

5. Before the measurements are obtained, the engine shall be brought to its normal operating

condition with regard to temperatures, settings, fuel, spark plugs, carburettor(s), etc.

6. If the vehicle is fitted with fan(s) having an automatic actuating mechanism, this system shall

not be interfered while taking measurements.

7. Prior to testing it shall be ensured that the vehicle is in running order as defined for the kerb

weight condition, and with the test driver hider. The kerb weight condition shall be the same as

defined in IS 921 1, IS 9726, IS 1 1422 as appropriate. In the case of two and three wheelers the

combined weight of the rider and the test equipment used on the vehicle shall be within 80 kg. If


73/81

73|P a g e

necessary additional weights may be added to the vehicle to meet this requirement.

8. If the vehicle is designed to be attached with trailer or semi-frailer, they shall be uncoupled

except in the case of vehicles where trailer or semi-trailer cannot be uncoupled.

9. Only the normal highway drive shall be engaged in vehicle with more than two drive wheels

10. In case of two wheelers fitted with a side car, the side car shall be detached.11. The test shall be carried out on fully built vehicles where applicable including cabin and load

body or on a drive away chassis manufacturer's request. If the manufacturer so desires the drive

away chassis may be loaded according to Table 1 below to compensate the weight of the cab and

load body.

SOUND MEASURING TOOL:-

THE BASIC SOUND LEVEL METER:-

A sound level meter is an instrument designed to respond to sound in approximately the same

way as the human ear and to give objective, reproducible measurements of sound pressure level.

There are many different sou