Tata Motors PCBU Pune - Case Study · Tata Motors PCBU Pune - Case Study 2 DSS Systems & Software Technologies Ltd Pune To be done Apart from DICOR Engine Assembly, they are having

Tata Motors PCBU Pune - Case Study

1 DSS Systems & Software Technologies Ltd Pune

Tata Motors PCBU Pune – Case Study

1. Requirement – Monitor the CTQ’s on the machining shops. Solution -

Started with – Implementation of ProQMS at Trans-Axle Machining (Hard) shop – For Part Parameters with Feedback to Operators.

Extended it to Engine shop – for part Parameters.

Advantages – Could take timely corrective actions in the shop based on the feedback from ProQMS.

2. Requirement – Analyzing data in Heat Treatment shop. Implemented customized solution at Heat Treatment plant – Monitoring Process Parameters. We took data from Honeywell SCADA system. Also done Tray Tracking System.

Advantage – study of input parameters. Then analyzing the output parameters like Hardness & Case Depth & correlating the input Vs Output parameters & arrive at the ideal combination of Input parameters to get best results.

Tray tracking system is useful for Traceability.

3. Trans Axle Assembly shop. – Monitoring Torque & Angle for each Trans Axle Assembly

It’s a conveyor where there are DC Nut Runners at several stations. At each station the data gets collected on a RFID tag & it is downloaded into a PC at the final station. This is done by PARI.We collect data of around 55 Torques & 55 Angles of each Trans Axle & store in ProQMS. We display Run Chart for each parameter (Torque & Angle).Also we monitor Cp/Cpk in ProQMS. We have given them various reports. Advantage - The torques get monitored & it helps them take corrective actions on specific controllers where the Torque is not in control. Also for Traceability purpose we record the Trans Axle no also. This helps them in Backtracking if required. They use the Dashboard (local not the web based) for monitoring the Cp/Cpk of all the Torques & angles.

4. Done similar Installation at Engine Assembly shop DICOR Engine. 5. Housing shop – Front & Rear Housing - Part parameter monitoring. Standard system.

6. Connect to Zeiss CMM (Co-ordinate Measuring machine) & collect data, demo given

– Proposal pending



To be done

Apart from DICOR Engine Assembly, they are having old Engine Assembly shops where there are controllers (no SCADA system) .Data has to be collected from the controllers directly.

Engine Testing – total 11 areas where Engine gets tested. Test data (testing parameters) to be collected in ProQMS. It is either thru Excel or from Access database.

Final Car Assembly – Requirement is being studied. They want to monitor certain critical Torques. Based on the Controllers of DC Nut Runners data needs to be collected.



Tata Motors PCBU, Pune – Hard Shop



Tata Motors Heat Treatment Shop

Dash Board for Process status with Cp & Cpk.



Engine Assembly shop - Dashboard



Trans Axle Assembly Shop - Dashboard



Few Special Reports



ProQMS – Future Roadmap at Tata Motors PCBU

Trans Axle Shop Database

Pro-QMS Dashboard Trans axle Shop Head

Trans Axle

Soft Shop

Trans Axle Hard Shop &

Housing Shop

Trans Axle

Assy. Shop

Engine

Shop

Engine

Assy Shop

Engine

Test Shop

Engine Shop Database

Pro-QMS Dashboard Engine Shop Head

Tata Motors PCBU Pune Database

Pro-QMS Dashboard PCBU, Pune Plant Head

Pro-QMS Dashboard PCBU, Sanand

Plant Head

Further Extension

Pro-QMS Dashboard

Anyone/Anywhere in World

Pro-QMS Dashboard PCBU Pantnagar

Plant Head

Further Extension

Tata Motors PCBU Pune - Case Study · Tata Motors PCBU Pune - Case Study 2 DSS Systems & Software Technologies Ltd Pune To be done Apart from DICOR Engine Assembly, they are having

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