Project On Shower Leakage Reduction TCF 1D

SHOWER LEAKAGE REDUCTION/ELIMINATION
REPORT ON
SHOWER LEAKAGE REDUCTION
Sub mitted ToYogesh Kumar Sardhana Assistance Manager Production Submitted ByNAME-Hemant Kumar Pant Branch-Mechanical College Name- UIT,Dehradun
HEMANT KUMAR PANT UIT, DEHRADUN
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ACKNOWLEDGEMENT
This training would not have been useful to me without the utmost support and guidance from many people in the TCF-1D Department of TATA MOTORS LIMITED SHOWER LEAKAGE REDUCTION PROJECT. Firstly, I would like to thank Mr. A. N. Banerjee (Factory Head, TCF-1D shop) who helped me throughout the training by sharing his knowledge and the lots of experience he possesses, weathered over the years in the automotive industry, it was indeed very precious working under you, Thank you Sir! Secondly, I would like to thank Mr. Pramod Popale (Manager, TCF-1D shop) for guiding me on the projects assigned to me, by helping me memorize all the minute things that we tend to forget during the course of our work. Also, I appreciate the guidance provided to me by Mr. Yogesh Kumar Sardhana (Assistant Manager,
Production, TCF-1D shop) who with his inspiring & innovative ideas, in a way, told
me how to stretch myself in order to increase the capacity to do work. I am extremely grateful to Mr. Kamal Kishore Pandey who taught me about those tiny, but absolutely important things in the TCF-1D Department which have given finesse to my training. I am grateful to Mr. Brijlal Arora (HR training coordinators) for letting me go through the training, & making it altogether a diverse experience. Last but not the least , I would like to thank the entire family of TATA MOTORS LTDPantnagar Plant, who helped me in every sphere they could, and didnt even let me gauge how long or short 1 months can be. Thank you all!
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INDEX
S. No.
1. 2. 3. 4. 4.1 4.2 4.3 4.4 4.5 4.6 5. 5.1 5.2 5.3 5.4 5.5 6 6.1 7 7.1 7.2 7.3 7.4 7.5 8 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7
Page No.
Acknowledgement World and Automobile India and Automobile Tata Group of Companies Tata Motors Ltd.
Area of Business Joint ventures, Subsidiaries and Associates Research and Development Location Tata motors Hierarchy Tata Motors Pantnagar
2 4 5 7 9 10 10 11 12 13 15 16 20 22 23 24 25 26 26 28 28 29 29 30 31 31 31 32 33 33 33 34 35 36
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Shower Leakage Elimination

Wind shield leakage Main harness leakage LH/RH leakage Head lamp joint Leakage Sticker missed
Proposed Solution
Possible further aspect in Project
In Tata Motors
BIW Paint shop TCF shop PDI shop Powertrain shop
By the End of Training Period Learning at Tata Motors

Kaizen Just In Time Manufacturing Just In Sequence Just In Sequence is Just In time Elimination of Waste Bill of Material Work Experience
10
Bibliography
37
1) World & Automobile
During the 1670s, Father Ferdinand Verbiest (Flemish Jesuit missionary, China) designed the first ever self-propelled vehicle many claim this as the world's first automobile but lack of evidence that it was actually built, in spite of its small size it could only operate for 12-15 minutes before running out of steam, and its tremendous weight and poor balance made it very difficult to steer The first car was built by Joseph Cugnot in 1769. It was powered by a steam engine and was very slow.
Notable Personalities of Past : 1 cylinder IC engine 4 cylinder IC engine 1st 4-wheel automobile & v-slanted engine Automobile powered by IC engine Over 15 million Model Ts by 1927 Hybrid cars 1st hybrid commercial truck J.J. tienne Lenoir N. August Otto Gottlieb (1886) Daimler
Karl Benz Henry Ford Since the 1900s. in 1910
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2) India & Automobile Automobile:

o o o o o o o o o Public Transport Personal Transport War-fare Law and order Trade Emergency Services Public Hygiene Sea Transport Aero planes
Indian Automobile has 12 % share in Indian economy AUTOMOBILE COMPANIES making the Dream Machines in India:
Page 5
The forecast of various type of 4-wheelers production in India:
Page 6

GRAPH 2 GRAPH 3
Passenger Vehicles
Commercial Vehicles
3) TATA GROUP OF COMPANIES

Tata Group, an Indian multinational conglomerate company, headquartered in the Bombay House in Mumbai, India, in terms of market capitalization and revenues, it is the largest private corporate group in India. The Tata Group comprises 114 companies and subsidiaries in eight business sectors, 27 of which are publicly listed. 65.8% of the ownership of Tata Group is held in charitable trusts. The group takes the name of its founder, Jamsedji Tata, a member of whose family has almost invariably been the chairman of the group. The current chairman of the Tata group is Ratan Tata. The Tata Group has operations in more than 80 countries across six continents and its companies export products and services to 80 nations. TATA Group's 114 companies are held by its main Company Tata Sons. The 2009 annual survey included 600 global companies by the Reputation Institute ranked Tata Group as the 11th most reputable company in the world.
TATA GROUP of COMPANIES

Information technologies
CMC Computational Research Labs Nelito Systems Tata Advanced Systems Tata Business Support Services T ata Consultancy Services Tata Elxsi Tata Interactive Systems Tata Technologies Tata Communication
Comunication
Page 7

Tata Teleservices Tata sky Tata Net Nelco Tata Projects TRF Voltas
Hooghly Met Coke & Power JAMIPOL Jamshedpur Utilities and Services Mjunction services NatSteel Holdings Tata BlueScope Steel Tata Metaliks Tata Sponge Iron Tata Steel Tata Steel KZN Tata Steel Processing and Distribution Tayo Rolls The Tinplate Company of India TM International Logistics
Metals

Automotive
Hispano Carrocera Jaguar Land Rover Tata AutoComp Systems Tata Cummins Tata Daewoo Commercial Vehicle Company Tata Motors Tata Motors European Technical Centre Telco Construction Equipments Engineering TAL Manufacturing Solutions Tata Consulting Engineers
TRL Krosaki Refractories
Hotels Property Developement

Indian hotel Root Corp. Taj Air Tata Housing Devlpmnt Co. Tata Realty & ure infrastruct Financial Services Tata AIG General Insurance Tata AIG Life Insurance Tata Asset Management T ala Capital T ala Financial Services Tata Investment Corporation
Energy
North Delhi Power Powerliks Transmission Tata BP Solar Tata Petrodyne Tata Power & Tata Power Trading
Consumer Product
Casa Decor Infiniti Retail Landmark Tata Ceramics Tata Global Beverages Titan Industries Trent Westland
Chemicals Page 8

Advinus Therapeutics Rallis India Tata Chemicals Tata Chemicals Europe Tata Chemicals Magadi Tata Chemicals North America Tata Pigments
Other services
Drive India Enterprise Solution Tata Industrial Services Tata Quality Management Services Tata Services Tata Strategic Management
4) TATA MOTORS
Tata Motors Limited is a multinational automotive corporation. A part of the Tata Group, it was formerly known as TELCO (TATA Engineering and Locomotive Company). Established in 1945 by J.R.D.Tata, Tata Motors' presence indeed cuts across the length and breadth of India. Tata Motors is India's largest automobile company, with consolidated revenues of Rs. 1, 23,133 crores ($ 27 billion) in 2010-11. Through subsidiaries and associate companies, Tata Motors has operations in the UK, South Korea, Thailand and Spain. Among them is Jaguar Land Rover, the business comprising the two iconic British brands. It also distributes Fiat cars in India, and has an industrial joint venture with Fiat in India. With over 5.9 million Tata vehicles plying in India, Tata Motors is the country's market leader in commercial vehicles and among the top three in passenger vehicles. It is also the world's 4th largest truck manufacturer and 3rd largest bus manufacturer. Tata cars, buses and trucks are being marketed in several countries in Europe, Africa, the Middle East, South Asia, South East Asia and South America
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4a) Areas of business:

Tata Motors makes passenger cars, multi-utility vehicles and light, medium and heavy commercial vehicles.
Passenger cars: compact Tata Indica in 1998, the sedan Indigo in 2002 and the station wagon Indigo Marina in 2004. Tata Motors also distributes Fiats cars in India. Utility vehicles: The Tata Sumo was launched in 1994 and the Tata Safari in 1998. Commercial vehicles: The commercial vehicle range extends from the light two-tonne truck to heavy dumpers and multi-axled vehicles in the above 40-tonne segment. Passenger buses: The Company also manufactures and sells passenger buses, 12-seaters to 60-seaters, in the light, medium and heavy segments.
4b) JOINT VENTURES, SUBSIDIARIES, ASSOCIATES

Tata Motors has joint ventures with MARCOPOLO, the Brazil-based maker of bus and coach bodies, and with FIAT-AUTO (to build a commercial vehicle at Fiat's facilities in Crdoba, Argentina). Other associates include: Tata Daewoo Commercial Vehicle Co.: heavy commercial vehicles Tata Motors European Technical Centre: design engineering and development of products. Telco Construction Equipment Company: construction equipment and allied services. Tata Technologies: design services, product lifecycle management and product-centric IT services. Tata Motors (Thailand): Tata Motors (70%) and Thonburi Automotive Assembly Plant Co (30%). Tata Cummins: manufactures high horsepower engines. HV Transmissions and HV Axles: make gearboxes and axles for commercial vehicles. TAL Manufacturing Solutions: provides factory automation solutions and provides machine tools.
HEMANT KUMAR PANT UIT, DEHRADUN Page 10
Hispano Carrocera: Spanish bus manufacturing company. Concorde Motors: retailing Tata Motors range of passenger vehicles Tata Motors Finance: the business of financing customers and channel partners of Tata Motors
4c) Research & Development

The companys Engineering Research Centre (ERC), in Pune (which has 1400 scientists and engineers), Tata Daewoo Commercial Vehicle Company Hispano Carrocera at Gunsan in Korea and Zaragoza in Spain. These three facilities together enable the company to share and access knowledge and technology for designing and developing world-class products which are environment-friendly technologies in emissions and alternative fuels. It was Tata Motors, which developed the first indigenously developed Light Commercial Vehicle, Indias first Sports Utility Vehicle Tata Indica, Indias first fully indigenous passenger car (Indias largest selling car) Tata Ace, Indias first mini-truck. The ERC in Pune, among whose facilities are Indias only certified crash-test facility and hemi-anechoic chamber for testing of noise and vibration has received several awards from the Government of India. Some of the more prominent amongst them are: National Award for Research and Development Efforts in Industry in the Mechanical Engineering Industries sector in 1999, National Award for Successful Commercialization of Indigenous Technology by an Industrial Concern in 2000 CSIR Diamond Jubilee Technology Award in 2004.
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Adopting the principle of Kaizen or continuous learning, versatile yet simple 5S approach to process improvement which helps to optimize various operations of the company and conserve precious resources is the way of life at Tata Motors. The company introduced emission-friendly engines in its products in India even before such norms were made statutory. It ensures that its products are environmentally sound by reducing hazardous materials in vehicle components, developing extended life lubricants, fluids and using ozonefriendly refrigerants.
4d) Location
Tata Motors' plants are located at o Jamshedpur (eastern India), o Pune and Sanand (western India), o Lucknow and Pantnagar (northern India). o Tata Motors and Fiat have a common manufacturing facility at Ranjangaon, near Pune. being marketed in several Europe, South East Asia, countries assembly operations
Malaysia, Ukraine, Senegal.. Africa, Middle East, South Asia and Australia Kenya, Russia, Bangladesh, Spain and
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4e) TATA Motors Hierarchy

Board of Directors
Mr. Ratan N. Tata (Chairman) Mr. Ravi Kant Mr. Nusli N. Wadia Mr. S. M. Palia Dr. R. A. Mashelkar Mr. Nasser Munjee Mr. Subodh Bhargava Mr. V. K. Jairath Mr. Ranendra Sen Dr. Ralf Speth Mr. Carl-Peter Forster Mr. P. M. Telang
Senior Management
Mr. Carl-Peter Forster Mr. P. M. Telang Mr. C. Ramakrishnan Mr. Ravi Pisharody Dr. Tim Leverton Mr. S. B. Borwankar Mr. Prabir Jha Mr. R. Ramakrishnan Mr. Girish Wagh Mr. R. T. Wasan Mr. Johnny Oommen Mr. H. K. Sethna Managing Director & Group CEO Managing Director - India Operations Chief Financial Officer President (CVBU) Head (Advanced and Product Engineering) Senior Vice President (Mfg Operations-CVBU) Senior Vice President (Human Resources) Vice - President (Commercial - PCBU) Head (Passenger Car Operations - PCBU) Head (International Business - CVBU) Head (International Business - PCBU) Company Secretary
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FIG. 2: Fuel type- Diesel, Gasoline and CNG
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4f) TATA MOTORS (Small Car Division) Pantnagar

This plant came into existence in 2007. TATA MOTORS LTD. Pant Nagar has four shops for manufacturing of vehicles.
DESCRIPTION OF SHOPS
ASSEMBLY SHOP
Also known as TCF Shop(TRIM CHASSIS FITTING). In this shop all the assembly works like Engine, Suspension, Tyres, Lights, Dashboard etc. fitting is carried out.
WELD SHOP Also known as BIW Shop(BODY IN WHITE) . Here the different parts are welded together and the whole structure of the car is built.
POWER TRAIN SHOP o This shop is divided into Power Train and Engine shop. Here various operations related to Engine, Gear Trains etc. are performed.
PAINT SHOP The TAIKISHA paint shop is the beauty parlors of the car plant. This shop paints the car in various shades. It takes 18 steps spread over less than 10 hours to accomplish the task.
GEAR 15 Page CKD(COMPLETE KNOCK DOWN) ASSEMBLY BIW-1C BIW-1B BIW-1A
TATA MOTORS SUMMER INTERNSHIP PROJECT (SIP)

SHOWER LEAKAGE ELIMINATION IN TATA ACE ZIP & TATA MAGIC IRIS
5)Shower test
The shower test is used for checking the leakage of water into the vehicle. It is also known as water testing.
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The nozzles spray the water on both right hand and left hand side of the vehicle at a pressure of 1.3 bar ( greater than the atmospheric pressure i.e. 1.01325bar). The pressure in the nozzle is controlled by the flow regulating arrangement. The following tests are conducted on the shower.
Windshield leak
Head lamp moist/ bezzle leak
Air vent leak
Canopy leak
Door pad leak
Weather strip leak
Floor leak
Tail lamp leak
Corner trims
Roof leak
Door seal leak
Window glass run leak
HMSL leak
STG gear grommet leak
Fire wall grommet leak
Repeater lamp leak
Shower defect monitoring sheet
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SHOWER LEAKAGE REDUCTION/ELIMINATION Defects 4Ju ne A B 4 3 8 5 3 7 6 5 0 4 6 3 4 3 2 0 2 0 4 6 57 44

FSO15
1.wind shield leakage 2.main harness leakage 3.LH/RH door leakage 4.dome nut leakage 5.cabin joint leakage 6.head lamp joint leakage 7.head lamp grommet leakage 8.rear glass leakage 9.sticker missed 10.LH/RH fender leakage Total vehicle tested Ok vehicle after test
5Jun e A B 3 6 7 6 11 13 5 0 0 7 4 6 1 6 2 1 2 2 3 7 44 50
FSO17
6ju ne A B 5 12 4 4 9 15 1 2 0 3 3 3 0 1 2 3 2 2 4 5 50 61
FSO30
7ju ne A B 3 2 9 7 7 10 3 1 0 5 3 3 3 2 0 6 5 5 2 1 51 41
FSO32
8ju ne A B 5 5 8 4 9 14 2 5 0 9 5 6 4 3 4 9 7 8 4 2 51 39
FSO18
9jun e A B 4 1 6 7 6 7 5 13 0 6 5 9 2 4 6 4 6 12 1 2 39 48
FSO16
tot al 53 75 11 1 48 34 56 33 39 53 41
Major shower leakages
Wind shield leakage-53
Main harness leakage-75

LH/RH leakage-111
Head lamp joint leakage-56
Sticker missed-53
5.1)Wind shield leakage
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Glass- it has two layers which are fabricated by adhesive such as poly vinyl beautyl (PVB).the thickness of glass is generally taken about 4.56mm and the adhesive is 0.76mm. The glass can be used in wind shield leakage is of two types. a) laminated b) tempered
laminated- the laminated glass is cheaper and having cost about 200rs. It has the property not to create sharp edges when it breaks so that it will not harm the driver during accident.
Tempered- the tempered glass is manufactured by heating it above re- crystalization Temperature and hold it for some time and cooled in some cooling medium. It has the property not to scatter when it breaks. It is costlier than laminated glass about 5times i.e. 1000Rs.
Robot timing- The sealant, used to make the surface nonporous is provided by the robot from the sealant drums. The process is repeated in about 2min.
Problem concerning with robot-
a)
priming- when the air stuck between the sealant pipes. It does not allow the sealant to flow by creating an air pressure head.
b) Voltage
fluctuation- if the fluctuation of light takes place in very short period of time, the robot does not sense it and the sealant flow rate vary that creates problem like porosity, leakage etc.
S. Wind shield No. leakage Fender leakage 1.
Causes
B.I.W , human, welding error.
Remedies
Automation and precise machinery
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2.
Profile leakage
Human, robotic and manufacturing problem.
Advanced manufacturing processes, training of workers
5.2)main harness leakage-
It is the leakage due to improper tightening of grommet.
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S. No . 1. 2.
Harness leakage Grommet leakage Fitting leakage
Causes Improper tightening Improper sealing or fittings
Treatment Inspection Testing and inspection
The leakage is due to improper size of grommet and imperfection in fitting. This can be eliminated by the providing a washer there.
5.3)LH/RH Door leakage
It is the leakage in the right hand and left hand door of the vehicle due to some misalignment and improper fitting of glasses. This is the major leakage in the shower test, so it must be eliminated by overcome the above problems.
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S. No. 1. 2.
Door leakage Door pad leakage Fitting leakage
Causes Misalignment of fittings. Improper fittings of doors and rubber pads.
Remedies Testing and inspection. Hammering the door.
In door pad, membrane is used.
5.4)Head lamp joint leakage-
It is the leakage in head lamp portion of the vehicle due to improper fittings and some BIW problem. The bezel gap must be within certain limit of range so that proper fitting and no leakage can be achieved.
S. No. 1. 2.
Head lamp leakage Bezel gap leakage
Causes
Remedies Precise machinery Testing and inspection
manufacturing inaccuracy(bezel gap must be controlled) Fitting leakage Due to improper fitting ,human error
5.5)sticker missed-
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sticker is used to prevent leakage due to some unwanted holes.
It has the property to sustain the high pressure at high speed (80km/hr).
Precaution-
a) sticker must be placed effectively.
b) It must have high plasticity.
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6) Proposed Solution:
Here at TCF-1D, I was trained by the Line-supervisor to identify the shower leakage which can be reduced by proper functioning during fitment process. During fitment due to human error or by some other way in trim section, shower leakage can occour.so proper care need to be to eliminate it.
Hence I observed that:

Testing and inspection should be carried out at every quality gate. Tightening of nut and bolt should be proper. By using automation and precise machinery. The assembly parts should be manufactured by advanced manufacturing processes in vendor company. The training and motivating policy should be applied to workers. Kaizen should be applied. Job rotation policy should be applied.
6.1) Possible further aspects in the project:

WHAT CAN GO WRONG ANALYSIS: By doing this one can also find the root cause of the untraceable line problems and take suitable steps towards its elimination and thus TML TCF-1D shop can assure nearly perfect fitment for the car .
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CONCLUSIONS
After analyzing the problem, in the trim section (magic iris and tata ace) the leakage can be eliminated within accepted limit of standards. So, the leakage is eliminated as well as quality is also improved. 1) The quality of vehicle is obtained within accepted limit of standards.
2) The leakage will be eliminated.
3) Rating of vehicle will be improved.
4) As the fouling is eliminated, the life will be improved.
5) Due to reduction in leakage , engine work properly and heat loss will be minimum.
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7) In
TATA MOTORS:
PRODUCTION SYSTEM
MANUFACTURING
PRODUCTION PLANNING
BIW(Body in white) PAINT TCF(Trim chassis fitment) PDI (Pre-Delivery Inspection) POWERTRAIN MATERIAL SUPPLY (JIT,KAIZEN,JIS) QUALITY MANAGEMENT MES(Manufacturing execution system) SAP
7a) BIW
This shop plays very important role in framing the body shell of Nano. The press panels are transported from Bhuj and Pune plant. It has three main assemblies, which includes-UB(under body), ML(Main line or main frame) and MF(metal finish) where different welding processes of Projection welding CO2 welding Stud welding MIG welding Spot welding are done and after that the parts are attached to the main assemblies
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SUB ASSEMBLIES
MAIN FRAME LINE METAL FINISH LINE
UNDER BODY LINE
PAINT SHOP
SUB ASSEMBLIES
9b) PAINT shop:

Here in Paint shop: Colour and appearance Covering of gaps between the weld joints Corrosion resistance Smoothening of sharp corners
SHOP LAYOUT:
WELD BODY
COOLING
PRETREATMENT
ELECTRODEPOSITION
ED OVEN
UNDERCOAT OVEN INTERMEDIATE COAT (I/C)
UNDER COAT
SOL SEALING(UB) SEALANT COOLING
DRY SANDING
I/C OVEN
TCF
TOUCH UP AND INSPECTION
T/C OVEN
TOP COAT (T/C)
DRY SANDING
7c) TCF (Trim Chassis Fitment) shop:

SHOP LAYOUT:
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SHOWER LEAKAGE REDUCTION/ELIMINATION TRIM LINE (TR1, TR2) UNDER BODY LINE (UB1, UB2, UB3, UB4) MECHANICAL LINE
WHEEL ALIGNMENT
To costumer
CANOPY TEST
NOK OK
ROLL AND BRAKE TEST
REWORK
PRE DISPATCH INSPECTION (PDI)
PAD
7c) TCFShop It is the biggest of all the shops in TML,Pantnagar.

Here the painted chassis delivered from the Paint shop is accessorized from scratch to a finish car ready for dispatch and also tested. The car delivered by the TCF shop is completely checked with reference to products utility quality and manufacturing quality. After several inspections made by line operators for operational conformance and ethical looks the Car is permitted to be dispatch from TCF shop by the assurance of Line supervisors and operators. The cart dispatched from the TCF shop is delivered, through drive test to the PDI (Pre-Delivery Inspection) shop where final touching to looks is given and the conformance of working of all the accessories is done.
7d) PDI Shop:

PDI is the final quality check, in this the overall checking of the vehicle takes place, in this the fitment is not done, only the outward checking is completed. The final QA OK of the vehicle is done here and after this the vehicle is sent for dispatch. Parts which are checked are mentioned below:
1. 2. 3. 4. 5. 6. 7. 8. 9. Brake, Brake oil. Carpet fitment. Central lock Coolant filling Dents Door pad Drive shaft Engine oil . Engine wiring harness. 21. Inner handle. 22. Instrument cluster. 23. Keys. 24. RH front door. 25. Roof lamp. 26. Roof lining. 27. Rear bumper. 28. Rear door LH, RH. 29. Rear door lock LH 30. Rear door lock RH. 31. Rear seat 32. Seat. Belt 33. Spare wheels 34. Scratches on whole body 35. Steering wheels. 36. Tail lamp. 37. Washer jet. 38. Window glass. 39. Wind shield washer. 40. Wiper.
10. Front bumper. 11. Front door LH 12. Front door lock LH 13. Front door lock RH 14. Front seat 15. Fuel. 16. Gear shifter. 17. Head lamp. 18. Hood LH. 19. Hood RH 20. Horn
7e) POWERTRAIN shop:

It consists of Engine Assembly Shop Transaxle Assembly Shop Engine Dressing Line In Engine assembly the various components of the Engine are assembled into a single unit and sent for the various tests.
8) By the end of training period:

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

Being one of the most technically sound and having few of the costliest technologies among the Asian automobiles, the culture in the Tata Motors is free, motivating and appreciative. Here the culture of Equality is fully nurtured all the people operator to senior level are given equal respect through all the possible manner like same Canteen facility, same transportation facility, same uniform among various levels. The lesson of Time is Money & Creativity is thinking up new things Innovation is doing new things. is taught from day 1 to all employees. The lesson of Appreciate your colleagues work is well taught from senior level manager to all the man-force in TML, Pantnagar. Other nice and unique things which I observed in the Plant were:
9.1KAIZEN
The Japanese refer to Kaizen as a simple parts-movement system that depends on cards and boxes/containers to take parts from one work station to another on a production line. The essence of the Kaizen concept is that a supplier or the warehouse should only deliver components to the production line as and when they are needed, so that there is no storage in the production area. Within this system, workstations located along production lines only produce/deliver desired components when they receive a card and an empty container, indicating that more parts will be needed in production.
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In case of line interruptions, each work-station will only produce enough components to fill the container and then stop. In addition, Kaizen limits the amount of inventory in the process by acting as an authorization to produce more inventories.
ADVANTAGES OF THE KAIZEN PROCESS:

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

JIT is a philosophy of continuous improvement in which non-value-adding activities (or wastes) are identified and removed for the purposes of: Reducing Cost Improving Delivery Improving Quality Adding Flexibility Improving Performance Increase innovativeness
JIT is not about automation. JIT eliminates waste by providing the environment to perfect and simplify the processes. JIT is a collection of techniques used to improve operations. It can also be a new production system that is used to produce goods or services.
9.3 JUST IN SEQUENCE (JIS):

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

Just in Sequence (JIS) is just one specialized strategy to achieve JIT. The process concept of JIT sees buffers at the production line as waste in capital bound. The aim is to eliminate buffers as much as possible at expense of stability when disturbances arise.
Just in Sequence is one of the most extreme applications of the concept, where components arrive Just In Time and sequenced for consumption. The sequencing allows companies to eliminate supply buffers as soon as the quantity in component part buffers necessary is reduced to a minimum. If not sequencing according to scheduled variety of production, all required components must be stocked in buffers.
For flexible production lines, as here in Tata Motors, a modern automotive assembly line, the variety is an option to produce directly on customer orders. As soon as the next order arrives at the work centre, the scheduler distributes the supply orders in line with the production sequence of the final production line. With JIS the buffer quantities are displaced upward in material flow to the components suppliers. It is a misinterpretation of JIS to assume that all buffers will be eliminated. Hence just the cost for buffer inventory becomes re-allocated to the producers of the supplies. Sequencing eliminates buffers in the final assembly line by consolidating all similar components into distributed and sequenced buffers, which partly reside on the paths of transportation to final assembly. This strategy thus reduces the line-side inventory buffer. However, the effect is worse when the sequence does not get not correctly scheduled upwards or when the transportation line gets congested.
9. 5 Elimination of Waste:
JIT usually identifies seven prominent types of waste to be eliminated: HEMANT KUMAR PANT UIT, DEHRADUN Page 36
SHOWER LEAKAGE REDUCTION/ELIMINATION Waste from Overproduction Transportation Waste Processing Waste Waste from Product Defects Waste of waiting/idle time Inventory Waste Waste of Motion
9.6 BILL OF MATERIAL:

A Complete formally structured list of the components that make up a product or subassembly
Here the bill of material is a complete, formally structured list of the components that make up a product or assembly The list contains the item number of each component, together with the quantity and unit of measure. The Internship program was quite beneficial for me. It helped me in improving my various technical skills and enhanced my knowledge in new areas. I gained new knowledge in the various issues involved and mechanisms to tackle them in automobile industries. By studying and analyzing the contents, I also learnt that how database, products and operations are all mingled up and how they function in coordination with each others. What are the various issues one need to be aware of while looking for Data Management and Problem tracing for solutions. Automobile is an ever-green and vast field and through the internship I got some insight into a how it looks like in world market. Page 37

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

My internship was quite satisfactory in terms of work environment. The team, I worked with, was very friendly and helped me a lot in all my problems. New experiences include:
Teamwork In this project I worked with line operators in order to understand the workin process thus providing enough opportunity for proper teamwork and coordination. This was a good experience for me as the team was very cooperative and understanding.
Communication Working along with the lower level operators and making them understand the process and also getting the valuable information out of them in a way that is comfortable to them not making them feel that they are inferior.
Responsibility and keeping commitments The importance of honouring commitments and time of others was an important thing, which I learnt as a Summer Intern. Especially, while working as a team it is very important to keep these points in mind.
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10) BIBLOGRAPHY
1. 2. 3. 4. 5. 6. 7.
8.
www.google.co.in www.wikipedia.com www.tatamotors.com http://www.acmainfo.com/pdf/Status_Indian_Auto_Industry.pdf (Graphs 2009, 15, 20). http://www.imaginmor.com/automobileindustryindia.html (Pi charts) http://www.tatamotors.com/know-us/milestone.php http://www.tata.com/businesses/sectors/index.aspx? sectid=aZ72PXPwpaI=#Informationsystemsandcommunication s (Tata Group of Companies) http://www.exampleessays.com/viewpaper/17379.htm (1800 1st automobile)
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Project On Shower Leakage Reduction TCF 1D

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Project On Shower Leakage Reduction TCF 1D

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SHOWER LEAKAGE REDUCTION/ELIMINATION

SHOWER LEAKAGE REDUCTION

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

Shower Leakage Elimination

By the End of Training Period Learning at Tata Motors

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

1) World & Automobile

Karl Benz Henry Ford Since the 1900s. in 1910

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

2) India & Automobile Automobile:

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

The forecast of various type of 4-wheelers production in India:

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

3) TATA GROUP OF COMPANIES

TATA GROUP of COMPANIES

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

Hotels Property Developement

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

4a) Areas of business:

4b) JOINT VENTURES, SUBSIDIARIES, ASSOCIATES

SHOWER LEAKAGE REDUCTION/ELIMINATION

4c) Research & Development

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

4e) TATA Motors Hierarchy

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

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

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

4f) TATA MOTORS (Small Car Division) Pantnagar

HEMANT KUMAR PANT UIT, DEHRADUN

GEAR 15 Page CKD(COMPLETE KNOCK DOWN) ASSEMBLY BIW-1C BIW-1B BIW-1A

SHOWER LEAKAGE REDUCTION/ELIMINATION

TATA MOTORS SUMMER INTERNSHIP PROJECT (SIP)

HEMANT KUMAR PANT UIT, DEHRADUN

SHOWER LEAKAGE REDUCTION/ELIMINATION

Head lamp moist/ bezzle leak

Air vent leak

Door pad leak

Weather strip leak

Tail lamp leak

SHOWER LEAKAGE REDUCTION/ELIMINATION

Door seal leak

Window glass run leak

STG gear grommet leak

Fire wall grommet leak

Repeater lamp leak

Shower defect monitoring sheet

HEMANT KUMAR PANT UIT, DEHRADUN