A

Final pr oject Repor t

on
Gener al Motor s 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:
Mr. Ashok kumar mougil
Dy Manager -PE

Rajkumar Taneja
PEM- PE

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INDEX
1. Acknowledgements....................................................................................................................04
2. Preface........................................................................................................................................05
3.Introduction.06
4.Birth of GM.07
5.Chronological of GM..10
6.Company Brands12
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 Halol22
13.Integrated Management System24
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...trol38
16.7Roles and Responsibilities..38
17.Localization..40
18. Statement Of Requirement..41

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19. Pr ojects.43
19.1Inter ior and exter ior functions43
19.1.1 Project no. 1 . Door latch43
19.1.2 Projects no.2: Front Door Squeaks noise46
19.1.3 Project no.3 Cargo door dent issue.48
19.1.4Project 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-357
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 Vibr ation And Har ness.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

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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 Dur eja and Mr . Amit Atalia,
TrainingHR for providing me an opportunity for training at GMI.
I express my profound gratitude to Mr . Gur pr 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 . Nir av Modi, Mr . Nayan Solanki & Mr . Pr itpal Singh, Mr .Ronak Shah,
&Mr . Chandr akant Par mar . 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 . Nir av Panchal for their patient replies to all my queries.

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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 product
development 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.

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3.INTRODUCTION:
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.

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

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.
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 mar ket is the United States, followed
by China, Canada, the United Kingdom, and Germany.
Gener al Motor s Company, was formerly incorporated (until 2009)as Gener al Motor s
Cor por ation, is an American multinational automotive corporation 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.

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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.

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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.
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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
J an 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
J uly 29, 1909 GM purchases Cadillac.
1909 - GM acquires Rapid Motor Vehicle Company and Reliance Motor Truck Co.
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J uly 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.

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6.Company Brands:
1. Buick:

It is a premium brand of General 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:

Cadillac is an American luxury vehicle marque owned by General 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
marque Buick and is among the oldest automobile brands in the world.
3. GMC:

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GMC is a manufacturer of trucks, vans, military vehicles, and Sport utility vehicles
marketed in North America and the Middle East by General Motors .

4. Chevr olet:

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

by Louis Chevrolet and ousted GM founder William C. Durant on November 3, 1911,[1] General
Motors acquired Chevrolet in 1918. In North America, Chevrolet sells and produces a wide
variety of automobiles, from subcompact cars 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 German automobile company founded by Adam Opel in 1862.
Opel has been building automobiles since 1899, and became an Aktiengesellschaft in 1929. The
company is headquartered in Rsselsheim, Germany. It became a majority-stake subsidiary of the
General Motors Corporation in 1929 and has been a wholly owned subsidiary since 1931.
6. Vauxhall:

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Vauxhall Motors registered name General Motors UK Limited) is a British automotive

manufacturing company owned by General Motors (GM) and headquartered in Luton. 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 Ltd is an automaker that operates in Australia, based in Port Melbourne,

Victoria. The company was founded in 1856 as a saddlery manufacturer. In 1908 it moved into
the automotive field, before becoming a subsidiary of the U.S.-based General Motors (GM)
automotive group in 1931. After becoming a subsidiary of GM, the company was named General
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 M998 Humvee. In 1998, General Motors (GM) purchased the
brand name and marketed three vehicles: the original Hummer H1, based on the Humvee; and the
H2 and H3 models that were based on smaller, civilian-market GM platforms

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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, Defense
Equipment 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 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.
100 % subsidiary of General Motors Corporation USA, State of the art plant at Halol Gujarat &
Start of sales on June 27, 1996

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ASIA PACIFIC OPERATION [APO]

The Gener al Motor s Gr oup wor ldwide consists of the var ious car newly acquir ed par tly or
fully owned subsidiar ies

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 ar ms ar e divided as per the decentr alization policy of GMC into var ious
geogr aphic r egions:

GMC, Corporate Affairs

NAO, North America Operations

LAO, Latin America Operations

GME, General Motors Europe

APO, Asia Pacific

Br ief Infor mation

1. GMC, Cor por ate Affair s

Detr oit

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Vehicle Sales, Service, & Marketing

Warren Michigan,

Group
Luxury car group

Los Angeles, California + Mexico & Canada sales

offices.

2. NAO, Nor th Amer ica Oper ations

3. LAO, Latin Amer ica Oper ations:
4. GME, Gener al Motor s Eur ope :

Br azil, Ar gentina
Poland, Ger many, Egypt, South Afr ica,

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)
Delphi is the world
s most diverse supplier of automotive systems and components.
Operating in 37 countries, Delphi offers expertise in the areas of chassis, interior, lighting,
electric, energy and engine management, and steering and thermal systems.
Nor th Amer ican Oper ations (NAO)
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.
Electr o Motive Division (EMD)
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.
EMD also supplies power for marine propulsion, offshore and land based drilling rigs,
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stationery generators and off-road vehicles.

Allison Tr ansmission Division (ALLISON)
Allison transmission is the world
s leading designer, manufacturer and seller of the
medium and heavy-duty commercial automatic transmissions.
Founded in1915, Allison built its reputation in the aviation industry in the early 20s.
In 1946 the company produced its first automatic transmission, and 1996 marks its 50th
year in the business.
Hughes Electr onic Cor por ation (HUGHES)
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 Gener al Motor s Inter national Oper ations (GMIO)
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 Gener al Motor s Acceptance Cor por ation (GMAC)
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.
9.3Cor por ate Affair s
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 Wor ld Wide Pur chasing
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 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:
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
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.

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.

GM power tr ain Gr oup - 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.

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 Heavy-duty automatic tr ansmissions

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

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11.INTRODUCTION TO GM INDIA:
2.1 Company Pr ofile
Manufactur ing Plants
(1) Talegaon Plant Capacity: 200000 car s per annum
(2) Halol Plant Capacity: 85000 car s 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)

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

Gur gaon, Har yana
Marketing Head Office
North Zone Office
Regional Sales / after sales Offices:
Mumbai, Chennai & Calcutta
R & D- Technical Centre, Bangalore

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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:
Pr oduct specifications, Designs, Infor mation, Par t list with dr awings / Releases Pr oduct
modification and engineer ing changes for Indian conditions, Test methods and pr ocedur es,
Vendor assessment/cer tification and development and per suade OE supplier s for tie ups.

Site ar ea

: 172 Acres

Plant ar ea

: 65,000 m2

Total plant size

: 44000 m 2

Utilized ar ea

: 27000 m2

Star t of Pr oduction : June 1996

Capacity

: 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
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ABOUT THE ORGANIZATION:

GM VISION

Be the world leader in transportation products and related services.

We will earn our customersenthusiasm 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 Cor e Values

Customer Enthusiasm

Integrity

Team Work

Innovation

Continuous Improvement

Individual Respect and Responsibility

GM Cultur al Pr ior ities

Enhance our Product and Customer Focus

Act as One Company

Embrace Stretch targets

Move with a sense of urgency

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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 itsenvironmental 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 several
previously separate management systems grouped 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
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 Quality

+ Health & Safety

Environment + Health & Safety
Quality + Environment + Health & Safety
The aim of an integrated system is to streamline processes even further and avoid
duplication. 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
(Integrated
Management
Sysytem)

QMS
(Quality
Management
System)

(i.)

EMS
(Environmental
Management
System)

GMS
(Global
manufacturing
System)

QMS(Quality Management System) :

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

procedures, processes and resources needed to implement quality management. QMS has tended
to converge with sustainability and transparency initiatives, as both investor and customer
satisfaction and perceived quality is increasingly tied to these factors. Of all QMS regimes the
ISO 9000 and ISO 14000 series are probably the most widely implemented worldwide - the ISO
19011 audit regime applies to both, and deals with quality and sustainability and their integration.

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(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):
Serves as a tool to improve environmental performance
Provides a systematic way of managing an organization
s environmental affairs
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
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
Focuses on continual improvement of the system
o

(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
People Involvement,
Built-in Quality,
Standardization,
Short Lead Time
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. In
total, 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.

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14.GM INDIA PRODUCTS

C H EVR O L E T O P TR A
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 hightension 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.

C H EVR O L E T T AVE R A
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.

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CHEVORLET 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.

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CHEVORLET 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.

CHEVROLET 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.

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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.

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CHEVROLET 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 64 kW engine and a 1.4-liter 76 kW
S-TEC III engine are available. The transmission options include a five-speed manual and a fivespeed electronic manual transmission (EMT). Airbags, central locking, AUX in / USB input and
power steering are standard equipment

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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. Manufactur ing Depar tment:

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.
Manufacturing department consists of body shop, paint shop and assembly line.
3. Finance Depar tment:
Finance Department looks after all the monetary transactions and is responsible for
budgeting.
4. Pr oduct Engineer ing:
The department is responsible for getting the localized parts only those, which confirm
the GM specifications.
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 Depar tment:
Quality department ensures the best quality to be delivered to customers.
Quality department audits vehicles right from body shop till final buyoff of the vehicle.

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6. Maintenance Depar tment:

The maintenance department at General Motors India has a lot of responsibilities to be
taken care of.
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 esour ces depar tment:
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.
Human Resource management includes (1) conducting job analyses, (2) planning
personnel needs, and recruitment, (3) selecting the right people for the job, (4) orienting
and training, (5) determining and managing wages and salaries, (6) providing benefits and
incentives, (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:
Training Function.
Recruitment Function.
Payroll Function.
Industrial Relation.
Safety & Security.
Administration.

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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 coordinate 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, productengineering 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,
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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
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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 befor e 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).

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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 coordinates 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 testdecision-making.

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

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 Pr oduct 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

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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
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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 LOCALIZATION 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 REQUI REMENT (SOR)

18.1 NEED FOR SOR:
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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:
Who is the Responsible Engineer for the concerned part?
Part Description: Part Description is provided for the supplier, where exactly the part, which
is being localized, is assembled on the vehicle.
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.
List of Engineering Drawings: The Engineering Drawing list provides the list of main
drawings and child drawings needed for making the part.
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.
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.
GMI Testing: The localized components must undergo validation testing in accordance with
the time plan developed by the supplier.

18.2 SOR RELEASE PROCESS:

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Design Release Engineer (DRE) to write the SOR taking into consideration of:
Applicable drawings and specifications
Generic Template of the SOR Check list
Approval of the SOR is done by signing off by relevant approval authority (DIRECTOR, PE).
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 PROJ ECT ON DOOR LATCH: PROJ ECT NO.1
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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 consisting
of 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 front
of 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 in
buildings.
DOOR LATCH: A door latch is defined as
a device or mechanism that is to close and open the
door, 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).
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Rod can
reciprocate up
& down.

Slot

PROPOSED DESIGN FAILED AT PRODUCTION TRAIL RUN (PTR): The door latch below failed
because the adjustable clip (highlighted) was fouling with glass run channel.

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Adjustable clip is
provided in place of
slot.

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).

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19.1.2FRONT DOORS SQUEAKS / ABNORMAL NOI SE: PROJ ECT 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

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PART NOT

After 4000Kms

New part introduced.

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After fitment

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19.1.3 CARGO DOOR DENT ISSUE: PROJ ECT 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.

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STRUCTURAL PATCH

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

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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.

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Break pipe

Regular part
So to avoid that situaton

We have changed the dimensions of the gap which

is highlighted in the picture and it has reduced
from

Regular part

Manual sample

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R eg ular part

Manual part

The gap between the brake pipe and the steering shaft increases from 10mm to 30mm.

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19.2.2 BRAKE PIPE CLIPS: PROJ ECT 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:

PERFORMANCE OF M- SHAPED CL IP

M-SHAPED:

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PERFORMANCE OF W- SHAPED CL IP

19.3HEAT VENTILATION AND AIR CONDITIONING FUNCTION

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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: Radiator s 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 to
the atmosphere, and then back to the engine in a closed loop. Engine coolant is usually waterbased, 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.

Shroud

Radiator fan

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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 : PROJ ECT
NO.8
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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: 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.

Shroud with L ug

PROPOSED SOLUTIONS:
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1. To change the design of lug, instead of being flat it should be of inter-locked one.
2. To change the material of shroud in order to control the warpage of shroud.
ACCEPTED SOLUTION
We have changed the material of shroud previously supplier was manufacturing the shroud by
using Glass Wool material but now it is using Talc Wool material, as a result of that the warpage
has been reduced from 10mm to 2mm.

19.3.3 COOLANT HOSE FITMENT PROBLEM: PROJ ECT NO.9

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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.
TYPE OF ISSUE: Plant issue and field issue.
IPTV: 100% (APPROX)
CASES REPORTED: Almost in every vehicle
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

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OK PART
Leakage not observed

NOT OK PART
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:
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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: PROJ ECT NO.10

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ISSUE: Rubber intercooler hose length has become short when it is assembled between the two
metallic hoses of the intercooler.
TYPE OF ISSUE: Plant issue and field issue.
PPH: 100% (APPROX)
CASES REPORTED: Almost in every vehicle
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.

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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.

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19.4 NOISE, VIBRATION AND HARNESS FUNCTION:

19.4.1 STUDY ON THE BASICS OF SOUND AND NOI SE:
WHAT IS SOUND?
Sound may be defined as any pr essur e var iation (in air, water or other medium) that the
human 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 fr equency of
the sound, and is measured in Her tz (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
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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 NOI SE TEST: PROJ ECT NO.11

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 OBJECTIVE: :- To Study and understand the pass by noise levels for various cost Saving
Proposals.
1) Proposal of removing the Hood insulation.
2) Proposal of removing the fender insulation.

INTRODUCTION:
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.
Pass by noise levels are defined as a noise generated by vehicle in moving condition.
It is a noise that person listens whenever a vehicle moves or passes through him.
It is very important to measure & control the pass by noise to save our precious
environment from noise pollution.
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 the
fast 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:69| 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 within
1 dB (A). These conditions shall be deemed to have been met, if there are no large soundreflecting 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:70| 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 m
and 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:
The sand fraction (0.063 mm <square mesh sieve size < 2 mm) shall include no more than
55 percent natural sand and atleast 45 percent crushed sand;
The base and sub-base shall ensure a good stability and evenness, according to best road
construction practice;
The chippings shall be crushed (100 percent crushed faces) and of a material with a high
resistance to crushing;
The chippings used in the mix shall be washed;
No extra chippings shall be added on to the surface;
The binder hardness expressed as PEN value shall be 40 to 60,60 to 80 or even 80 to 100,
depending on the climatic conditions of that place. It is recommended that to the extent
possible a hard binder shall be used; and
The temperature of the mix before rolling shall be chosen so as to achieve by subsequent
rolling the required voids content. In order to increase the probability or complying with
the requirements the compactness shall be studied not only by an appropriate choice of
mixing temperature, but also by an appropriate number of passing and also by the choice
of compacting vehicle.

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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
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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 sound measuring systems available. Although different in detail, each
system consists of a microphone, a processing section and a read-out unit.
The microphone converts the sound signal to an equivalent electrical signal. The most suitable
type of microphone for sound level meters is the condenser micr ophone, which combines
precision with stability and reliability. The electrical signal produced by the microphone is quite
small and so it is amplified by a preamplifier before being processed. Several different types of
processing may be performed on the signal. The signal may pass through a weighting networ k.
It is relatively simple to build an electronic circuit whose sensitivity varies with frequency in the
same way as the human ear, thus simulating the equal loudness contours. This has resulted in
three different internationally standardized characteristics termed the " A" , " B" and " C"
weightings.
When more detailed information about a complex sound is required, the frequency range from 20
Hz to 20 kHz can be divided up into sections or bands. This is done with electronic filters which
reject all sound with frequencies outside the selected band. These bands usually have a
bandwidth of either one octave or one thir d octave. An octave is a frequency band where the
highest frequency is twice the lowest frequency. For example, an octave filter with a centr e
fr equency of 1 kHz admits frequencies between 707 and 1414 Hz, but rejects all others. (The
name octave stems from the fact that an octave covers eight notes of the diatonic musical scale).
A third octave covers a range where the highest frequency is 1,26 times the lowest frequency.
The process of thus dividing a complex sound is termed fr equency analysis and the results are
presented on a chart called a spectr ogr am. After the signal has been weighted and/or divided
into frequency bands the resultant signal is amplified, and the Root Mean Squar e (RMS) value
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determined in an RMS detector. The RMS is a special kind of mathematical average value. It is
of importance in sound measurements because the RMS value is directly related to the amount of
energy in the sound being measured.
The last stage of a sound level meter is the read-out unit which displays the sound level in dB, or
some other derived unit such as dB (A) (which means that the measured sound level has been Aweighted). The signal may also be available at output sockets, in either AC or DC form, for
connection to external instruments such as level or tape recorders to provide a record and/or for
further processing.
SOUND L EVEL METER

TEST SITE AND PREPARATION OF THE VEHICLE:

The test site shall consist of a central acceleration section surrounded by a substantially
flat test area .
The test acceleration section shall be level, moreover the track surface remain dry so that
the rolling noise remain low.
The Microphone shall be located at a distance of 7.5+-0.2m from reference line cc1 of the
track and 1.2+/- 0.1m above the ground. Its axis of maximum sensitivity shall be
horizontal and perpendicular to the path of the vehicle.
For all the measurements, the vehicle shall be driven in a straight line over the acceleration
section in such a way that the median longitudinal plane of the vehicle is as close as possible to
the line cc1.

APPROACH SPEED: FOR FOUR WHEELERS AND MULTI -AXLE VEHICLES.

In case of M1 category vehicles the approach speed should be equal to three quarters of the
speed at which the engine develops its maximum rated power.
In case of vehicles of other categories having an engine power not greater than 225KW.
If the vehicles equipped with a manually operated gear box having more than four
forward gear ratios should be tested in second and the third gear.
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CONCLUSION:
Sr .No

Configur ation

Pass by noise levels (dBA)

Status

Existing Condition

Pass

Proposal 1 Removal of Hood insulation

X+ 0.2

Pass

Proposal 2 Removal of Fender insulation

X+1.2

Failed

19.4.3 ULTRASONIC LEAK DETECTION: PROJ ECT NO.12

OBJECTIVE: To detect the sources and the points through which the sound leaks.
What is ultr asound?
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Sound has been defined as vibration of an air column to which a human ear would respond.
Ultrasound is those frequencies that are above human hearing. Humans can usually begin to hear
low frequency sound at about 30 Hertz (cycles per second). This is comparable to the low bass
frequencies in a good music system. The upper range for high frequency hearing is usually in the
neighborhood of 15,000-20,000 Hertz or 15 to 20 kilohertz.

Even though we humans don't have much sensitivity to the higher (or to us, ultrasonic)
frequencies, these sounds exist in nature.
ULTRASONIC LEAK DETECTOR:
An ultrasonic leak detector is designed to listen for sound in the 40 kHz range. These instruments
are used to pinpoint pressure or vacuum leaks, detect mechanical wear of bearings or brushes or
locate electrical arcing or discharge. As something is passing through a hole, crack or crevice, thr
friction generates ultrasound at 40 kHz or above. The instrument will detect this sound. You can
also create sound at 40 kHz through a tone generator or a transmitter.
Equipments USED DURING THE ACTIVITY
1. Sound Source
2. External Senso
3.

Headphone

PROCEDURE TO BE FOLLOWED:
1.

Ultrasound energy is excited through piezo sensor inside the source and modulated and
convereted to audible range thorugh the external sensor consist of piezo sensor and
displayed on figure.

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2. After placing the ultrasound source inside the car close all the doors of the car.
3.

Hold external sensor with display unit on the hands

4. Take the Sensor near all the possible leakage points.

5. note down all the points.

SOUND SOURCE

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Exter nal Sensor with display unit and Headphones

POINTS WHERE THE LEAKAGE HAS BEEN DECTECTED:

1.Body panel; grommet under body.

2.Front door glass mould:

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3.Rear door wheel arc area:

19.4.4 IN CABIN NOI SE TEST: PROJ ECT NO. 13

OBJECTIVE: To measure the incabin noise for various VAVE(value Added Value Engineering)
proposals.
AIM:
1. Incabin noise measure by removing the hood insulation.
2. Incabin noise measured by removing fender insulation.
INTRODUCTION:
Noise and vibration have an important influence on a customer
s perception of vehicle quality
and cabin
interior noise levels are a key criteria. The interior sound levels of automobiles have significantly
reduced over the years, with reductions in power train, tyre and external wind noises. New model
vehicles are well insulated from sounds fromthe outside, but the noise from the interior of the
cabin also needs to be addressed.
EQUIPEMENTS USED:
1. Microphone.
2. Accelerometer.
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3.
4.
5.
6.

Rpm sensor.
Laptop.
Head acoustics frontend.
Head audio recorder.

PROCEDURES TO BE FOLLOWED:
1. Place the microphones on the driver seat and third row seat.
2. Place the accelerometer at the particular point.
3. Attach the rpm sensor on the engine compartment such that its light should fall on the
pulley directly.
4. Attach the wires to the frontend.
5. With the help of the laptop take the particular readings.
6. The readings should be taken at various gears for the particular time seconds at the WIDE
OPEN THROTTLE.
CONCLUSIONS:
1. Incabin noises increases by removing the hood insulation.
2. Incabin noises increases by removing the fender insulation.

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SETTINGS OF THE INSTUMENTATIONS.

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