SEMINAR ON

SUMMER TRAININGS
• 1st SUMMER TRAINING: SHIRDI INDUSTRIES LTD. (1ST JUNE
2017 to 30TH JUNE 2017)
• 2nd SUMMER TRAINING: TATA MOTORS LIMITED (1ST JUNE
2018 to 30TH JUNE 2018)

By: THAKUR SINGH KHARAYAT

48667
 ABOUT THE INDUSTRY
• Shirdi Industries Limited established in 1993, is a wood
based interior furnishings solution provider, engaged in the
manufacturing and distribution of an array of wood based
panel products which include:
• Medium density fiber (MDF),
• Pre-laminated MDF (PLM),
• Particle boards (PB), and pre- laminated PB (PLP),
• High Pressure Laminates (HPL),
• Flooring, door skins, panel doors, modular furniture and
other allied products
• PVC edge bends used to cover the edges of boards,
• Plywood, doors etc.
 OUR MOTTO IS–
`AAO GHAR SAVARE`

Our Vision
To provide the best services to our clients, and to
maintain our pioneer and leading position in the
industry by using our creative and innovative
approach in the projects implemented, without
compromising the product and service quality.
Our Mission
To become an automation systems manufacturer
providing high-quality, reliable and customized
solutions using our longstanding knowledge,
experiences and development power, without
requiring the sources and support of any other
domestic or international companies, and by
protecting the social and physical environment.
 MANUFACTURING FACILITIES IN INDIA

• Pantnagar, State of Uttarakhand – MDF, PB, pre-laminated

MDF & pre-laminated PB, HPL, doors and door skins, furniture
& furniture components, laminated floorings
• Bhivandi, near Mumbai – cutting / slitting of imported edge
bends
• Coimbatore – Pre-lamination and door plant
• Roorkee, State of Uttarakhand – Plywood & Doors
 PANTNAGAR PLANT
• Commenced operation in Feb 2007
• The company sells products with a strong B2B
distribution and not B2C distribution
• 550 employees across its corporate office
and manufacturing facilities on rolls and
nearly 700 employees on contract.
PRODUCTS PORTFOLIO
 THE MANUFACTURING PROCESS
• Soaking the paper
The process begins by soaking strips of paper in resin.
• Drying
The resin-soaked sheets are then put into a drying chamber.
• Thermosetting
The layers of paper are then loaded onto a flat-bed hydraulic
press for final curing. The press compresses the sandwich of resin-
soaked paper at 1,400 psi, while heating it to a high temperature.
The heat catalyzes a reaction in the resins. The phenol and
formaldehyde molecules attach to each other.
• Finishing
The dry sheet is cut into the desired size and shape. It may also be
bonded to a building material such as plywood, flake board,
fiberboard, or metal.
 ABOUT THE ORGANIZATION

• Tata Motors Limited is an Indian multinational automotive

manufacturing company headquartered in Mumbai. It is
a subordinate of Tata Group. Its products include
passenger cars, trucks, vans, coaches, buses, sports cars,
construction equipment and military vehicles.
• Tata Motors has auto manufacturing and assembly plants
in Jamshedpur, Pantnagar, Lucknow, Sanand, Dharwad,
and Pune in India, as well as in Argentina, South Africa,
Great Britain and Thailand.
 MISSION, VISION & VALUES
• Mission
We innovate mobility solutions with passion to
enhance quality of life.
• Vision
1.The preferred choice for customers in delivering
excellence, efficiency and value in design and
engineering solutions
2.Achieving sustainable financial performance
3.Delivering exciting innovations
• Values
1.Integrity
2.Teamwork
3.Accountability
4.Customer focus
5.Excellence
6.Speed
MANUFACTURING UNITS IN INDIA
PRODUCT PORTFOLIO
 ABOUT PANTNAGAR PLANT

• The Tata Motors' plant at Pantnagar is the site where the best-selling Tata
Ace - the mini one-tonne truck, and its variants are manufactured. The
plant is a world-class project that is spread across 1,000 acres in
Uttarakhand's State Industrial Development Corporation.
• The plant has been designed to enhance speed and efficiency in
manufacturing. It is the company's first plant with an integrated vendor
park, which occupies 337 acres of the plant's total area. This helps keep
inventory low and ensures 'just-in-time' (JIT) supplies. The 73 vendors based
here account for nearly 75% of the items supplied to the plant.
• Fact File
1. Fourth Tata Motors plant to come up, after Jamshedpur,
Pune and Lucknow
2. Spread over 1,000 acres
3. Began commercial production in 2007
4. Facilities include weld shops, paint shops, engine and gear
box shops, and assembly lines
5. Over 5,000 employees and 2,500+ contractual workforce
(including vendors and service providers)
6. First plant of TML to house an integrated vendor park

• Milestones
1. Production started in record time after acquisition of land (in
just 11 months)
2. Achieved the 1 million ACE milestone in FY12 and aims to
achieve the 2 million milestone in FY19
PRODUCTS FROM PANTNAGAR PLANT
LAYOUT OF PANTNAGAR PLANT
 TO IDENTIFY THE CAUSES OF HIGH
PRESSURE LINE LEAKAGE AND THEIR
PREVENTION

UNDER THE GUIDANCE OF

Mr. Sanjeev Mishra (HEAD, Engine Shop)

Mr. Devesh Pandey (Engine Shop)

 PROJECT: IDENTIFICATION OF
CAUSES OF HP LINE LEAKAGE AND
THEIR PREVENTION.
First, we must know the basic
concept and use of HP line.
It is clear from the diagram
that HP line is the linkage
between FIP (Fuel Injection
Pump) and Injector. An
Injection Pump is the device
that pumps diesel into the
cylinders via an injector. Its
function is to pressurize the
charge and to discharge it
into combustion chamber.
FIG. HIGH PRESSURE LINE
 OPERATIONAL PROCEDURE FOR
INSTALLATION OF HP LINE

Fig.: Green marker ticks to verify on line inspection.

FISH BONE DIAGRAM FOR THE ESTIMATION OF CAUSES
WHY-WHY ANALYSIS
H.P. Line
Leakage

Mis-
allignment

Improper
Bend Angle
 PROBABLE CAUSES OF
LEAKAGE
• ERRORS AT VENDOR’S END
• Alignment or Design Mismatch
• Injector top or HP line thread damaged
• ERRORS AT OPERATOR’S END
• Loose or Improper Tightening
 Frequency of defects due to
various causes
8
8
number of defected units 7
6
5 4
4 3
3
2
1
0
Misalignment Damaged Loose fitting
Thread
causes of defects

ROOT CAUSE: ON OBSERVING THE ABOVE CHART IT IS

CLEAR THAT THE MAJOR PORTION OF DEFECTS FOUND
WERE DUE TO MISALIGNMENT. AND THIS DEFECT IS
OBSERVED IN FINAL ENGINE INSPECTION WHICH LEADS
TO A HUGE WASTE OF TIME, ENERGY AND MANPOWER.
SO THIS NEEDS TO BE IDENTIFIED AS EARLY AS POSSIBLE.
 RECOMMENDED SOLUTIONS

• FOLLOW THE SEQUENCING ORDER OF NUT

TIGHTENING.
• CLEAN AREA AROUND THE FUEL INJECTORS
PROPERLY BEFORE TESTING.
• MODIFY THE SAMPLING PLAN AS PER
FREQUENCY OF USAGE AND DETECTION OF
ERRORS IN HP LINE.
• MASTER FIXTURE CALIBRATION AS PER
FREQUENCY OF USAGE.
• FUTURE SCOPE: PART AND FIXTURE
MODIFICATION