“A STUDY ON TQM FOR EXISTING PROCESSES USING TOOLS & TECHNIQUES

FOR 4ST SOLENOID SWITCH IN LUCAS INDIAN SERVICE”

Submitted as a part of MBA IInd year Course Requirement 

By

P.SATHISH KUMAR

Regno : 3511040141

Under the guidance of

MRS. VALLIAMMAL

SRM B-SCHOOL

FACULTY OF ENGINEERING AND TECHNOLOGY

SRM UNIVERSITY (RAMAPURAM II)

VADAPALANI, CHENNAI

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BONAFIED CERTIFICATE

This is to certify that _________ SATHISH KUMAR. P_(3511040171)_________________ is a

Bonafide Student of SRM B-School, SRM University, Vadapalani, Chennai. He is in the IInd year of

Masters Degree Program in Business Administration (MBA). He has done this project under my

guidance and supervision towards part fulfillment of II year MBA course requirement.. 

 

 

 

 

 

Project Guide  :   Mrs . valliammal HOD

Date:

Place:  

 

DEPARTMENT SEAL

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DECLARATION

I SATHISH KUMAR. P (3511040171) studying in II year MBA program at SRM B-School, SRM

University, Vadapalani, Chennai, hereby declare that this project is an original work of mine and I have

not verbatim copied / duplicated any material from sources like internet or from print media, excepting

some vital company information / statistics and data that is provided by the company itself.

 

 

 

 

 

Signature of the Student :

Date: 

Place: 

 

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ACKNOWLEDGEMENT

I am extremely glad to present my summer project report as a part of our curriculum. I take this

opportunity to express my sincere gratitude those who have helped me in bringing out the project

report.

First and foremost I wish to thank God, the almighty his immense blessings and guidance

throughout the training programmer.

I express my heartfelt thanks to Mr.PATCHAMUTHU founder and chairman of SRM

GROUP OF EDUCATIONAL INSTITUTIONS. Mr.N.VASUDEVAN, our beloved dean for their

support and encouragement to carry out this project.

I wish to convey sincere and heartiest thanks to Professor Mr.T.P.NAGESH, Head of the

department of the management studies, Srm University, Vadapalani for his kind approval to work on

this project.

I express my deep profound feeling of gratitude to Mrs. VALLIAMMAL my respected project

guide for the help and critical suggestions for timely completion of the training.

I further express my deep sense of gratitude to Mr. C.SATHYA MURTHY, HR of Lucas Indian

Service Ltd., Chennai for his constant encouragement and valuable help.

I would like express my sincere gratitude to Mr. VEERA RAGAVAN, External guide for his

unfailing guidance and support at every stage of this project.

And above all, I would like to express our heartfelt thanks to all members of the HRD and

PRODUCTION department of LUCAS INDIAN SERVICE LIMITED, CHENNAI for their constant

help & co-operation rendered during the project work.

Place: Chennai

Date: P. SATHISH KUMAR

4

ABSTRACT

To gain an understanding of the theories and concepts of production process to apply

concepts to understand what manufacturers do in “the real world”. To improve skills in the

research and analysis of production segments, demand, and market potential. To utilize

knowledge of the production to enhance strategic decision-making. To analyze the production

process of the manufacturing unit when selecting a particular brand.

Bridging the gap between performance expectations of the customer and Most of the people

looking for achieving the demand and Next preference are given to the rejection of defectives in

daily basis. In the case of LUCAS INDIAN SERVICE LTD. the customer is considering

quality & performance of the product.

Performance delivered to them will ensure customer delight. It is advised that the customers are

educated about the services and employees updated on the expectations of the customers. Even

the employees in the retail outlets have to be well trained to help the customers.

The data for the study has been obtained from secondary sources i.e., from various books and

journals fact sheets of different ignition coils and websites. From this it can be seen that

97.88% of the customers of LUCAS INDIAN SERVICE LTD. They are satisfied with their

ignition coil and again they are willing to buy the same.

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TABLE OF CONTENTS

6

S.NO PARTICULARS PAGE NO

CHAPTER 1

1.1

1.2

1.3

1.4

1.5

1.6

INTRODUCTION

COMPANY BACKGROUND

STATEMENT OF THE PROBLEM

OBJECTIVES

NEED FOR THE STUDY

SCOPE & SIGNIFICANCE OF THE STUDY

LIMITATIONS

CHAPTER 2

2.1

2.2

2.3

REVIEW OF LITERATURE

NEWSPAPER ARTICLES

MAGAZINE ARTICLES

INFORMATION FROM WEB

CHAPTER 3

3.1

RESEARCH METHODOLOGY

TOOLS USED FOR ANALYSIS

CHAPTER 4

4.1

4.2

DATA ANALYSIS

CLASSIFICATION

DESCRIPTIVE STATISTICS

CHAPTER 5

5.1

5.2

INTERPRETATION & FINDINGS

DATA INTERPRETATION

MAJOR FINDINGS

CHAPTER 6 SUGGESTIONS & CONCLUSION

CHAPTER 6 BIBLOGRAPHY

CHAPTER NO.1

INTRODUCTION ABOUT THE TOPIC :

Total Quality Management :

In today’s world due to insufficient quality or indifference to quality lead to disputes, which imposes

serious drain on the financial resources of a company and limits profit potential. To be competitive in

today’s market, it is essential for construction companies to provide more consistent quality and value

to their owners/customers. It is high time to develop better and more direct relationships with our

owners/customers, to initiate more teamwork at the jobsite, and to produce better quality work. Total

quality management is a management’s approach towards the quality, it can be in regard to products,

customer satisfaction and employees satisfaction. The concept of TQM was developed by an American

W. Edwards Deming and i.e. why it is called as Deming’s concept of TQM .He introduced this concept

for improving the quality of various products and services. Earlier it was just related with the quality of

products which a organization is producing but now other concepts like marketing, finance design,

customer service has also joined the area. Which means that now good number of things are there to

manage. TQM works on one belief that mistakes can be avoided and defects can be prevented. And

management should believe in watching each and every step.

TQM is now a days called as TPM (total productivity management) and an organization needs to

consider ABCD for the effective application of TQM where A stands for accident cure , B stands for

breakdown , C stands for cost reduction and D stands for damage. This policy of ABCD is in relation to

product and if TQM needs to be introduced a positive attitude from the side of management and

employees is required and then a collective effort will come up. TQM should give chance for

unleashing employee’s creativity and potential. The aim of TQM is to reduce variations in quality of

the products as well as in the working of whole organization. For the successful implementation of

TQM, an organization must consider the commitment from all the level of organization. A concept of

Six sigma is a part of TQM. It is a strategy developed by Motorola and it helps to detect the defects and

to remove them.

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TQM talks about the satisfaction of customer, supplier, employees etc. and it requires continuous

improvement. If the workers of an organization are efficiently working then their morale will go up.

TQM works effectively if the organization works in a family manner. Here management is like a father,

employees are the children and manager is like mother and as father and mother takes care for their

home collectively the same way , management and managers are supposed to take care for their

organization with the help of tool called TQM. Total quality management is called total because entire

organization is involved, Quality means degree of excellence. And management in literal sense means

getting things done by others. In a TQM effort, all members of an organization participate in improving

processes, products, services and the culture in which they work. The earlier introduced quality

management concept is now taken over by Total quality management. To have effective TQM the first

requirement is strong internal motivation and emotional involvement for implementation. So the

concept of TQM talks about adopting the new policy, creating quality products, eliminate defects,

estimate for breakdown, accidents etc . Hence TQM should be purpose driven so first the whole

organization should be willing to accept the change then only TQM can actually affect the organization

in a positive way.

What is Total Quality Management

Definition:

TQM is a management philosophy, a paradigm, a continuous improvement approach to doing business through

a new management model.

TQM is a comprehensive management system which:

Focuses on meeting owners’/customers’ needs, by providing quality services at a reasonable cost.

Focuses on continuous improvement.

Recognizes role of everyone in the organization.

Views organization as an internal system with a common aim.

Focuses on the way tasks are accomplished.

Emphasizes team work.

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Total Quality Management (TQM) is a management approach to long–term success through customer

satisfaction.

In a TQM effort, all members of an organization participate in improving processes, products, services

and the culture in which they work.

The methods for implementing this approach come from the teachings of such quality leaders as Philip

B. Crosby, W. Edwards Deming, Armand V. Feigenbaum, Kaoru Ishikawa and Joseph M. Juran.

A core concept in implementing TQM is Deming’s 14 points, a set of management practices to help

companies increase their quality and productivity:

Create constancy of purpose for improving products and services.

Adopt the new philosophy.

Cease dependence on inspection to achieve quality.

End the practice of awarding business on price alone; instead, minimize total cost by working

with a single supplier.

Improve constantly and forever every process for planning, production and service.

Institute training on the job.

Adopt and institute leadership.

Drive out fear.

Break down barriers between staff areas.

Eliminate slogans, exhortations and targets for the workforce.

Eliminate numerical quotas for the workforce and numerical goals for management.

Remove barriers that rob people of pride of workmanship, and eliminate the annual rating or

merit system.

Institute a vigorous program of education and self-improvement for everyone.

Put everybody in the company to work accomplishing the transformation.

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1.1 COMPANY BACKGROUND

INTRODUCTION ABOUT THE COMPANY:

Lucas Indian Service (LIS) established in 1930, is a specialist organization in sales and

service of "Lucas-TVS" auto electricals and "Delphi-TVS" diesel fuel injection equipment. LIS also

manufactures automotive products like ignition coils and solenoid switches in Chennai which are

marketed under the brand name "Lucas". LIS distributes "LISPART" range of auto parts and

"Lucas" range of automotive batteries through tie-ups with leading manufacturers. Besides

manufacturing, sales and distribution, LIS offers servicing and training in auto electrical and diesel fuel

injection equipment.

Lucas - TVS established in 1961 as a joint venture between Lucas UK and T V Sundram Iyengar &

Sons (TVS), India to manufacture Automotive Electrical Systems. Lucas-TVS is the Leader in Auto

Electricals in India today with 48 years experience in design and manufacturing. 4 out of 5 vehicles

rolled out daily are fitted with Lucas-TVS products.

Lucas - TVS is a TS16949 and OSHAS 18001 certified company. Lucas-TVS has bagged the

Deming application price in 2004 from the Japanese Union of Scientists and Engineers (JUSE). Lucas-

TVS, believes that quality begins and ends with the customer. This means identifying customer needs

and comprehensively meeting them. For the company, quality is not just conformance to drawings or

specifications but ensuring customer satisfaction.

The TVS Group traces its origin to a rural transport service, founded in 1911 in Tamil Nadu,

India. Today, this renowned business conglomerate remains faithful to its core ideals of trust, values,

service and ethics. The TVS Group is India's leading supplier of automotive components and one of the

country's most respected business groups. With a combined turnover of more than USD 5 billion, the

TVS Group employs a total workforce of around 25,000. Charting a steady growth in terms of

expansion and diversification, it currently comprises around 43 companies. These companies operate in

diverse fields ranging from two-wheeler and automotive component manufacturing to automotive

dealerships, finance and electronics. Uniting these multiple businesses is a common ethos of quality,

customer service and social responsibility.

Lucas-TVS Limited, along with its subsidiaries, designs, develops, manufactures, and supplies

automotive electrical systems. The company offers starter, wiper, blower, and fan motors; and

alternators, headlamps, dynamo regulators, dynamos, ignition coils, diesel fuel injections, fuel injection

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equipment, electronic ignition systems, and automotive lighting products. Its products are used in

passenger cars, commercial vehicles, tractors, jeeps, two-wheelers, and off-highway vehicles; earth

moving equipment and gensets; and stationary and marine applications. Lucas-TVS Limited offers its

products through a network of branches and outlets serving customers in the United States/European

markets.

INDUSTRY PROFILE:

The features of the industries that produce ignition coils other than Lucas Indian Service ltd. is

listed below.

Aaditya Auto Care

Manufacturer & exporter of Ignition coil, primary ignition coil, motorcycle ignition coil,

honda ignition coil, trigger coil, vehicle brake shoes, motorcycle brake shoes, engine parts, roller and

needle bearings, gear shifter for lml vespa

Hueco Electronic (India) Pvt. Ltd.Manufacturer & exporter of coils ,ignition coils, automotive ignition coils, auto ignition coils,

heat resistance coated o rings, enameled o ring, ring washers, rubber rings, communication tower parts,

ms diptrey glass top model, automotive fuel pump, feed pumps, high pressure pumps.

United Traders Corporation:Manufacturer & exporter of ignition coils, automotive ignition coils, two wheeler ignition coils,

three wheeler ignition coils, three wheeler parts,etc..

Neha Implex:Engaged in exporting of auto ignition coil system, ignition coil for bajaj vehicles, induction

coils, Honda ignition coils, primary ignition coils, trigger coil, motorcycle ignition coils.

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Swami Auto Products:Manufacturer of source coil, pick up ignition coil, electronics part, 2 wheeler & 3 wheeler pick

up coils, magnet wires, regulators, lighting coils, ignition coils, flashers, startors,etc..

Diksha Springs Udyog:Exporter, manufacturer and supplier of coils, choke coil, cooling coils, dc coils, economizer

coils, field coil, hot dip galvanized coils, hot rolled steel coils, ignition coil, ss.

Punjnad Auto & Rubber Inds. Pvt. Ltd.

Manufacturer of coil, pressure blade, primary ignition coil, pvc grip cover, rear control rod, rear drum

plate, rear fork, rotor cover,etc..

COMPANY PROFILE

Basic Information

Company Name: Lucas Indian Service Ltd

Business Type: Manufacturer

Product/Service

(We Sell):Ignition coil,4st switch

Address: #6, Pattulos Road, Anna Salai

Number of Employees: 51 - 100 People

Ownership & Capital

Year Established: 1930

Legal

Representative/Business

Owner:

B.Sreeram

Trade & Market

Main Markets: North-America12

South-America

Western-Europe

Eastern-Europe

Eastern-Asia

Southeast-Asia

Mid-East

Africa

Oceania

Total Annual Sales Volume: US$1 Million - US$2.5 Million

MISSION:

The mission of Lucas Indian Service is to provide high proactive after sales and service

to vehicle makers and users in its areas of specialization(electrical and diesel systems).LIS will

continuously expand the scope of its sales and service offerings for vehicle and non-vehicular

applications in anticipation of customer needs. LIS will continuously expand its network and enhance

the technical skill of its people & the network through use of contemporary technology.

VISION:

Lucas Indian Service (LIS) will strive to become India’s dominant and most respected service

provider in its areas of specialization by 2013. LIS will expand overseas with focus on SAARC,

ASEAN and Middle East.

STRENGTH:

MANUFACTURING:

Manufacturing Products are manufactured using State-of-the-Art facilities organized in

Product Units, Modules, Nagare Cells and Assembly Cells and incorporating Quick Change

Tooling, Pokka Yoke, Chakku Chaka (Auto Unloading). The condition of machines is

monitored and maintained by TPM techniques and the schedule adherence is monitored by

DRM (Daily Routine Management) while Process & Product Quality is sustained and improved

by ZED-Q (Zero Defect Quality) activities. The Manufacturing system is competently backed

13

up by an advanced Tool Room and an in house SPM/ Process Plant manufacturing facility. The

entire organization is firmly entrenched in the change process and committed to CIP

(Continuous Improvement Program me).

Our Journey Towards Manufacturing Excellence:

Products are manufactured using State-of-the-Art facilities organized in Product Units,

Modules, Nagare Cells and Assembly Cells and incorporating Quick Change Tooling, Pokka

Yoke, Chakku Chaka (Auto Unloading). The condition of machines is monitored and

maintained by TPM techniques and the schedule adherence is monitored by DRM (Daily

Routine Management) while Process & Product Quality is sustained and improved by ZED-Q

(Zero Defect Quality) activities.

Total Quality Management (TQM):

Lucas-TVS, believes that quality begins and ends with the customer. This means

identifying customer needs and comprehensively meeting them. For the company, quality is not

just conformance to drawings or specifications but ensuring customer satisfaction. This belief

forms the basis of its approach to Total Quality Management (TQM). Quality Assurance

methods like Advanced Product Quality Planning, Statistical Process Control Techniques,

Effective Tool Management System, Process Capability Improvements, Preventive

Maintenance, Producer Control and Small Group Activities form the backbone of the system

approach adopted. In its continuous pursuit of both technological as well as methodological

excellence, Lucas-TVS has scripted yet another new dimension to manufacturing by not only

adopting the Cellular Manufacturing System / JIT but also extending the same to its Suppliers.

By the implementation of this system components from its suppliers are delivered on a pull

basis with First In First Out concept supported by simple visual controls and supplied to the line

on an hourly basis with KANBAN system.

Distribution Network:

LIS extensively covers the country through its 4 regional offices located at the main

metros and 20 branches equipped with warehousing facilities. The widespread distribution

network of LIS reaches 650 towns and cities. LIS has established a network of over 1500

dealers. The company also maintains close bonds with a large number of institutional clients,

State Transport Undertakings, Coal fields, Public Sector Undertakings and Defense

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Establishments.

QUALITY POLICY:

We are committed to achieving ever increasing levels of customer satisfaction by ensuring

delivery of high products, high reliability in the delivery of the offerings and a high quality of after

sales service. This is to be achieved continually improving the effectiveness of the quality management

system. It will be our endeavor to increase customer trust and confidence in products manufactured,

marketed and serviced by LIS.

CUSTOMERS:

The major customers are:

Maruti Suzuki India Limited.

Enfield India Limited.

Ashok Leyland Limited.

Tata Motors Limited.

Cummins India Limited.

TAFE.

Mahindra & Mahindra Ltd.

Lucas-TVS Pondicherry Limited.

AVTEC.

Swaraj Mazda Ltd.

AMW.

Some of the customers are;

Yamaha Motor India, LML, Hero Honda, Kirloskar Oil Engines Birla Yamaha, Greaves Cotton,

Tata Cummins, Caterpillar India, TAFE, Johndeere, Tata Motors, Ashok Leyland, etc..

INTERNATIONAL PRESENCE:

The company exports its products to U.S.A, U.K, DENMARK, IRELAND, BELGIUM,

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SPAIN, ITALY, TURKEY, SRILANKA, BANGLADESH, OMAN, EGYPT, U.A.E, KUWAIT,

etc.. Some of the OE customers Artic Cat- U.K, IVECO- Italy, Proton- Malaysia, etc..

Milestones:

In 1930, Joseph Lucas ltd, U.K. established.

In 1930, Lucas Indian Service in Bombay was started.

In 1937 Calcutta operation was started.

In 1946 Chennai operation was started.

In 1960 Lucas Indian Service Ignition Coil factory was started.

In 1968 Lucas Indian Service became subsidiary of Lucas- TVS

In 1972 New Delhi operation was started.

In 1977 marketing of LISPART alto equipment was started.

In 1985 promotion of Indian Nippon Electricals ltd was started.

In 1994 manufacturing of solenoid switch was started.

In 2003 Lucas Care was launched.

In 2004 total quality management(TQM) was launched.

In 2005 platinum jubilee was celebrated.

In 2006 inverters and inverter batteries were launched.

Achievements:

Lucas-TVS, believes that quality begins and ends with the customer. This means identifying

customer needs and comprehensively meeting them. For the company, quality is not just conformance

to drawings or specifications but ensuring customer satisfaction. The awards got by LIS are

II PLACE IN NATIONAL ENERGY CONSERVATION, AWARDS – 2008

Lucas-TVS is Awarded "OUTSTANDING SUPPLIER & EXCELLENCE PERFORMANCE

during the year 2007 by CUMMINS INDIA LIMITED

Maruti VA - VE Award:

1. Best Vendor Award (2000 & 2006)

2. VA / VE Award (2006)

3. Outstanding Overall Performance Award (2004)

4. Superior Kaizen Award (2004)

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ACMA Technology Award:

1. Gold Trophy for Manufacturing Excellence (2004-05)

2. Productivity Award (2001-02)

3. Technology Award (1998-99)

Platinum Award for Manufacturing Excellence (2005)

Managerial Excellence in Manufacturing (2004-05)

5 Star Award on 5S (2002)

Energy Conservation Award(2000 and 2001)

Best Supplier Award (2007)

Rajiv Gandhi National Award (2006)

Best Performer Award (2001-2002)

VA/VE Award (2002-2003)

Deming Application prize JUSE, Japan:

1. INTERNATIONAL RECOGNITION

2. JIT Innovation Award from JIT Management Lab, Tokyo (2001 & 2004)

3. JIT Grand Prix Award from JIT Management Lab, Tokyo (2002, 2005 & 2006)

4. 3 Times Deming Application Prize 2004

Best Quality Award (2007)

100 PPM Award (2003)

ZONAL SALES CENTRES:

Andhra Pradesh

Karnataka

Kerala

Tamil Nadu

Maharashtra

Goa

Gujarat

Madhya Pradesh

West Bengal

Totally there are 21 sales centers in India.

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Service Policy:

Lucas Indian Service is dedicated to providing high quality service to its customer focus and

solution process.

Customer focus means:

1. To understand the problems and needs of the customer

2. To ascertain the nature of the problem and understand the root cause based on the past

history of the vehicle recorded in our system.

3. To provide warranty back up for a period of six months to all services rendered to

customers.

4. To extend customer friendly facilities like- extended work hours, Sunday working, call

centers and mobile service

5. To measure the satisfaction level of customers and implement corrective actions for

improvement.

Solution process means:

1. To offer solutions aimed at corrective and preventive action to avoid recurrence of the

same problem.

2. To follow standard operating procedure on all workshop processes.

3. To provide customized infrastructure with a choice to include preventive maintenance,

float units, pick up & drop facility etc., to customers.

Benefits & Features:

Lucas Indian Service Limited (a subsidiary of Lucas TVS) is a specialist organization,

providing solutions for auto electrical and diesel fuel injection equipment.

With over seven decades of expertise in the automobile industry, we know how important your

car is to you. Lucas Indian Service Limited provides you with a unique preventive maintenance

program "Lucas Care" which optimizes your car's performance and helps to prevent breakdowns.

What is Lucas Care?18

Lucas Indian Service is one of the first organizations to introduce a solution-based program, which

focuses on preventing breakdown through regular maintenance checks.

What are the car systems that the program covers?

Starting System

Charging System

Ignition System(Petrol)

Fuel Injection System(Diesel)

Lighting System

Wiping System

What is the process involved during the periodic check up?

Check up, cleaning & top up your car battery

Check up of starting system to facilitate quick start

Check up of charging system to protect car battery and other electrical accessories

Check up and "timing/tuning" of ignition/fuel injection system to facilitate smooth running and

minimize pollution

Electrical load validation and comprehensive system screening

Check up and cleaning of air filter, fuel filter and heater plugs( for diesel cars)

Free consultation on car maintenance

Unmatched Features of Lucas Care

Four FREE service check ups in a year covering quote electrical and fuel injection

equipment(for diesel cars)

FREE labor charges - if the auto electrical units require repair or overhauling during the

program period

25% DISCOUNT on labor charges in case the fuel injection unit (for diesel cars) requires

repairs, overhauling or re-calibration during the program period

Breakdown attention within city(up to 25 kms, 9 am to 6 pm)

5% DISCOUNT on spare parts

Lucas Care Benefits19

Prevention of breakdowns to enable a stress free driving experience

Service at your doorsteps and at your convenience

Access to genuine spares

1.2 STATEMENT OF THE PROBLEM

The study focused on the quality problems with regard to man & machinery defect free products.

Manpower.

Machinery.

MANPOWER:

The quality problems with regard to manpower;

Rivet damage.

Bracket hole upset.

Body bulk plating.

Base crack.

Thread damage.

Sold ring damage.

MACHINERY:

The quality problems with regard to machinery;

Low pulling.

Pulling failed.

N/C (no continuity).

Flash failed.

1.3 OBJECTIVES

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The main objective consists of organizing equipment and working areas in most efficient way,

satisfactory and safe for the personnel doing the work.

Primary objective : "To study on total quality management for existing processes using tools and

techniques and suggesting improvements for better effectiveness." for 4ST Solenoid Switch.

Secondary objective:

To study the existing quality practices done in the factory. Understand the usefulness of

existing quality control tools.

To minimize In-House rejection and customer complaints in 4st switch.

To achieve shipment of 100% defect free products.

1.4 NEED FOR THE STUDY

Production of quality products.

Customers satisfaction.

Good image in public.

Better utilization of resources.

Reduction in wastages.

Highly motivated employees.

For Employer:

Review on the functioning of various Production processes of finding and solving the

problems.

For Employee:

Employee involvement improves quality and increases productivity.

1.5 SCOPE & SIGNIFICANCE

Total quality management study is carried out in the LIS for a period of two months.

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Total quality management study for the existing process to improve in the quality level

of production. Those study is carried out using quality control tools like;

Check-sheet.

Pareto chart.

Pie chart.

Histogram.

The study helps to identify the area in which quality can be improved to achieve 100%

defect free product.

1.6 LIMITATIONS

Total quality management study is carried out in the LIS for a period of two months.

The new quality tools are not used due to lack of time.

The collected data have been analyzed in the systematic manner.

CHAPTER 2

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REVIEW OF LITERATURE

2.1 NEWSPAPER ARTICLES

Date:07/06/2011

Lucas to market U.S. firm's lubricants

NEW DELHI: The U.S.-based TOP1 Oil Products Company on Monday joined hands with Lucas

Indian Service, a part of Lucas-TVS Group, for sale and distribution of its premium range of lubricants

in the Indian market. “We see huge potential in the Indian lubricant market which today is worth

Rs.25,000 crore. Of this, over Rs.2,000 crore is for high quality synthetic and semi-synthetic oil

segment, the market which we are targeting in India,” TOP1 Oil Products Company Vice-President

(Sales & Marketing) Frank Ryan told journalists here.

“We are known for producing lubricants for niche market segment and new generation vehicles. We

hope our high quality and innovative products will soon become popular in the Indian automobile

market, which is world's fastest growing market. As our marketing partner, Lucas Indian Service will

strengthen our presence in India,” Mr. Ryan added.

According to Lucas Indian Service President Sandeep Abbi, “We are optimistic that the arrival of

famous global lubricant brand TOP1 in India will add to the growth of the premium lubricant market.

Through our wide distribution network, TOP1 will soon become popular in India.”

LUCAS Indian Service Limited Ties Up with Top1 Oil Products Company

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Jun 9 11

LUCAS Indian Service Limited tied up with Top1 Oil Products Company to introduce the foreign

firm's products in India. The company has been appointed as the distributor for Top1 brands in India,

has launched lubricants for the motorcycles, passenger cars and heavy duty diesel vehicles segments.

Top1 products for motorcycles will be available in the range of INR 285 to INR 750 per litre, while

those for passenger cars are priced between INR 285 and INR 1,200 for every litre. The per litre cost of

heavy duty diesel vehicles' lubricants will be INR 310 to INR 370.

TOP1 oil products company, USA launched its premium range of lubricants in India

TOP1 Oil Products Company, based in USA has launched its premium range of lubricants for the first

time in India at a press meet held at New Delhi yesterday. TOP 1 has tied-up with Lucas Indian Service,

a specialist organization in sales and service of auto electrical and automotive products as their

marketing partners for distribution.

Mr. Frank Ryan of TOP1 &

Mr. Sandeep Abbi during the launch

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Mr. Frank Ryan during his presentation

Mr. Frank Ryan of TOP1

& Mr. Sandeep Abbi of Lucas

launching TOP1 Lubricants in India

Mr. Frank Ryan, Vice president, Sales & Marketing, TOP1 Oil Products Company, USA and Mr.

Sandeep Abbi, President, Lucas Indian Service Ltd. have jointly done the honor of launching this

premium category of lubricants from USA in India. Amongst the others present during the occasion

were Mr. R. Ramesh, Chief Executive, TOP1 Lubricant Products Company India and Mr. M.S.

Kumaran, Business Development Advisor, TOP1 Oil Products Company, USA. Top 1 lubricants target

niche market segment which comprises of high quality users and are used mostly in new generation

vehicles. Lucas Indian Service has a strong network in distribution of premium products ranges from

automotive electrical parts, fuel injection system and automotive filters all across the country. Both

being leaders in their respective segments, this strategic tie-up would bring favorable competition in the

premium lubricant market in India.

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Speaking on the occasion, Frank Ryan, Vice president, Sales & Marketing, TOP1 Oil Products

Company, USA said “In the spirit of excellence, Top1 always strive to provide the highest quality

lubricants using the most innovative methods and focusing on customer satisfaction and value. We are

extremely proud in extending our business in India. Further to this, having Lucas Indian Service as our

marketing partners would certainly strengthen our presence in India.”

The market potential of lubricants is more than 20,000 crore in India. Limited players are there in the

synthetic & semi synthetic oil segment, which is estimated of Rs. 1,000 crore of the total market value.

In 21st century, it is clear that the lubricant industry is undergoing a tremendous transformation. The

companies are facing increasingly stringent lubricant specifications that have been mandated by both

the major car manufacturers as well as governments around the world. Oil prices remain at the highest

levels in history and raw material shortages remain an ongoing challenge. Despite the challenges,

TOP1 think it’s their prime responsibility to provide the highest quality lubricants using the most

innovative and cost-effective methods.

During the occasion, Sandeep Abbi, President, Lucas India Service Limited said, “We are extremely

honored to be chosen as the marketing partners of this lubricant giant from USA. We are also very

optimistic about the arrival of TOP1 in the Indian market, as it will add on to the growth of ever

growing premium lubricants’ market in India. TOP1 already have a strong presence in USA and the

other western market and are targeting for the same in India too.”

About top1 oil products company

Established in 1979 in USA with the objective of providing its customers premium and high quality

automobile and synthetic blend lubricants all across the globe. All Top1 Oil Products Company

products made in the USA. are formulated with the latest state-of-the-art base oil called Syngen 2000

technology. This patented Syngen 2000 technology results in lubricants that are significantly less

volatile. Today, spread over more than 40 countries, Top 1 brand is the preferred choice of discerning

customers of automotive lubricants in automobile centric markets like South East Asia, Latin America,

etc. Equipped with modern facilities and automatic batch blending, TOP1 factory consistently

manufactures high quality advanced world-class lubricants.

About Lucas Indian Service Limited

Established in 1930, it is a specialist organization in sales and service of “Lucas -TVS” auto electricals

and “Delphi –TVS” diesel fuel injection equipment. The brand portfolio of LIS consists of leading 26

product brands –“Lucas-TVS” Automotive Electricals, “Delphi-TVS” Diesel Fuel Injection Equipment,

“LISPART” Auto Parts, and “LUCUS” Automotive Batteries, Ignition Coils & 4ST Switches. LIS also

promotes preventive maintenance services under the brand name “Lucas Care”. Lucas Indian Service

extensively covers the country through its 4 regional offices located at the main metros and 23 branches

equipped with warehousing facilities. The widespread distribution network of the company reaches 650

towns and cities through 2000+ dealers, 500+ service dealers and 200+ institutional customers.

2.2 MAGAZINE ARTICLES

27

28

2.3 INFORMATION FROM WEB

INFOMEDIA YELLOW PAGES

Lucas Indian Service – The Retail Connection

Business Articles

Chennai headquartered Lucas Indian Service (LIS), a specialized aftermarket player—focused on auto

electrical and diesel injection systems in the country—is firming up its foray into car retail accessories

under the brand Car plus. The pilot project, introduced a little over a year ago, is ringing in positive

signals for the company to help finalize its plan in this area of business. The company feels that the

response from the two dedicated showrooms in Gurgaon and Ludhiana is encouraging and it is now

trying out several options to reach out to the discerning customers. As part of its initiative, LIS has

opened a counter in a departmental store in Delhi a couple of weeks ago. This move is expected to help

the company to understand the customers’ expectations in terms of reach and convenience besides, the

availability of the range of products, said the President, Lucas Indian Service, Sandeep Abbi.

Talking to Aftermarket, he said, “This is a pilot project, an experiment to see how we can go about it in

a big way. It is in the nascent stage and we are trying to understand the retail business. Retailing is

different from the normal aftermarket sales and service support business, since it involves vehicles and

accessories. Right now, we are going through the learning curve in understanding what the customers

look for—the accessories purchasing pattern of both new vehicle owners and the old ones. Opening a

smaller format, in the departmental store, is again a learning process to understand whether we should

have standalone stores or be part of a mall or a departmental store. The idea is to offer a unique and

different buying experience to the customers. They can touch and feel the products and have a different

experience as far as car accessories are concerned. Abbi said that at this point of time, these outlets are

owned by the company and going forward, when it wants to expand in a big way, it might look at

franchise model also. “We have a roadmap, which basically envisages us to look at about 120 outlets

over a period of five to seven years. This is contingent on us first having our learning and business

29

model in place,” he said. It will escalate once the learning is completed in about a year or so.

The company will be focusing on the entire range of cars. Normally, in high-end cars, a lot of

accessorisation has already happened. And so it is really at the A, B and C segments of cars that require

accessories. And to support the requirements, Car plus deals with the complete range of accessories—

from infotainment to security systems, navigation, upholstery, interiors and exteriors. It also deals with

different brands. Besides, the retail outlets carry out several services including anti-rust treatment,

wheel balancing and such things. The two retail outlets have specific bays where the customers can see

the work in progress from an air-conditioned lounge. The retail store also deals with tyres for passenger

cars. Asked if LIS would extend a similar concept to two-wheelers, he said, “We may consider at a later

stage but at this point of time we would like to focus on passenger cars and multi-utility vehicles.

The network that LIS has established over a period of time is largely oriented towards dealing with

electrical and fuel injection systems of automobiles. And the entire value chain is aligned to that.

Therefore the company will be largely confined to these two segments as it feels that there are still

many unrepresented avenues within auto electrical and fuel injection systems. However, there are

certain items including high performance lamps and HIDs that are currently dealt with by car plus,

which might come in as part of the company’s distribution network, he said. Lispart already deals with

these kinds of products including halogen lamps, and it will only be a natural movement for the

company to expand the product portfolio.

The entire aftermarket businesses of Lucas-TVS and Delphi-TVS is overseen by LIS. It sees

tremendous synergies amongst different business divisions such as Lucas-TVS (auto electrical),

Delphi-TVS (diesel fuel injection system), Lispart (outsourced auto parts) and Lucas (batteries, ignition

coils and switches). The core business of the company is to provide sales and service to auto electrical

components manufactured by Lucas-TVS and diesel injection systems made by Delphi-TVS. “We have

specialized in auto electrical and diesel injection systems. And we are looking to expand in adjacent

areas of business. For example, we have recently tied up with lubricant company—Top1 of the US, to

distribute its products all over the country except south India. This is basically for exclusive

distribution of synthetic and semi-synthetic lubricants and not the mineral-based lubricants. Although

the market is largely towards mineral-based lubricants, the new generation vehicles and quality

conscious customers see merit in going for the synthetic lubricants. We would not be playing the

volume game. However, it could become the mass market in the future. It’s a strategic move for us,” he

said. The company will be catering to the requirements of motorcycles, passenger cars and diesel

segment in both cars and commercial vehicles. Later on, it hopes to cater to industrial lubricants too, he 30

added.

Under the brand ‘Lucas’, the company sells ignition coils, switches and batteries. Except for batteries,

the other two products are manufactured by LIS. It has been supplying ignition coils to the earlier

generation of Maruti vehicles. With the change in technology the company has now been catering to

aftermarket requirements of those vehicles. Besides, it also deals with switches that are primarily meant

for starter circuits. In addition, it also outsources batteries and sells under ‘Lucas’ brand. This is a small

part of its operations. Asked if the company will look at expanding its product portfolio, he said the

range of switches may expand. The company directly sells its batteries through its dealerships. Besides,

it also sells to OEMs who in turn rebrand and sell as genuine parts.

Today, the company has a network of over 2,000 dealers covering close to 700 towns and cities. About

two wheelers he said, “We are already in two-wheelers through some of our products since Lucas-TVS

is catering to two wheeler segment. Also we now handle lubricants.” Under Lispart it has some spare

parts for this segment and this is the area where the company is hoping to strengthen further. “Over the

last few years we have started building a portfolio for more two-wheeler parts,” he said. Auto electrical

and filters are the areas where the counterfeit is more. The industry estimate is around 30 percent,

however, he feels that it should be more in the auto electrical and filters. New generation vehicles with

advanced technologies become a natural barrier for the counterfeit. The company has three mobile units

with auto electrical and fuel injection test equipment, to hold campaigns and also to train the people in

the outlets. Each unit caters to one of the three regions—north, east and west. The southern region is

catered through the TVS group companies themselves, he said. Lucas Care, which was launched few

years ago to cater to the passenger car users, is now oriented towards the institutional customers on

preventive maintenance. This is because of rigorous demand in this segment.

The company deals with over 10,000 parts and it has developed an in house software to manage the

supply chain from the manufacturers till the part is delivered to the end customers. The software built

within its IT systems with certain principles works on the basis of supply chain management. It helps

the company to integrate with its suppliers and subsequently to distributors and dealers. Since retailers

are smaller entities, they do not have the capability of holding a wide range of parts. The software

developed by the company helps in replenishing the stocks at the earliest possible time, he said. The

company has 23 branches with warehousing capabilities. It is currently building ‘Central Warehousing’

units in Chennai and Pondicherry, which will become part of the larger supply chain management. LIS

has 350 service dealers and 40 company-owned workshops through which, it sets the benchmark for

servicing. The company-owned outlets will play a significant role in imparting training to the service 31

dealers. LIS maintains the history of vehicles and even if the vehicles move from one city to the other,

the service history can be retrieved to facilitate easier service.

With the vehicle parch and variety increasing, there will always be growth in the aftermarket business

despite the fact that the life-span of the spare parts is significantly increasing. Besides, the increasing

awareness of preventive maintenance will also spur the demand. According to him, some categories

that fall under the replacement cycle and the aftermarket, will also move from repair to reconditioning.

When asked about remanufacturing, he said that LIS is already into this in a small way on starters and

common rail systems. “These are in very early stages for us to understand on how the processes are to

be handled. As we go through our learning, we would definitely look at expanding, “he said

32

PRODUCT PROFILE

IGNITION COIL Function and Testing - IG-108:

Maybe you don't really need to know how an ignition coil works to test it, but it helps. I will

try to keep the explanation in layman's terms for simplicity. 

WORKING PROCEDURE:

WORKING OF IGNITION COIL

The ignition circuit on the MGA is quite simple. One primary terminal on the coil gets

system power, and the other terminal is connected in series with a capacitor to ground return

in the distributor. Additionally the contact points in the distributor parallel the capacitor to

complete the ground return when the points are closed. .

 

The ignition coil is a transformer with about 100 to 1 ratio between secondary and

primary windings. The output voltage will be 100 times greater than the input voltage.

Picture here is for reference only. You should never need to open a sealed ignition coil. If it

doesn't work it must be replaced. . 

You can think of the capacitor as a small high speed storage battery. It can build up a

positive charge on one side and negative charge on the other side. When polarity is suddenly

reversed current will flow out of one side and into the other side. No current flows

completely through the capacitor, but the current going in one side equals the current

coming out the other side for the short time when it is charging or discharging. Meanwhile it

33

simply stores a small electrical charge temporarily. The amount of power stored there is

proportional to the voltage and frequency. . 

When the contact points are closed the primary winding of the transformer is

connected in series with the battery and carries an electrical current of about 4 amps. Since

the points are shorting across the capacitor, the capacitor does nothing (at that time). The core

of the transformer is an electromagnet with magnetic field induced by the current flowing in

the primary winding. . 

When the points open to break the ground contact the primary current must stop

flowing, and the magnetic field in the transformer will collapse. The collapsing magnetic

field forces current to continue flowing in the same direction momentarily, and that current

will charge up the capacitor. Forward inertia of this forced current raises voltage at the

capacitor momentarily to about 300 volts, at which time this high voltage stops the current.

The current then reverses direction, being driven backward by the high voltage at the

capacitor. After the charge in the capacitor is depleted, inertia of the current in the

transformer continues to drive the current in that direction to charge the capacitor in

opposite polarity. The cycle then reverses. The result is an electrical ringing like a bell

which reduces rapidly with time. . 

The initial 300 volt spike in the primary winding will drive an output in the

secondary winding up to 30,000 volts. The output current going to the spark plug will

likewise ring in harmony with the input current, for as long as the output voltage is high

enough for current to jump the spark gap under compression. Assuming the initial spark

ignites the fuel air mixture, combustion pressure will rise rapidly, and the spark will stop

almost immediately as voltage falls. By now it should be obvious why the capacitor is an

essential part of the ignition circuit, and the engine will not run without it.

34

Picture from an oscilloscope showing multiple traces of sparks 

For those following along with a little math, a four cylinder engine running 6000

RPM generates 200 sparks per second, so the full spark cycle lasts just 0.005 second. Dwell

(time when points are closed) for the standard Lucas distributor is 60 degrees out of each 90

degrees of rotation of the distributor shaft, so the points are open only one third of the time,

or 0.00167 seconds. How fast can you say "RING"? The only way you can ever see or

measure this ringing, as in the picture above, is with an oscilloscope. 

TESTING OF IGNITION COIL:  

For preliminary test, use an ohm meter to check the resistance of the windings of the

coil. For a non-ballasted ignition system like the MGA, coil primary resistance should be

about 3.2 ohms. A high energy coil may have slightly lower primary resistance. A coil for use

with a ballasted type ignition system (such as late model MGB) will have about half as much

primary resistance, around 1.6 ohms. Resistance for the secondary winding will be very high,

something like 10,000 ohms. Check that circuit resistance between the HT output and one of

the primary input terminals. . 

To test the ignition coil function you will need a battery, a few wires, and a capacitor

(about 0.01 mF value). Connect battery power to the coil. Mount the capacitor physically to a

grounding point (return to battery opposite the power terminal), and connect the capacitor

wire to the other side of the coil (terminal opposite the power input terminal). Connect a

jumper wire to the coil along with the capacitor connection. . 

Touch jumper wire to ground (the capacitor mounting point) to complete the coil

primary circuit. When you disconnect the jumper from ground, and you should get a nice

35

spark from the coil. Touch jumper to ground, then pull away to make spark. Hold the coil

output high tension wire near a grounding point to see how far the spark jumps. Spark should

jump more than 1/4 inch in open air. . 

With all parts in place in the car, you can do this test with a single jumper wire. Leave all

wires in the car connected. Remove distributor cap, and rotate engine until the contact points

are open. This leaves the grounded capacitor in series with the coil. Turn on the ignition

switch. Short the off side coil terminal (the one not connected to ignition switch power) to

ground with the jumper wire. When you disconnect the jumper wire you should get the spark.

This of course assumes that the primary wires inside the distributor are properly connected

and are not shorted to ground. As a point of clarification, the two wires connected to the

contact points must be in contact with the spring arm of the points and must not be touching

the mounting screw. . 

If you do not connect the capacitor the spark may be so small as to be hardly visible, and

lucky if it will jump 1/32 inch gap. The capacitor is an essential part of the circuit, providing

an electrical "ringing" in the primary side of the coil at up to 300 volts. Without the capacitor

the spark voltage would be reduced dramatically. If you get no spark from the coil, you need

a new coil (or a new capacitor). If you get good spark from the coil, you know your problem

lies elsewhere.

 IGNITION COILS VARIETY

36

These are examples of ignition coils you may find on an

MGA.

. 

The primary terminals would be screw posts for 1500 and early 1600 cars, but may

have Lucar push on terminals like this one for late 1600 and 1600-MK-II cars. The bracket is

a more modern replacement type with a tab in the center which might be used to attach a

condenser (capacitor) for RF noise suppression, or a bracket for a ballast resistor. . 

The coil in the center is a period accessory style Lucas High Energy Coil. This has it's

own unique bracket with the Lucas logo in blue. The high tension connector is original screw

in type. Primary terminals are original screw posts. . 

The coil on the right is a modern Lucas Sport Coil (40,000 volts capacity). The gold

37

color case is standard for this item as well as the bracket with the black sticker. The high

tension terminal has the more modern push in type connector. The primary terminals have

screwed on Lucas connectors which can be removed if you want to use early style ring lugs

for the wire connectors. This model has been available since at least the early 1990's, and

may be longer. . 

If you just need a replacement coil to keep you running, you can pick one up at almost

any local auto parts store. You may expect these to be painted black, and they may have push

on terminals which may be either riveted in place or removable to expose screw posts. The

key feature is that you need a coil designed for 12 volts non-ballasted ignition system. This

will have primary coil resistance of about 3.2 ohms. A coil for ballasted ignition system (like

late model MGB) will have primary resistance of about 1.6 ohms. You should take an ohm

meter with you when you go to buy a coil, and look for about 3.2 ohms primary resistance for

the MGA. A high energy coil may have slightly lower primary resistance, perhaps around 2.7

ohms. 

Ignition coils are available under many brand names such as Bosh, Crane, Mallory,

and a great variety of house brands, and the many available colors are irrelevant. Many of the

well known brands will feature high energy or high voltage, while the house brands may be

either high energy or lower cost standard coils. .

. 

There is nothing magic about a high energy coil, but it may help the engine start a

little easier in cold weather or adverse conditions (like fouled spark plugs). When parts of the

ignition system are older and somewhat deteriorated the higher voltage may help fire the

spark through high resistance plugs or wires. It might also cause arcing and misfire if the high

tension wire insulation is breaking down, or the end boots are deteriorating. 

A final note about terminal markings: Later production ignition coils were marked

"+" and "-" on the primary terminals, which makes hook up pretty much self-evident. The

primary terminals of early coils for positive earth setup were marked "SW" for Switch, and

"CB" for Contact Breaker". In the positive earth system the ignition switch supplies power

from the Negative battery post, and the contact points ground the other side of the coil to the

Positive battery post. Therefore "SW" = "-" and "CB" = "+". This bit of knowledge and logic

can avoid confusion if you change your vehicle from positive earth to negative earth. In that

38

case you reverse the coil wires, and the "CB" terminal connects to the positive Switch wire

while the "SW" terminal gets grounded to negative through the Contact Breaker. If you're still

confused, buy a new coil with the "+" and "-" markings. 

39

Car Ignition System

LAYOUT OF IGNITION COIL:

40

Dismantled Ignition coil

Ignition coil forms the basic and important part of ignition system in petrol engine.

An ignition coil is made up of step-up windings or coil immersed in the transformer oil.

This step-up winding is placed inside on aluminum container for safety and

transportation.

The ignition coil consists of primary winding and secondary winding. The primary

winding is made up low resistance winding and secondary is made up of high resistance

winding.

Secondary coil is wound first. The layer of the coil are insulated with kind of glassy

transparent paper. The coil are wound with the help of semi-automated machines. The

first four layers are wound manually and the rest of the layers are wound with the help of

semi automatic machine. Totally 24-25k windings are done with copper wire of dia

0.070mm. Once the secondary winding is done the coil is sent for insulation in “Make

Of Stage”.

After” make of stage” it is sent to primary winding section. In primary winding

section the first resistance of the coil is checked. It must be between 7.05 to 14ohms

The turns for primary and secondary windings depends upon the demands. For eg:25k

25K---46 swg-- secondary windings

41

310turns--------21.5 swg- Primary windings

Then the tested coil is sent for the varnish. The varnish is mainly done to make the

copper wire insulated so that the short circuit in the winding can be avoided. Then the

coil is heated at about 120°c for about 20 minutes. Then the coil is dipped in the varnish

for about 2minutes and heated about 30minutes for 120°c

The tested leads of the coil are tinned with a soldering lead. Then “I” core is fixed into

the coil and the bottom of the coil is fitted with ceramic material. The coil thus produced

is placed inside the aluminum container. The top end of the container is closed with

plastic cap with two inputs and an output in the centre. Then the container is filled with

transformer oil and then sealed. Then the manufactured coil is tested by giving an input.

The speed of the input contact point is kept in 1300rpm and the output voltage must be

35kva and at 3000 rpm the output must be 28kva.

QUALITY INSPECTION:

At each and every step of the ignition coil manufacturing, there is a quality

inspection. The coils are checked for

Perfectly sealed

Without any damage

Proper output

Proper packing

SOLENOID SWITCHES:

Solenoid switches are used to provide better switching and they help to

transfer electric current from battery to the starter motor. Solenoid switches ensure safety

and prevent damage.

Solenoid switches consists of an input to the coil, an input from battery and an

output. The ground connection is given to the frame or the bracket in the case of 12V

switches.

42

4ST SOLENOID SWITCH

Lucas Indian Services manufactures 12V and 24V solenoid switches. In 12V

switches, the frame or bracket is grounded. In 24V switches a separate lead is provided

for grounding purposes.

For 12V solenoid switches 450 turns of copper wire are wound around plastic

spools. For 24V solenoid switches 870 turns of copper wire are wound.

A solid iron core fixed with copper plate at one end is placed inside the coil.

The plate comes in contact with the input and output leads. The coil and the core are

packed inside the steel bracket. 11A, 13A, 24A solenoid switches are available.

Quality Inspection:

Solenoid coils are checked as soon they wound. After the manufacturing

process of the solenoid switch is completed, they are tested under pulse condition. They

are tested with the help of solenoid switch test rig.

The switches are then inspected for any damage or any other missing

components then they are packed and labeled.

43

CHAPTER 3

RESEARCH METHODOLOGY

In general “research” can be termed as an inquiry in to the nature of, the reason for,

and the consequences of any particular set of circumstances. It is the process of finding

solution for a problem after a thorough study and analysis of the situation factors. It tries

to solve complex and complicated problem through use of various tools and techniques.

These tools and techniques try to bring out a logical, accurate and scientific solution to

given problems.

“METHODOLOGY” as the name suggests is the method through which the problem

or situation is tackled. Managers in organization constantly engaged themselves in

studying and analyzing issues and hence are involved in some form of research activity as

they make decisions at the work place. It involves a lot of factors like research design,

sample size, segment, and techniques of sampling, tools used etc all these steps and

factors put together to bring out a clear and accurate result.

The research methodology adopted for the present study has been systematic and was

done in accordance to the objectives set, which has been discussed in the earlier pages.

RESEARCH DESIGN

A research is the arrangement of conditions for collection and analysis of data in a

manner that aims to combine relevance to the research purpose with economy in

procedure. In fact the research design is the conceptual structure within which

research is conducted; it constitutes the blue print for the collection, measurement and

analysis of data. The research design adapted in the study was descriptive study.

DESCRIPTIVE RESEARCH

Descriptive research includes surveys and fact-finding enquiries of different kinds.

The major purpose of descriptive research is description of the state of affairs, as it

exists at present. The main characteristic of this method is that the researcher has no

control over the variables; research can only report what has happened or what is

happening. A descriptive study is undertaken in order to ascertain and be able to

describe the characteristics of the variable of interest in a situation. Descriptive studies

are also undertaken to understand the characteristics of organizations that follow

certain common practices.

44

SOURCE OF DATA:

Data refers to information or facts. The two main sources of data for the

present study have been primary data and the secondary data.

Minimize rejection and customer complaints in free product.

The secondary data is ensure that delivery of 100% defect free product and

thus improves the overall efficiency and productivity using quality tools and

techniques.

3.1 TOOLS USED FOR ANALYSIS DATA

The collected data have been tabulated and analysed in a systematic manner. The

following tools and statistical method have been used in the study for analyzing the data.

.

Check-sheet.

Pareto chart.

Pie chart.

Scatter diagram.

Cause & effect diagram.

1.Check Sheet: Also called: defect concentration diagram

Description: A check sheet is a structured, prepared form for collecting and analyzing data.

This is a generic tool that can be adapted for a wide

variety of purposes.

When to Use a Check Sheet

When data can be observed and collected repeatedly by the

same person or at the same location.

When collecting data on the frequency or patterns of events,

problems, defects, defect location, defect causes, etc.

When collecting data from a production process.

45

2. Pareto Chart : Also called: Pareto diagram, Pareto analysis

Variations: weighted Pareto chart, comparative Pareto charts

Description

A Pareto chart is a bar graph. The lengths of the bars represent

frequency or cost (time or money), and are arranged with longest bars

on the left and the shortest to the right. In this way the chart visually

depicts which situations are more significant.

When to Use a Pareto Chart

When analyzing data about the frequency of problems or

causes in a process.

When there are many problems or causes and you want to

focus on the most significant.

When analyzing broad causes by looking at their specific

components.

When communicating with others about your data.

3.PIE CHART:--

Description

A pie chart is used to show visually the proportions of parts of something being studied. The

area

of each slice of the pie shows the slice’s proportion to the entire category being studied and to

the

other slices. A pie chart shows data at one point in time, like a snapshot; it does not show

change

46

in data over time like a line chart does.

When to Use a Pareto Chart

Determine proportions. Find the total value for the entire category being studied and

calculate

the percentage for each segment or part.

Calculate degress. Convert the percentage values for each segment into degrees relative to

the

360 degrees in the circle. (For example, 12% X 360 degrees = 43 degrees)

Construct the chart. Draw a circle and divide it into appropriately sized segments.

Add labels and a title. Label each segment or add a legend to identify the segments. Then

clearly title the chart.

4.Scatter Diagram:- Also called: scatter plot, X–Y graph

Description

The scatter diagram graphs pairs of numerical data, with one variable

on each axis, to look for a relationship between them. If the variables

are correlated, the points will fall along a line or curve. The better the

correlation, the tighter the points will hug the line.

When to Use a Scatter Diagram

• When you have paired numerical data.

• When your dependent variable may have multiple values for

each value of your independent variable.

• When trying to determine whether the two variables are related,

such as…

47

When trying to identify potential root causes of problems.

After brainstorming causes and effects using a fishbone

diagram, to determine objectively whether a particular

cause and effect are related.

When determining whether two effects that appear to be

related both occur with the same cause.

When testing for autocorrelation before constructing a

control chart.

5.Fishbone:- Also Called: Cause-and-Effect Diagram, Ishikawa Diagram

Variations: cause enumeration diagram, process fishbone, time-delay

fishbone, CEDAC (cause-and-effect diagram with the addition of

cards), desired-result fishbone, reverse fishbone diagram

Description

The fishbone diagram identifies many possible causes for an effect or

problem. It can be used to structure a brainstorming session. It

immediately sorts ideas into useful categories.

When to Use a Fishbone Diagram

• When identifying possible causes for a problem.

• Especially when a team’s thinking tends to fall into ruts.

CHAPTER- 4

DATA ANALYSIS

48

Data analysis is made based on the collection of data which is done which is

shown on the following

1.1 CHECK SHEET:-

For March 2012 to April 2012

REASONS NO OF REJECTIONPULLING FAILED 26BODY DAMAGE 4RIVERT NOT OK 86BRACKET HOLE OFF-SET 14N/C 8LOW PULLING 15SOLDRING NOT OK 8BODY BULK PLATE 6

1.2 PARETO CHART:-

SAMPLES DEFECTIVE

014A 97

013A 30

003A 21

012B 9

021A 4

011A 3

020A 3

1.3 PIE CHART:-

49

SAMPLES DEFECTIVE CUMULATIVE PERCENTAGE

014A 97 97 58

013A 30 127 76

003A 21 148 89

012B 9 157 94

021A 4 161 96

011A 3 164 98

020A 3 167 100

1.4 SCATTER DIAGRAM:-

REASONS MARCH 2012 APRIL 2012PULLING FAILED 22 4

BODY DAMAGE 3 1

RIVERT NOT OK 53 33

BRACKET HOLE OFF-SET 11 3

N/C 5 3

LOW PULLING 11 4

SOLDRING NOT OK 4 4

BODY BULK PLATE 2 4

CHAPTER 5

INTERPRETATION & FINDING

50

CHECK SHEET:-

For March 2012

REASONS NO OF REJECTIONPULLING FAILED 26BODY DAMAGE 4RIVERT NOT OK 86BRACKET HOLE OFF-SET 14N/C 8LOW PULLING 15SOLDRING NOT OK 8BODY BULK PLATE 6

REASONS

01-

MAr

03-

MAr

05-

MAr

09-

MAr

10- MAr

12-

MAr

15-

MAr

19-

MAr

21-

MAr

22-

MAr

23-

MAr

24-MAr

26-MAr

28-

MAr

29-

MAr

30-

MAr

31-

MAr

TOTAL

PULLING FAILED

4 18

22

BODY DAMAGE

2 1 3

RIVERT NOT OK

3 3 13

2 4 20

8 53

BRACKET HOLE OFF-SET

1 4 1 1 4 11

N/C 1 1 1 1 1 5

LOW PULLING

5 2 2 1 1 11

SOLDRING NOT OK

4 4

BODY 2 2

51

BULK PLATE

TOTAL 1 7 1 3 5 3 7 2 13

3 1 4 2 5 4 20

30

111

APR 2012:-

REASONS 04-Apr 05-Apr 07-Apr 09-Apr 11-Apr 12-Apr 14-Apr TOTAL

PULLING FAILED

3 1 4

BODY DAMAGE

1 1

RIVERT NOT OK

16 3 2 2 4 3 3 33

BRACKET HOLE OFF-SET

2 1 3

N/C 2 1 3

LOW PULLING

3 1 4

SOLDRING NOT OK

4 4

BODY BULK PLATE

3 1 4

TOTAL 23 7 3 2 5 7 9 56

1.2 PARETO CHART:-

SAMPLES DEFECTIVE

014A 97

013A 30

003A 21

012B 9

52

021A 4

011A 3

020A 3

1 2 3 4 5 6 70

20

40

60

80

100

120

140

160

180

0

20

40

60

80

100

120

140

160

180

97

127

148157 161 164 167

58

7689 94 96 98 100

Series1Series2

1.3 PIE CHART:-

SAMPLES DEFECTIVE CUMULATIVE

PERCENTAGE

014A 97 97 58

013A 30 127 76

003A 21 148 89

012B 9 157 94

021A 4 161 96

011A 3 164 98

020A 3 167 100

SAMPLES DEFECTIVE PERCENTAGE

014A 97 58

013A 30 76

003A 21 89

53

012B 9 94

021A 4 96

011A 3 98

020A 3 100

1.4 SCATTER DIAGRAM:-

REASONS MARCH 2012 APRIL 2012

PULLING FAILED 22 4

BODY DAMAGE 3 1

RIVERT NOT OK 53 33

BRACKET HOLE OFF-SET 11 3

N/C 5 3

LOW PULLING 11 4

SOLDRING NOT OK 4 4

BODY BULK PLATE 2 4

SHIFT-1 SHIFT-222 43 1

54

97

30

21

94 3 3

014A013A003A012B021A011A020A

53 3311 35 311 44 42 4

1 2 3 4 5 6 7 80

10

20

30

40

50

60

22

3

53

11

5

11

4 241

33

3 3 4 4 4

SHIFT-1SHIFT-2

FINDINGS:

55

CHAPTER 6

SUGGESTIONS & CONCLUSION To eliminate the defect LIS can use cause & effect diagram tool and

why? Why? analysis techniques for each type of defects in 4st relay assembly line.

It is a tool for discovering all the possible causes for a particular effect.

CE may indicate the best potential areas for further exploration and analysis.

It helps to find out the actual root cause of the problem.

They can use 100% cause & effect diagram tool for each type of defects.

CE diagrams are best generated in brain storming sessions, when you are talking to the operators about making improvements.

LIS can conduct the tools and techniques refreshment program in a defined intervals to achieve their goals.

Using one of the new qc tools called “swap analysis” can be used.

56

CHAPTER 6BIBLOGRAPHY

BIBLIOGRAPHY

REFERENCES:-

TOTAL QUALITY MANAGEMENT - DALE H. BESTERFIELD

PRODUCTION PLANNING - S.K.MUKHOPADHYAY

AND CONTROL

WEBSITES:-

57

1. www.google.com

2. www.managementparadise.com

3. www.udel.edu/alex/chapt6.html

4. www.lucas-tvs.com

5. www.auto.indiamart.com

6. http://articles.yellowpages.co.in/lucas-indian-service-the-retail-connection/

http://economictimes.indiatimes.com/news/news-by-industry/auto/automobiles/lucas-to-market-us-firms-lubricants-in-india/articleshow/8760191.cms

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59

60

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