Summer trainee project report.doc

Summer Training

TATA Motors, Lucknow

KRITIKA RASTOGIB. Tech. Part-IIMechanical EngineeringInstitute Of TechnologyBanaras Hindu UniversityVaranasi.

Study of various machinery available and operations performed at Production engineering manufacturing shop.

Study of various operations on CV (Commercial Vehicle) assembly line.

Spare parts management of Robotic Welding setup used for manufacturing of Low Floor Buses at IB Factory.

Spare parts management for fixtures used for assembly of COWL and CAB in the BIW shop.

ACKNOWLEDGEMENTS

The writing of this dissertation has been one of the most significant academic challenges I have ever had to face. Without the support, patience and guidance of the following people, this study would not have been completed. It is to them that I owe my deepest gratitude.

Mr. Ashish Kumar (Manager, P. E. Design) and Mr. Uday Kumar (Assistant Manager, P. E. Design) who undertook to act as my project supervisors despite their many other industrial & professional commitments. Their wisdom, knowledge and commitment to the highest standards inspired and motivated me.

Mrs. Jasneet Rakhra (Manager, Human Resources) for providing me the opportunity to add a new dimension in my knowledge by getting trained in this esteemed company TATA MOTORS LTD. LUCKNOW,

All the employees of the P. E. Design department who guided & suggested me to understand the depth of the subject. They have provided me with the wonderful and conducive environment to work in. they have been ever helpful and supportive.

Thanks are also due to all the operators on the CV assembly line, BIW Cowl and Cab Line, Integrated Bus Factory and Production Engineering Manufacturing Unit alongwith my trainee colleagues, with whom I had developed a special bond.

Dated: 5 June, 2010 Kritika Rastogi

CERTIFICATE

This is to certify that Kritika Rastogi pursuing B.Tech. from Mechanical Engineering department of the INSTITUTE OF TECHNOLOGY, Banaras Hindu University, Varanasi has successfully completed the two projects given to her during the course of summer training at Tata Motors, Lucknow.

Project Guide: Mr. Ashish KumarManagerP. E. Design

Project Undertaken:

Spare Parts Management of Robotic Welding and Tack Welding and Assembly features for IB Factory.

Project Guide: Mr. Uday KumarAssistant ManagerP. E. Design

Project Undertaken:

BIW Cowl and Cab line.Fixture Spare Parts Management which includes design and re-engineering of spare parts.

INDEX

COMPANY PROFILE

INTRODUCTION – TATA MOTORS, Lucknow

STUDY OF VARIOUS OPERATIONS PERFORMED AT PRODUCTIONENGINEERING MANUFACTURING UNIT.

STUDY OF VARIOUS OPERATIONS THAT ARE PERFORMED IN THE INTEGRATED BUS FACTORY: THE ROBOTIC WELDING FIXTURES.

STUDY OF VARIOUS OPERATIONS PERFORMED ON CV (COMMERCIAL VEHICLE) ASSEMBLY LINE.

STUDY OF VARIOUS OPERATIONS PERFORMED ON BIW COWL AND CAB LINE. SPARE PARTS MANAGEMENT FOR THE SAME.

COMPANY PROFILE

Established in 1945, Tata Motors is India's largest and only fully integrated automobile company. Tata Motors began manufacturing commercial vehicles in 1954 with a 15-year collaboration agreement with Daimler Benz of Germany. Since 1969, the company's products have come out of its own design and development efforts.Today, Tata Motors is India's largest commercial vehicle manufacturer with a 59 per cent market share and ranks among the top six manufacturers of medium and heavy commercial vehicles in the areas of business Tata Motors' product range covers passenger cars, multi-utility vehicles as well as light, medium and heavy commercial vehicles for goods and passenger transport. Seven out of 10 medium and heavy commercial vehicles in India bear the most trusted TATA mark.

CV Unit

It stands for Commercial Vehicle Business unit. The company has over 130 models of light, medium and heavy commercial vehicles ranging from two tonnes to 40 tonnes, buses ranging from 12-seaters to 60-seaters, tippers, special purpose vehicles, off-road vehicles and defense vehicles.

Passenger Car Unit

The company's passenger car range comprises the hatchback Indica, the Indigo sedan and the Marina, its station wagon variant, in petrol and diesel versions. The Tata Sumo, its rural variant, the Spacio and the Tata Safari (the country's first sports utility vehicle) are the company's multi-utility offerings.

The Tata Indica, India's first indigenously designed and manufactured car, was launched by Tata Motors in 1999 as part of its ongoing effort towards giving India transport solutions that were designed for Indian conditions. Currently, the company's passenger cars and multi-utility vehicles have a 16-per cent market share.

In addition to the growth opportunities in the buoyant domestic market, the company is pursuing growth through acquisitions (it acquired Daewoo Commercial Vehicles, Korea, in 2004) and alliances (it has entered into a tie-up with MG Rover, UK, to supply 1,00,000 Indicas to be badged as City Rover) in other geographies.

Research and Development

Tata Motors invests up to 1.3 per cent of its annual turnover on research and development, with an emphasis on new product / aggregates development and technology up gradation. Its Engineering Research Center in Pune employs over 900 scientists and engineers and has India's only certified crash-test facility and hemi-anechoic chamber for testing of noise and vibration.

The company also draws on the resources of leading international design and styling houses like the Institute of Development in Automotive Engineering, SPA, Italy and Stile Bertoni, Italy. The company has also been implementing several environmentally sensitive technologies in manufacturing processes and uses some of the world's most advanced equipment for emission checking and control.

Environmental responsibility

Tata Motors has led the Indian automobile industry's anti-pollution efforts through a series of initiatives in effluent and emission control. The company introduced emission control engines in its vehicles in India before the norm was made statutory. All its products meet required emission standards in the relevant geographies. Modern effluent treatment facilities, soil and water conservation programmes and tree plantation drives on a large scale at its plant locations contribute to the protection of the environment and the creation of green belts.

Exports

Tata Motors' vehicles are exported to over 70 countries in Europe, Africa, South America, Middle East, Asia and Australia. The company also has assembly operations in Malaysia, Bangladesh, Kenya, South Africa and Egypt.

Associates

With an aim to expand its business horizons, Tata Engineering has always sought opportunities to form alliances with business leaders. In a world driven by

specialization, this policy adopted by Tata Engineering has ensured overall business control and an edge over competition. The joint ventures that Tata Engineering has formed over the years were guided by the contemporary technologies of the partners. Tata Engineering entered into a joint venture with Cummins Engine Company, USA, in 1992 – long before emission control norms were prevalent in India. Cummins was the leading name in manufacturing engines that used emission control technologies. This alliance was the result of Tata Engineering’s foresight and concern for the environment. It is a business practice at Tata Engineering to make strategic investments. These investments provide technologies, markets and capabilities to strengthen the company's existing businesses. Tata Engineering is India's largest exporter of engineering goods.Tata Engineering invests in opportunities that can enhance and reinforce its presence in the corporate world. The Company has numerous subsidiary companies, Foreign Collaborations, Technical Collaborations and Financial Collaboration.Tata Motors has made substantial investments in building associate and subsidiary companies that complement and support its business activities. These include:

Tata Daewoo Commercial Vehicle Company, manufactures heavy trucks ranging from 15T GVW to 45T GVW. Tata Motors acquired this company in March, 2004

HV Transmissions, supplies gearboxes for the company's medium and heavy commercial vehicles.

TAL Manufacturing Solutions, manufactures painting systems, welding lines, material handling systems and robotics. It also develops factory automation solutions and provides consultancy services in the field of manufacturing processes and factory layouts.

Concorde Motors (India): Retails Tata Motors' range of passenger vehicles.

Tata Precision Industries, Singapore and Tata Engineering Services, Singapore, are engaged in the manufacture of high precision tooling and spare parts, and warehousing, respectively.

Nita Company, Bangladesh, is engaged in the assembly of Tata vehicles for Bangladesh market.

Locations

Tata Motors has manufacturing plants at Jamshedpur, Pune, Lucknow and

http://www.tata.com/tata_precision/index.htm

http://www.tata.com/tal/index.htm

Dharwad as well as a well-integrated national sales, service and spare parts network that is focused on providing users with easy access service solutions

TATA Motors, Lucknow Works

TATA MOTORS Lucknow is the third manufacturing unit of Tata Engineering and Locomotive Company. This unit covers an area of 600 acres. In this unit the assembly of chassis and spare parts takes place. On 14th January 1992, the recruitment of operators started in Lucknow plant. On 25th June, induction of Engineers (first phase) began which also included ITI diploma holders. Occupancy of administration office of assembly shop began in September 1992. First vehicle (LP 1210 52) rolled out from Lucknow plant on 20 th October 1992. Construction of MRS was completed on 6th January 1993. It took approximately 9 years since the conception of the plan to rollout the first vehicle from this latest manufacturing facility of Tata Motors. Senior General Manager, Mr. Alok Saxena, currently heads this Unit.

There are five divisions in TATA Motors Lucknow:

Training divisionThe Training Center at the Lucknow plant aims at providing high quality Apprenticeship Training. In addition, the Centre provides both internal and external training, support to operators, supervisors and managers in areas like special skills and technology, safety, personnel practices etc. The Lucknow plant, after a major restructuring exercise, executed a smooth transition from function-based to process-based structure. By this structure, process owners are required to meet stretched targets, and in order to do so, are required to encourage individual learning and development of employees. A structured process is being followed to establish and reinforce an environment that encourages innovation.

Assembly divisionLucknow Plant started with the assembly of Medium Commercial Vehicles (MCVs) to meet the demand in the Northern Indian market. However, in 1995, the unit started manufacturing bus chassis of Light Commercial Vehicles (LCVs) and SUMOs. The facilities for manufacturing the spare parts were set up and started

supply of Crown wheel & pinion (CWP) in 1994. Subsequently, G-16 & G-18 Gear Parts started in 1998. With the availability of G-16 gear parts manufacturing facility, the Plant also started assembly of G-16 Gear Box to meet in-house requirement for SUMO vehicles in the year 2000.Now TATA Motors Lucknow has started assembling of CNG MCVs to meet the consumers demand. TATA Motors is also producing Rear Engine CVs.

Transmission DivisionIn TATA Motors Lucknow Crown Wheel and Pinion are manufactured by various gear cutting process. Machining (grinding and heat treatment) of Gear Box parts is also done here. These gears are used in gear boxes or as spares. Now TATA Motors is assembling Gear Box of ACE(Newly launched small –CV) in Lucknow itself. The Manufacturing unit of Tata Motors at Lucknow is the latest manufacturing facility of Tata motors and is located towards East of Lucknow plant.

Integral Bus DivisionLow floor DTC buses are manufactured on this line. Tata Starbus is a full forward control vehicle available in Standard version, School bus application and Low floor version. It incorporates the well proven features of TATA diesel vehicles to give economic life cycle cost, high reliability and ease of maintenance.

Eastern Complex DivisionThe eastern complex that lies opposite to the main plant unit is the most recent dimension of TATA Motors, Lucknow. There are two assembly lines in the complex where different model vehicles are assembled. There is a BIW shop where sheet metal parts of the cowl and cab are assembled and welded together by different welding techniques on various COWL and CAB lines for different models of vehicles. A paint shop situated in the complex is Asia’s biggest paint shop for commercial vehicles. Cabs and cowls of different models undergo a sequential process of paint.

ABOUT VEHICLE CLASSIFICATION:- In the Commercial Vehicle Business Unit, the models are classified on the basis of GVW as under:

HCV: Heavy Commercial VehiclesMCV: Medium Commercial Vehicles.LCV: Light Commercial Vehicles.

The HCV segment is further classified into three segments: ICV: Intermediate Commercial Vehicle, GVW 8-10 tonnes. MCV: Medium Commercial Vehicle, GVW 10-15 tonnes. HCV: Heavy Commercial Vehicle, GVW above 15 tonnes.

MCVs & HCVs are classified into two categories depending on their usage. Buses are passenger carriers. Trucks include goods carriers along with specialized vehicles like dumpers, tractor-trailers etc.

Naming Conventions:-

Any Bus/Truck will always be named by its classification. The last two digits multiplied by 10 indicate the Brake Horsepower (BHP) rating of the engine.The digits prior to last two digits indicate the Gross Vehicle Weight (GVW) .GVW = payload + vehicle weight3118: GVW = 31 Tonnes, 18 * 10 =180 BHP.2515: GVW = 25 Tonnes, 15 * 10 =150 BHP.

Engines:-

The TATA Cummins Engine: This Euro2 complaint Engine has been developed in association with Cummins, the world leader in Engine Technology. The first turbocharged (TC) engine was rolled out from TELCO, Lucknow on 9thApril 1999.The CMVR (Central Motor Vehicle Regulation Act) Engine: TATA Engineering has developed this engine. Now CMVR engines are more common.

There are three factories in Tata Motors, Lucknow:

CV-CX (Commercial Vehicle) FactoryFrame CXCowl CXCV-CX (Chassis Assembly Line)

MUV-CX (207DI) FactoryTrim CXChassis Assembly line407 cowl assembly line

Transmission Factory CWP-CX*Gears CXHT-CX*STANDS FOR “CENTRE OF EXCELLENCE

Other departments in Tata Motors Lucknow are :

PLANNINGTRANSMISSIONP. E. DESIGN (THE DEPTARTMENT I WORKED UNDER)TECHNICAL SERVICESCENTRAL PROCUREMENTDESPATCHCENTRAL LOGISTICSFACTORY LOGISTICSSQIGENGINEERING SERVICESCENTRAL MAINTENANCE

FPIGCENTRAL QUALITY (CQ)ZONAL SERVICE OFFICE (LUCKNOW)AREA OFFICE, LUCKNOWREGIONAL SALES OFFICE (LUCKNOW)SERVICE DEPARTMENT, LUCKNOW WORKSCEBU – LUCKNOWPLANT HEAD OFFICEMANUFACTURING HEAD OFFICEHUMAN RESOURCESTRAININGBUSINESS EXCELLENCE FINANCEMATERIALS AUDITINTERNAL AUDITADMINISTRATIONSECURITY AND VIGILANCEMEDICAL SERVICESPRICE PANEL & CONTRACTSCONSTRUCTION

P. E. Manufacturing UnitThe Production Engineering Department in Tata Motors consists of two sections:-

Design Unit Manufacturing Unit

The latter manufactures jigs, fixtures and templates which are designed by the former. The production in the Manufacturing Unit is not mass-production but physical samples of solutions are manufactured to the problem statements generated in any department of the Tata Motors.

The machines that are used in the Manufacturing Unit are of high precision and accuracy. Main machines in the Unit are:-

1.) CNC Universal Grinding Machine 2.) NC Surface Grinding Machine 3.) CNC Universal Machine 4.) CNC Lathe Machine 5.) Centre Lathe Machine 6.) Radial Drilling Machine 7.) Profile Gas Cutting Machine 8.) Radial Milling Machine 9.) Hurth Shaving Cutter Resharpening Machine10.) Hardness Tester Machine

Other Facilities:-

1.) Quenching Drum2.) Tube-cutting by Band Sawing Machine

Machine No. : - 1

CNC Universal Grinding Machine

Main Features:-

Make and Model No. - STUDER S-36Connected Load-25.5 kW

It is a universal grinding machine. Both internal and external grinding operations are performed on it. The least count of the machine is 0.1 micron. It has a granite

bed for absorbing vibrations produced by movement of tool and by the motor, thus increasing the accuracy of the machine.

Machine No. : - 2

NC Surface Grinding Machine

Main Features: -

Make and Model No. – FSG 1020AD ChevalierConnected Load-36 kW

It is used for surface grinding. A magnetic chuck is used in the machine.

Machine No. : - 3

CNC Universal Machine Variety of tools used on this machine.

Main Features: -

Make and Model No. - DECKEL MAHO DMU-80TConnected Load-34 kW

It is a CNC Milling and Drilling machine. This machine is used both in vertical and horizontal mode. It has a working axis and the other axes are used for programming. A Fanuc controller is used.

The adjacent picture shows the tools that are used on this machine.

Machine No. : - 4

CNC Lathe Machine

Main Features:-

Make and Model No. - GOODWAY GCL-3LConnected Load-2125 kW

The lathe consists of a turret on which 12 tools can be mounted. The language and software for the CNC Lathe is provided by Fanuc.

Machine No. : - 5

Centre Lathe Machine

Main Features:-

Make – Kirloskar

This is a conventional lathe machine. Taper turning attachment is provided with the lathe.

Machine No. : - 6

Radial Drilling Machine

Main features:-

Make and Model - RM 62 by HMT.

Both tapping nad drilling is performed on the radial drilling machine. A rotation of 360° arc is possible on the machine. Automatic feed characteristic is available.

Machine No. : - 7

Profile Gas Cutting Machine

Main Features:-

Make and Model- TANAKA, Japan

The machine has multiple options. Standard shapes and sizes can be cut by defining dimensions by using the STD-S option. Manual design is possible by the second option. By using the option of TEACH, a specific profile can be generated by using the spot light provided. The last option is used to detect a profile from a printout by the use of a head provided. And final product can thus be obtained by

cutting of the sheet metal with the help of the gas cutter operated automatically according to the desired profile.

Integrated Bus Factory

Integrated Bus Factory (IBF) is located at the rear end of the western complex. Low floor DTC buses are manufactured on this line. The bus consists of two modules- rear module and front module. The two modules are joined by welding. Manual welding as well as robotic welding technique is employed for this purpose.

BUS BODY – CONSTRUCTION AND ASSEMBLY

FrameThe bus body frame consists of floor cross member, floor support, seat support, skirt pillars, pipe upper, pipe lower, window pillars, door pillars, door pillars, roof frame, etc. each of these parts uses pressed steel; rolled steel and square steel pipes. These pipes are securely connected together.

Front structureThe front structure consists of front frame, front lower die panel, interior linings, centre flap (for front engine), toe board, cross beam, windshield glass, bumper, etc. Full front structure assembly is connected to the side structure, floor and roof.

RoofRoof consists of roof panel, roof side frame, roof stiffeners, etc. These parts are assembled by means of spot/plug welding. On the roof assembly ventilator, luggage carrier, roof lamps, etc. are installed. Complete sealing is ensured to prevent water ingress.

Outer panelsThe outer panels are composed of side stretch panel, skirt panel, window panels, etc. Outer panels are assembled on skirt pillars, window bottom rail, pipe lower, door pillar, etc. Side stretch panel is stretched and then spot welded on pipe lower and pipe upper.

Rear structureThe rear structure is composed of rear steel sections of the bus body. On the rear structure windshield, marker lamps, baggage room door, tail lamps, number plate, etc. are installed. A bumper is installed at the rear.

In order to have uniform tyre wear and there by to achieve a better tyre life, tyre rotation at every 9000 km is recommended.

ROBOTIC WELDING SETUP

Our prime concern is the spare parts management of the two robotic welding setups in the IB Factory.The robotic welding setups used in the factory are provided by PRECISION AUTOMATION AND ROBOTICS INDIA LTD.

Fig1: Front Module Fixture

Fig 2: Rear Module Fixture

The robots were provided by PARI Ltd. under the WELDING TURNKEY PROJECT.

Introduction

This system is used to weld the front and rear modules. The proposed system also performs manual Tack welding.

This system consists of 6 axes Fanuc Robot with 2 extended axis & Mitsubishi PLC with MMI (GOT593).

Functional Description

The system is designed for the automatic robotic welding of different types of automotive body components for TATA Motors. The system consists of one 6 Axis 120iB Arc Mate FANUC ROBOT with two extended axis with total welding set up of Lincoln make. The system has two fixtures controlled by the robot controller. Both the fixtures have rotary movements to facilitate the component welding. The Robot will weld on one of these fixtures and the operator loads the component to be welded, on other fixture. The Fanuc robot has the facility to check the position of the indexing fixture before welding as it has multiple indexing positions for welding. PLC system is used to display all possible Fanuc Robots status and fixture status.

Fixture has different sets of clamps, which are used to hold different types of components for welding. Proper clamping is achieved by a combination of pneumatic cylinders operating in a defined sequence.

The following is the list of main spare parts required and the draft of the spare parts follows:

ITEM CODE DESCRIPTION QTY.AA0100501413 Adapter 1AA0100501419 Rest Pad 2AA0100501423 Pusher Pad 1AA0100501427 Side Butting Block For Sheet 1AA0100501445 Locking Pin 2AA0100501455 Guide Pin 2AA0100502404 Rest Block 1AA0100502413 Location Pin 2AA0100502418 Toe Hook Location Pin 1AA0100502427 Bush 2AA0100502429 Pin Lock 2AA0100503409 Washer 4AA0100503410 Connector 2AA0100503449 Guide Piller 2AA0100503494 Clamp Pad 2AA0100503804 Spacer 2AA0100503848 Pivot Pin 2AA0100503855 Location Pin for Stearing Gear Box 2AA0100503863 Coupler 2

SPECIMEN DRAFTS FOR THE SPARE PARTS OF THE FIXTURE:

CV Assembly LineThis vehicle assembly division is divided in three shops—

1. Frame Shop2. CV (Commercial vehicle) Shop3. Cowl Shop

1. FRAME SHOP:-

The work for assembly of vehicle starts at the frame shop, where frames are prepared. The main and prime requirement in truck manufacturing is the preparation of frame.

Frame consists of the long members and the cross members, which comes semi-prepared in the frame shop. Before fitting them together to form a frame, different types of operations are performed on these members at respective stations, which include punching, drilling, riveting etc. There are following stations in the frame shop:-

1. FRAME PREPARATION AREA2. PUNCHING STATION3. PREPARATION STATION4. HEFT FIXTURE STATION5. RIVET CONVEYOR STATION6. PAINT BOOTH7. BAKING OVEN

The first section consists of the punching station and the preparation station. At punching station, the punching is performed on the long members and at preparation station; the long members are attached with other members with the help of riveting guns. This section consists of the roller conveyors. In addition to the circular rollers, elliptical rollers are also used to enhance the speed of the drive.

The long and cross members keep moving on these conveyors while different operations are being performed on them. Both the long members and the cross members are prepared separately. A single frame consists of two long members, which are prepared on two parallel roller conveyors. These two long members are

then moved along another conveyor, which is perpendicular to the already existing ones, with the help of a cross transfer unit.

These two long members are then carried on a hoist to the heft fixture, where these long members along with other cross members are fixed together with the help of riveting guns.

Now these semi-prepared frames are carried on a hoist to the second section of the frame shop. This section of the frame shop consists of the rivet conveyor. It consists of six stations, in which different operations such as drilling, riveting, fixing of axle brackets and other brackets etc are performed. After performing these operations at there respective station, the frames are lowered down on a trolley and the axle brackets are checked for their alignment, both the front and the rear axles must be perfectly aligned for the proper functioning of the vehicle.After this the frame is brought out side the paint booth, where operations such as grinding, sand rubbing etc are performed on it to smoothen its surface, before it is taken inside the paint booth for painting. After performing these operations the frame is carried on a hoist inside the paint booth, where it is painted with the help of paint guns. For making the job of painting easy, the hoist used is of rotating type. As the hoist used is of rotating type, it is easy to paint the frame from all the sides. This helps the worker also, as he can work for longs hours without getting tired.

Exhausters and water pumps used in the paint booth have a very important function. The floor of the paint booth is made of grills under which water keeps flowing. Painting in the paint booth in done with the help of spray guns, due to this mist is created in the paint booth. This mist has two negative effects. Firstly it creates difficulty in breathing and secondly it might settle on the newly painted frame and thus effect its finishing. In order to get rid of these negatives, exhausters and water pumps are used. Exhausters blow air vertically downwards, this air takes the mist along with it and the mist gets mixed with water flowing below the grill floor. Now the painted frame is carried out of the paint booth with the help of the same hoist & is put on the baking oven conveyer. The conveyer carries the frame inside the baking oven, so that the paint on the frame can be dried out. In baking oven, temperatures of 135ºC can be reached with the help of superheated steam, which is coming from both side of the inside of oven through small vents. Generally the whole process is completed in about 25 to 30 minutes. Maximum 5 frames can be baked at the same time.

Now the frame is carried out of the baking oven with the help of the conveyer. The frame is ready to be dropped in CV-CX area.

2. CV SHOP :-

The assembly lines are Slat Conveyors with roller chains whose speed can be varied between 0.1 to 1 .1 m/min.

The length of Slat Conveyor for MCV line is 76.2 mts. and can accommodate a maximum of 24 vehicles

The length of Slat Conveyor for LCV line is 68.85 mts. and can accommodate a maximum of 24 vehicles.

The HCV/MCV/LCV assembly line is semi-automated and is divided into 19 stations.

STATIONS AT CV-CX LINE

Station 1: (Frame Drop)

The prepared frame from the Frame-CX is accepted here. At station 1 following attachment is made:

Basic holding attachments Initial Body wiring Shock absorber brackets Engine mtg. Bracket. Cowl mtg. Brackets. Rear suspension Link rods are fitted (e.g. model .2515which have 2 rear axles) In CNG models rear gas cylinder mtg. brackets, and rear cylinders are fitted here

Now the frame is put on a trolley attached to a conveyor belt on the assembly line.

Station 2: (Air Tank)

Fitment of Air dryer and Purge tank Two Air tanks are generally fitted Fitment of SPV

Purpose of Air tank is to dry the compressed air and Purging of the air is done by Purge tank. These systems are fitted for the purpose of braking (in HCVs/MCVs there are Air brakes). In LCVs Air tank, dryer, purge tank are not fitted because in LCVs there are hydraulic brakes.SPV (System Protection valve) connects the air compressor to Air tank, (SPV is the mechanism that isolates the two braking systems. Its job is to keep a constant pressure of7.4 bar in the brake lines. In case of failure of one line, the pressure in the failed line drops to 6.5 bar while the working line remains unaffected.)12 pipe are also fitted here.15 pipe from air tank are also fitted here.15 pipe connects Air Dryer to compressor. In case of LCV’s Tubing for hydraulic systems are installed here. In case of HCV, e.g. LPT 2515 Relays (Quick release valve) are installed here. Water separator is fitted (in CMVR vehicles)

Station 3: (Leaf Spring)

The following attachments are made in a sequence. Front end springs. Rear end springs. Dead axle’s spring. Connections of brake pipes

Station 4: (Rear Axle)

The following attachments are made in a sequence. Fitment of Brake actuator to rear axle. Fitment of Brake actuators to dead axle (only for LPT 2515). Rear axle is placed on the top of the spring with the help of tackle. Axle is fastened to rear axle by U bolt with the help of Pneumatic nut gunner. Supporting plates hold the U-bolt. Fitment of Dead axle (Only for LPT 2515)

Station 5: (Front Axle)

The following attachments are made in a sequence Fitment of brake actuators to front axle. Fitment of front axle to front spring with the help of U-bolt. Greasing of all the axles.

Station 6: (Propeller Shaft)

Sub assy. of propeller shaft. Fitment of Propeller shaft to rear axle and cross member. Fitment of Exhaust pipe.

Station 7-8: (Inversion)

The whole frame is now inverted used hoists and `D` tackle.The following attachments are made in a sequence

More hydraulic tubing(for LCV`s). Chassis number punching. Fitment of side cylinder brackets and side cylinders (for LPO CNG).

Station 9: (Control Lever)

Sub assembly of steering gear box Fitment of steering gear box to frame Combined assembly of brakes accelerator and clutches. Fitment of HPR & LPR for CNG

Station 10-11: (Engine Drop)

Previously gearbox comes separately from Pune and Jamshedpur plants. But now Telco Lucknow is assembling its own gearbox. Gearbox is assembled with engine in a separate conveyor line. Then whole assembly is fitted to frame.

Other end of Propeller shaft is fitted to gearbox. Further engine attachments are done (i.e. Acc. pull rod). Fitment of Radiator (loading &assembly). Attachments for the fuel tank (bracket for the fuel tank).

Station 12: (Fuel Tank Fitment)

The fuel tank is assembled and mounted here. LP and the LPO have a 160 L fuel tank. LPT and the SE have a 250 L fuel tank. 2515 have 350 L fuel tank.

407 HAS a 75 L fuel tank. The Taillights are fixed.

Station 13-14: (Cowl Drop)

The prepared cowl from the trim line is fixed here. The required attachments to the cowl are made. All attachments under the front grill completed. Accelerators, brakes and clutches fixed.

Station 15: (Battery Fitment)

The is battery is fixed (Exide freedom EF120) (the”120” means that it is meant to supply120 ampere hours of energy)

Station 16: (Spare Wheel)

The following attachments were made in a sequence: Spare wheel holder Indicators, reflectors, headlights Front panel and headlights tested Radiator filled with a coolant (this is Green in color. apart from its primary

function of cooling the engine, it also prevents rusting. This coolant is long life and is normally from Castrol or Sun star (Golden cruiser GC1200)

Station 17- 18: (Wheel Mounting)

The rear wheels were mounted one frame under study; these were CEAT, APPOLO, GOODYEAR, MRF etc.Front wheels are also mounted here. A tyre manipulator is provided here to ease operator fatigue.

Station 19: (Start Off)

Bleeding of the fuel tank is done and after that for the first time diesel is filled in the fuel tank all the systems are switched on and the vehicle is driven off the assembly line.

Now it is taken for a dynamometer test. Here all the attributes of the vehicle during actual driving conditions are approximated. The parameters tested are:

Acceleration during 1St ,2ND ,3RD,4TH,5TH gear (overdrive) Peak velocities during these gears. Emissions Balance

Any defect occurred is rectified in R-1. From there, the vehicles are taken to R2 area where pit test is done and after that the left over defects are rectified. Then, the vehicle is taken to the paint shop where any scratches left are repainted.

3. COWL SHOP:-

Cowl is the front portion of the Chassis, which has driving seat, engine hood, lights, blinkers, dashboard, different meters, indicators and other electrical connections to regulate the vehicle. Blank Cowls are being received from Tata Motors, JSR and are assembled here. Blank cowls are put on the trolley with the help of 0.5 ton jib hoist and different fitments are made. Trolley runs over rails and is pushed manually. Cowls of all the vehicles are firstly assembled at Cowl-CX and then it is finally bolted to the chassis at the chassis assembly line.The Cowl-CX is divided into two areas:

1. Bare Cowl Rectification area The flow process at the Bare Cowl Rectification area proceeds as follows:

Washing of bare cowls. Inspection for defects. Rectification of defects observed. Paint touch up as required.

2. Assembly lines MCV/HCV assembly line. LCV assembly line.

WASHING UNIT:-Cowl structures are brought from other manufacturing units which are situated in Jamshedpur & Pune. In transportation course, cowl structure gets dirty & a layer of dust gets stuck on it, so before it is subjected to further operations, it is firstly cleaned with pressure water at washing unit.

Washing unit consists of ELGI PUMP [CWM403]

INSPECTION ZONE:-A thorough inspection of cowl structure is carried out in the inspection zone. Further, several marks are made on the structure depicting the areas where welding, denting, etc. has to be carried out. Then that particular cowl is forwarded for further operations.

WELDING ZONE:-Cowl structure is marked with respective regions requiring welding. At these regions, welding is carried out as per instructions. MIG WELDING is followed in above process.

DENTING ZONE:-Commonly it is observed that on a few occasions cowl get blemished. So to bring it back to normal shape it is forwarded to denting unit. It restores it is original shape by application of pressure through hammers. After denting, putty is applied to smoothen & level the surface to ensure proper application of paint.

SURFACE GRINDERS are also used to level down the cowl surface. SEALANT is used at particular points to fill the gapping as left after the welding.

CENTRAL PANEL ALIGNMENT ZONE:-Central panel is the central portion in front of the cowl it is usually it is closed but it may be kept in open mode through PIE ROD.Central panel of the cowl has to be fit according to their rubber bus & Lock strip through which it is locked. After that it has to be adjusted in accordance with the pie rod.Proper alignment of central panel is ensured through hammers & other tools.

PUTTY CUTTING ZONE:-In this zone putty being applied in denting zone & is grinded further to level down the surface through surface grinders. PAINTING ZONE:-In this section of the shop the actual & final painting of the cowl is done.

PROBLEMS FACED DURING ASSEMBLY:-

During the assembly process, a number of problems arise that result in line stoppage. The line is started again only after the problem is rectified. This methodology encourages people to concentrate on quality over quantity. The problems are standardized as:

1. Materials problem: A particular component, which is required for the manufacturing of the vehicle, is out of the supply.2. SQIG problem: The quality of the material supplies may be suspect or it may be damaged.3. Aggregate Problem: There may be some problem with the aggregates supplied from JSR or Pune. Normally the term means bare cowls, Engines, Axles etc.4. Maintenance Problem: There may be some problems with tools, hoists, etc.

BIW COWL AND CAB LINE

CAB LINEFRONT WALL:STATION NO. 1 (ASSY PANEL OUTER COMPLETE)

Following parts are being fitted sequentially at this station:

1. Panel Outer bottom W/S

2. Nut Plate

3. Panel Face side bottom LH

4. Panel Face side bottom RH

5. Panel Side outer W/S LH

6. Panel Side outer W/S RH

7. Support Face panel LH

8. Support Face panel RH

STATION NO. 2.1 (SUB ASSY WAIST RAIL)

Following parts are being fitted sequence wise at this station:

1. Waist rail

2. Steering Mtg. Bkt.

3. Nut with Plate

4. Support waist rail with face

STATION NO. 2 (ASSY DOOR POST)


1. Sub assembly waist rail from

station 2.1

2. Door post LH

3. Door post RH

4. Nut M6

STATION NO. 3 (ASSY FRAME FRONT)


1. Frame Front LH

2. Frame Front RH

3. Horn Mtg. Bkt.

4. Cover Door post LH

5. Cover Door post RH

6. Dash Board support

7. Taper Spacer

STATION NO. 4 (ASSY TOE PANEL)


1. Toe Panel LH

2. Toe Panel RH

STATION NO. 5 (ASSY BONNET)

Following parts are being fitted

sequence wise at this station:

1. Assembly Bonnet

2. Reinforcement Waist Rail

Component

STATION NO. 6.1 (SUB ASSY DASH BOARD)


1. Panel Inner Bottom

2. Assy Cover Plate

3. Clips with projections

4. Clips without projections

STATION NO. 6 (ASSY DASH BOARD COMPLETE)

Sub assembly from station no. 6.1 is fitted.

STATION NO. 7 (ASSY STEP WALL)

Following parts are fitted sequenially:

1. Step Wall component LH

2. Step Wall component RH

STATION NO. 8 (ASSY PARTITION WALL)

Following parts are fitted sequentially:

1. Partition Wall LH

2. Partition Wall RH

3. Z Bkt small

4. Z Bkt large

STATION NO. 9 (ASSY W/S INNER TOP)


1. Sub assy Inner top rail W/S

2. Panel Inner side LH

3. Panel Inner side RH

STATION NO. 10 (GATE INSPECTION)

This station is for spot welding all around wind

screen aperture & for GATE INSPECTION.

SUB STRUCTURE:STATION NO. 1.1 (SUB ASSY R/F MUD GUARD)

Following parts are fitted sequence wise at this station:

1. Mud guard Reinforcement LH/RH

2. Strip mud guard R/F

3. Hex Nut M6

STATION NO. 1 (ASSY FRAME WITH FLOOR)


1. Substructure 4018/2516

2. Floor panel LH 4018/2516

3. Floor panel RH 4018/2516

4. Floor center 4018/2516

5. Cover front LH (long member)

6. Cover front RH (long member)

STATION NO. 2 (ASSY MUD GUARD )

Reinforcement Air Filter Mtg Bkt 4018 is

fitted at this station.

STATION NO. 3 (ASSY MUD GUARD)


1. Mud guard LH/RH

2. Retainer

3. Hydraulic Mtg Bkt 2516

4. Air filter Mtg Bkt 4018

5. Support mud guard LH/RH 2516

STATION NO. 4 (WELDING SUB STRUCTURE COMPLETE)

Hydraulic Mtg Bkt 4018 is fitted at this station.

This station is meant for MIG welding on entire Sub structure & for GATE

INSPECTION.

REAR WALL STATION: (ASSY REAR WALL COMPLETE)


1. Assy Rear Wall 4018/2516

2. Assy corner panel outer LH

2516/4018

3. Assy corner panel outer RH

4018/2516

FINISHING LINE:RESPOT STATION:


1. Window panel inner LH/RH

2. Assy cover support (stepwall)

STATION NO. 1 (DOWN WELDING)


1. Assy R/F safety belt

2. Y bracket

3. Gusset bottom rear LH/RH 4018

4. Gusset Bottom LH/RH

5. Gusset top rear LH/RH

6. Support Guide (Side wall)

7. Bkt toggle clamp

8. Angle door sealing rubber

9. Support rear wall

STATION NO. 2 (DOWN WELDING & ASSY BERTH BOX)


1. Assy R/F roof top (L shaped)

2. Angle (roof rail)

3. Berth Box 4018

4. Assy angle support (berth box)

5. Assy Support bonnet side

6. Angular support

STATION NO. 5 (GAS WELDING)


1. Corner panel inner rear wall LH/RH

2. Air ventilation unit

3. Hand Break valve Mtg Bkt

STATION NO. 6 (CENTRE FLAP

FITMENT)


1. Grab handle & Hinge Leaf

2. Bush & Stay Rod (centre flap)

3. Assy centre Panel

4. Support centre flap LH/RH

STATION NO. 7 (DOOR FITMENT)

Following parts are being fitted sequence wise

at this station:

1. Door hinge

2. ASSY door shell LH/RH

STATION NO. 8 (BUFFING & GRINDING)


at this station:

1. Support retainer bonnet side LH/RH

2. Support face panel LH /RH

STATION NO. 9: This station is meant for PDI check of cab before dispatching.

COWL LINEMAIN LINE:STATION NO. 1 (ASSY BONNET WITH

SUBSTRUCTURE)


1. ASSY bonnet front

2. ASSY sub structure with floor

STATION NO. 2 (IDLE STATION)

MIG welding is done at this station & no part is assembled here.

STATION NO. 3 (ASSY WHEEL ARCH)


at this station:

1. ASSY wheel arch RHD LH

2. ASSY wheel arch RHD RH

STATION NO. 4

No part is being fitted at this station.

Only MIG welding is done at this station.

STATION NO. 5 (ASSY CROSS

MEMBER)

Following parts are being fitted sequence

wise at this station:

1. ASSY cross member frame front

STATION NO. 6 (ASSY FRONT PORTION)



1. Support plate door post LH/RH

2. Gusset LH/RH

SUB ASSEMBLY LINE:

STATION NO. 1 (ASSY FRAME

FACE)


1. ASSY frame face LH

2. ASSY face side LH

STATION NO. 2 (ASSY FRAME

FACE)



1. ASSY frame face RH

2. ASSY face side RH

STATION NO. 3 (ASSY CP TOP)



1. ASSY reinforcement front post

LH/RH

2. Bracket front post LH/RH

3. Gusset LH/RH

4. ASSY center Panel top

FINISHING LINE:

STATION NO. 1



1. Stay rod center flap

2. ASSY center flap complete

3. ASSY air filter Mtg Bkt

4. Hex FL screw M8X16 TS 17130-8.8-SS845

5. Nyloc Nut M8 IS7002-8-SS-8451-8C

Documents

Summer trainee project report.doc