TATA MOTORS LIMITED LUCKNOW
PROJECT REPORT Under the Guidance of MR. BEDANTA BORTHAKUR MR. BHAVINKUMAR H PATEL
Submitted by ADVAIT MOHAN 11BMA0017
School Of Mechanical and Building Sciences VIT University Vellore
4thDecember 2013 -2rd January 2014
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Self-Certificate This is to certify that this report which is submitted by me in partial fulfillment of the requirement for the award of degree B. Tech to “VIT UNIVERISTY” comprises of my learning experience at Tata Motors Limited, Lucknow.
ADVAIT MOHAN 11BMA0017 B.TECH (Mechanical 3rd YEAR) VIT UNIVERSITY VELLORE
Forwarded by:
Mr. BedantaBorthakur Div.Manager BIW Tata Motors Ltd Lko
Mr. Bhavinkumar H Patel Asst. Manager, BIW Tata Motors Ltd Lko
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ACKNOWLEDGEMENT
Industrial training is a crucial period in engineering curriculum since it exposes a student to the real world which he or she is going to enter after the completion of the graduation. This is the period during which an engineer actually becomes an engineer by gaining the Industrial experience. I am very thankful to God who has given me the opportunity to get training in TATA MOTORS, LUCKNOW one of the most renowned organization of India. First of all, I would like to thank Mr. Kumar Lalit, Mrs. Jasneet Rakhra and Mr. Pranshant Pandey for giving me a chance to work in the Body in White or Weld Shop. I would like to express my deep gratitude to Mr. Bedanta Borthakur, Div. Manager, BIW for having provided me with the wonderful & conductive environment to work in. He has been ever helpful and supportive. All that, I have acquired would not have been possible without the kind guidance of my Project Guide Mr. Bhavinkumar H Patel, Asst. Manager, BIW for his guidance throughout the project. I would like to render my sincere thanks to BIW department for providing infrastructure facilities, support and cooperation to complete the project. I would also like to thank Tata Motors family for providing me with such an opportunity to get an insight into the system of the industry, the first experience of its kind to me.
ADVAIT MOHAN
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TABLE OF CONTENTS TATA MOTORS - AN INTRODUCTION...................................................................................................6 TATA MOTORS LIMITED LUCKNOW ....................................................................................................7 IMPORTANT DEFINITIONS: .................................................................................................................9 ABOUT VEHICLE CLASSIFICATION ...................................................................................................... 10 NAMING CONVENTIONS: ................................................................................................................. 10 BIW (BODY IN WHITE) SHOP ............................................................................................................. 11 BIW AT TATA MOTORS, LUCKNOW ................................................................................................... 13 CAB LINE .......................................................................................................................................... 15 LAYOUT OF CAB LINE........................................................................................................................ 17 COWL LINE ....................................................................................................................................... 18 LAYOUT OF COWL LINE .................................................................................................................... 20 WELDING TYPES USED IN BIW SHOP ................................................................................................. 21 SPOT WELDING ............................................................................................................................................... 22 RESISTANCE SEAM WELDING ............................................................................................................................. 24 METAL INERT GAS WELDING (MIG): .................................................................................................................. 25 PROJECTION WELDING ..................................................................................................................................... 27 SOME OTHER MAJOR OPERATIONS IN BIW SHOP.............................................................................. 28 GRINDING ...................................................................................................................................................... 28 DENT REMOVAL .............................................................................................................................................. 28 BUFFING ........................................................................................................................................................ 29 MACHINES AND EQUIPMENTS USED................................................................................................. 30
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BASICS OF WCQ ............................................................................................................................... 31 WCQ MANAGEMENT SYSTEM (5 ABSOLUTES) ..................................................................................................... 33 BIQ MIGRATION STRATEGY............................................................................................................................... 34 5 F TECHNIQUE OF PROBLEM SOLVING ............................................................................................................... 36 STANDARDIZATION: LAYERED AUDITS ................................................................................................................. 37 DRR (DIRECT RUN RATE) ................................................................................................................................. 38 DRL (DIRECT RUN LOSS) .................................................................................................................................. 39 ANDON OPERATION ......................................................................................................................................... 40 TROLLEY MASTER LIST GENERATION ................................................................................................. 41 INTRODUCTION ............................................................................................................................................... 42 WHAT IS A TROLLEY AT THE BIW SHOP? .............................................................................................................. 43 IDENTIFICATION OF THE TROLLEYS USED AT EACH STATION ................................................................................... 45 CREATION OF A MASTER LIST............................................................................................................................ 47 UNIQUE NAMING SYSTEM ................................................................................................................................ 50 IDENTIFICATION OF THE RUN DOWN CAUSES....................................................................................................... 50 FINAL RESULT ................................................................................................................................................. 51
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TATA MOTORS - AN INTRODUCTION Tata Motors Limited (formerly TELCO, short for Tata Engineering and Locomotive Company) is an Indian multinational automotive manufacturing company headquartered in Mumbai, Maharashtra, India and a subsidiary of the Tata Group. Its products include passenger cars, trucks, vans, coaches, buses, construction equipment and military vehicles. It is the world's seventeenth-largest motor vehicle manufacturing company, fourth-largest truck manufacturer and second-largest bus manufacturer by volume.[5] Tata Motors has auto manufacturing and assembly plants in Jamshedpur, Pantnagar, Lucknow, Sanand, Dharwad and Pune in India, as well as in Argentina, South Africa, Thailand and the United Kingdom. It has research and development centers in Pune, Jamshedpur, Lucknow and Dharwad, India, and in South Korea, Spain, and the United Kingdom. Tata Motors' principal subsidiaries include the British premium car maker Jaguar Land Rover (the maker of Jaguar, Land Rover and Range Rover cars) and the South Korean commercial vehicle manufactures Tata Daewoo. Tata Motors has a bus manufacturing joint venture with Marcopolo S.A. (Tata Marcopolo), a construction equipment manufacturing joint venture with Hitachi (Tata Hitachi Construction Machinery) and a joint venture with Fiat in India. Founded in 1945 as a manufacturer of locomotives, the company manufactured its first commercial vehicle in 1954 in collaboration with Daimler-Benz AG, which ended in 1969. Tata Motors entered the passenger vehicle market in 1991 with the launch of the Tata Sierra, becoming the first Indian manufacturer to achieve the capability of developing a competitive indigenous automobile.[6] In 1998 Tata launched the first fully indigenous Indian passenger car, the Indica, and in 2008 launched the Tata Nano, the world's cheapest car. Tata Motors acquired the South Korean truck manufacturer Daewoo Commercial Vehicles Company in 2004 and purchased Jaguar Land Rover from Ford in 2008. Tata Motors is listed on the Bombay Stock Exchange, where it is a constituent of the BSE SENSEX index, the National Stock Exchange of India and the New York Stock Exchange. Tata Motors is ranked 314th in the 2012 Fortune Global 500 ranking of the world's biggest corporations. In health, the company's intervention is in both preventive and curative health care. The goal of environment protection is achieved through tree plantation, conserving water and creating new water bodies and, last but not the least, by introducing appropriate technologies in vehicles and operations for constantly enhancing environment care. With the foundation of its rich heritage, Tata Motors today is etching a refulgent future. 6
TATA MOTORS LIMITED LUCKNOW
Tata Motors Lucknow (TML-Lucknow) is an important production facility of Tata Motors Limited, which was established in 1992 to meet the growing demand for Commercial Vehicles in the Indian market. The state of art plant is strongly backed up by an Engineering Research Centre (ERC) & Service set-up to support with latest technology & cater to the complexities of automobile manufacturing. Fully Built Vehicle business (FBV), which is one of the fast growing areas of business, is also head quartered here. This plant rolls out commercial vehicles & is specialized in the designing & manufacturing of a range of modern buses which includes Low-floor, Semi Low-floor, and High Deck & CNG Buses. Lucknow plant also specializes in integral bus manufacturing & has recently commissioned JV Company, Tata Marcopolo Motors Ltd. in the premises. The major facilities at the plant comprise of:  
Vehicle Factory - Assembly Plant for Trucks and Bus Chassis Integral Bus Factory - Assembly Plant for Module Buses catering to the needs of Tata Marcopolo Motors Limited and FBV operations 7
Transmission Factory - Gear Parts, Crown wheel & Pinion and Heat Treatment facility Production Engineering Shop catering to the tool design and manufacturing needs A well-established Training Centre through which around 500 apprentices are trained in various trades. Engineering Research Centre with specific focus on buses, including a Digital prototyping lab, use of PLM software etc. Service Training Centre providing training to drivers and technicians of the STU's. RECON Factory (for Reconditioning Business) The satellite plant of TMML which caters to the Hi-end buses for the Northern Market. State of the art facilities like the Paint Shop, BIW Shop and the TCF factory with automated lines have been benchmarked with the best in the world.
TML Lucknow Layout
Western complex RECON Shop
Gear CX & HT shop
IBF &Marcopol o
CV Assembly line- 1
LakeArea
Main Gate WC Deva
Chinhut
Eastern complex CRS Gate
MY PROJECT AREA
BIW Shop
CV Assembly Line 2 & 3
Paint Shop Vendor Area
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IMPORTANT DEFINITIONS: Gross Combined Weight (GCW): The total weight of a vehicle, including all its cargo, plus the weight of a trailer and its entire contents. Gross Combined Weight Rating (GCWR): The maximum allowable weight of the GCW as specified by the manufacturer. Exceeding this limit compromises safety. What you need to know: Vehicles that operate above the GCWR are a potential safety hazard because the engine, frame, suspension, brakes and tires are not designed for weight above the rating the manufacturer has set. Gross Vehicle Weight (GVW): Maximum legal weight at which a vehicle can be operated. The total weight of a vehicle with driver and passengers, cargo, fuel, coolant, any dealer or after-market installed accessories, and tongue weight if towing.
Gross Vehicle Weight Rating (GVWR): It is the maximum permissible total weight of the vehicle that may not be exceeded, as designated by the manufacturer. GVWR is identified on the manufacturer's label, which is usually located on the driver's door or door jam. What you need to know: Vehicles that operate above the GVWR are a potential safety hazard because the engine, frame, suspension, brakes and tires are not designed for weight above the rating the manufacturer has set. Curb Weight:The weight of an empty vehicle, without cargo and driver and passengers, but including maximum amounts of fuel, oil, coolant and standard equipment, including the spare tire and tools. Payload: The maximum amount of weight, including driver and passengers that can be carried in the truck's bed and cabin. Basically, the payload is the GVWR minus the Curb Weight.
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ABOUT VEHICLE CLASSIFICATION In the Commercial Vehicle Business Unit, the models are classified on the basis of GVW as under: HCV:
Heavy Commercial Vehicles
MCV:
Medium Commercial Vehicles.
LCV:
Light Commercial Vehicles.
The HCV segment can be further classified into three segments based on gross vehicle weight as follows: ICV: Intermediate Commercial Vehicle with GVW of 8 to 10 ton.
MCV:
Medium Commercial Vehicle with GVW of 10 to 15 ton.
HCV: Heavy Commercial Vehicle with GVW of 16 ton and above. MCV & HCVs can also be classified into two categories depending on their usage as Trucks and Buses. Buses are passenger carriers. Trucks include goods carriers along with specialized vehicles like dumpers, tractor-trailers etc. the ICVs fall in the load category of 8 to 10 ton GVW and are often substituted for medium or heavy commercial vehicles in trunk routes or cities. EICHER Motors and SWARAJ MAZDA are two manufacturers operating in this segment.
NAMING CONVENTIONS: Any Bus/Truck will always be named by its classification. The last two digits multiplied by 10 indicate the Brake Horse Power (BHP) rating of the engine. The digits prior to last two digits indicate the Gross Vehicle Weight (GVW) GVW = payload + vehicle weight That is: 607 :
GVW = 6 Tonnes , 7 * 10 = 70 BHP.
4018 :
GVW= 40 Tonnes, 18 * 10 =180 BHP.
LP
stands for full forward control bus model.
LPT stands for full forward control truck model. LPK stands for full forward control tipper. LPO stands for full forward control with extra overhang SFC stands for semi forward control. 10
BIW (BODY IN WHITE) SHOP What is Body in White? Body in white or BIW refers to the stage in automotive design or automobile manufacturing in which a car body's sheet metal components have been welded together — but before moving parts (doors, hoods, and deck lids as well as fenders) the motor, chassis sub-assemblies, or trim (glass, seats, upholstery, electronics, etc.) have been added and before painting has been done. The name derives from manufacturing practices before steel unibody or monocoque bodies when automobile bodies were made by outside firms on a separate chassis with an engine, suspension, and fenders attached. The manufacturers built or purchased wooden bodies (with thin, non-structural metal sheets on the outside) to bolt onto the frame. The bodies were painted white prior to the final color. A folk etymology for Body in White suggests the term derives from the appearance of a car body after it is dipped into a white bath of primer (undercoat paint) despite the primer's actual gray color. In car design, the Body in White phase refers to the phase in which the final contours of the car body are worked out, in preparation for ordering of the expensive production stamping die. Extensive computer simulations of crash worthiness, manufacturability, and automotive aerodynamics are required before a clay model from the design studio can be converted into a Body in White ready for production.
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Figure: Face Cowl at Tata BIW shop
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BIW AT TATA MOTORS, LUCKNOW Infra-Structure Three Bays are being developed in the current phase, one Bay is kept for future expansion. Width of each bay : 30 meter Length of each bay : 180 meter Height of the building below truss : 10.5 meter Total Shop Floor Area : 21600 sq meter (Developed area 16200 sq meter, available for future plan 5400 sq meter)
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BIW Shop
CAB LINE
COWL LINE
With Face
Without Face
Non-Sleeper
Sleeper (R&C)
As can be seen from the above flowchart, the BIW Sop at Tata Motors, Lucknow is composed of two main parts: On one side of the shop is the CAB Line and on the other side is the COWL line. Both of these are further sub-divided into categories, as mentioned in the above flowchart.
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CAB LINE The Closed Pilot Cabins are known as CABs. The CAB line is almost 40 years old. It was first commissioned at Pune plant and was later transferred to Jamshedpur. After being written off at Jamshedpur, it was finally transferred to Lucknow in 2008. The CAB comes in two models: 1) Sleeper: This CAB comes with a berth box in which the driver can sleep. Generally customers who have to move large distances prefer the Sleeper model. 2) Non- Sleeper: This model comes without the berth box and is thus smaller as compared to the Sleeper model. Unlike Cowls, CABs remain the same irrespective of the model and make of the overall truck or lorry i.e. there is no difference between the CAB of one model and that of another model.
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The following is a basic process flow diagram for the production of a CAB:
ASSEMBLY FRONT WALL
ASSEMBLY REAR WALL
ASSEMBLY ROOF
ASSEMBLY SUB-STRUCTURE MAIN FRAMER
COMPLETED CAB 16
LAYOUT OF CAB LINE (For Both Sleeper and Non-sleeper Models) ROOF ASSEMBLY St. 1: Assy Roof & Panel St. 2: Seam Welding St. 3: Brazing St. 4: Top Rail Sub- assy 1 St. 4.1: Top Rail Sub-assy St. 5: Reinforcement Assy St. 5: Roof Final Dropping
REAR WALL ASSEMBLY St. 1: Rear Wall Assy
FRONT WALL ASSEMBLY St. 1.1: Face Panel Sub-assy St. 1: Assy Wind Shield Panel St. 2: Assy Door Post St. 3: Assy Frame Front St. 4: Assy Toe Panel St. 5: Assy Bonnet Centre St. 6.1: Dashboard Sub-assy St. 6: Assy Dashboard
SUB-STRUCTURE ASSEMBLY
St. 7: Assy Foot-step
St. 1: Assy Floor Panel
St. 8: Partition Wall Assy
St. 2: Floor Panel Respot
St. 9.1: Wind Shield Sub-assy
St. 3: Assy Mud- Guard
St. 9: Wind Shield Inner Top
St. 4: Sub-structure Full
St. 10: Wind Shield Spot Welding
Welding
MAIN FRAMER Assy of Sub-structure, Roof, Front Wall and Rear Wall
FINISHING LINE St. 1: Wheel Arc Respot St. 2: Cab Respot St. 1,2,3: Full Welding 1,2,3 St. 1: Loose Fitment St. 5: Corner Panel St. 6: Gas Welding St. 7: Grinding St. 8: Door Fitment St. 9: Dusting Cleaning And Buffing St. 10: Buy Off Gate
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COWL LINE The Open Pilot Cabins are known as Cowls. The Cowl Line is almost 30 years old. It was first commissioned at the Pune Plant and then it was transferred to Lucknow in 2009. A total of 27 models of Cowls are manufactured in the BIW Shop. However, the differences between the various models are minor. The major classification of Cowls is as follows: 1) Face Cowls: These are the more prominent type of Cowls produced in the BIW Shop. Face cowls differ depending on the make and model of the lorry or truck even though the differences are only minor. 2) Faceless Cowls: Faceless Cowls have no Front wall as the name very well suggests.
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The following diagram shows the BIW Shop Process Flow Diagram for the Cowl Line:
FIGURE: Process Flow Diagram for Cowl Line (with Face)
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LAYOUT OF COWL LINE Station 1: Sub-structure Welding with Bonnet Station 2: Assembly Welding Station 3: Assembly Welding with Wheel Arch Station 4: Wheel-arch Spot Welding Station 5: Cross Member welding with Sub-structure
Station 6.1: Face Panel LH side Station 6.2: Face Panel RH side Station 6.3: Face Panel Welding with Centre Panel Top
Station 6: Front wall welding with Assembly Station 7.1: Full Welding 1 Station 7.2: Full Welding 2 Station 7.3: Full Welding 3 Station 8: Center Flap Fitment Station 9: Dent Removal Station 10: Grinding Station 11: Ventilation Panel Fitment Station 12: Gate Audit
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WELDING TYPES USED IN BIW SHOP
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INTRODUCTION A cab is the part of a vehicle which is meant for sitting of driver, co-driver and other persons but is a covered compartment. A cowl is front covering portion of the vehicle and it is not covered. The main function of Tata Motors, Lucknow new weld shop (BIW shop) is to make cab and cowl. Mainly following types of welding is used in BIW shop:
Spot Welding Spot welding is a type of resistance welding used to weld various sheet metal products. Typically sheets are in the range of 0.5 mm to 3.0 mm thickness. The process used two shaped copper alloy electrodes to concentrate welding current into a small spot and to simultaneously clamp the sheets being welded together.
How spot welding works Spot welding is one form of resistance welding, which is a method of welding two or more metal sheets together without using any filler material by applying pressure and heat to the area to be welded. The process is used for joining sheet materials and uses shaped copper alloy electrodes to apply pressure and convey the electrical current through the work pieces. In all forms of resistance welding, the parts are locally heated. The material between the electrodes yields and is squeezed together. It then melts, destroying the interface between the parts. The current is switched off and the "nugget" of molten materials solidifies forming the joint.
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Typical spot welding gun is shown as below:
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The various types of spot welding guns used are as below:
Bhaskar spot gun
Nash spot gun
Tips of different kinds of alignment
A spot welded joint is shown as below:
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Resistance Seam Welding Resistance Seam Welding is a resistance welding process that produces a weld at the faying surfaces of overlapped parts along a length of a joint.
Metal Inert Gas Welding (MIG): Metal Inert Gas Welding (Gas Metal Arc Welding) is the arc welding process, in which the weld is shielded by an external gas (argon, helium, CO2, argon + oxygen or other gas mixtures). Consumable electrode wire, having chemical composition similar to that of the parent material, is continuously fed from a spool to the arc zone. The arc heats and melts both the work pieces edges and the electrode wire. The fused electrode material is supplied to the surfaces of the work pieces, fills the weld pool and forms joint. Due to automatic feeding of the filling wire (electrode) the process is referred to as a semi-automatic. The operator controls only the torch positioning and speed.
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The MIG Welding in Tata Motors uses a mixture of CO2 and Argon with a Copper coated Mild Steel wire:
MIG welded joint is shown as below:
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Projection Welding Projection Welding is a type of resistance welding in which only the projected portion of the metal is melted and joined to the base metal.Projection welding is a modification of spot welding. In this process, the weld is localized by means of raised sections, or projections, on one or both of the workpieces to be joined.
In Tata Motors, Lucknow projection welding is used at the cowl line for welding of nut in a hole on frame LH side. Nut is kept on the lower fork of the projection welding machine manually. The alignment of the nut and the hole on the frame must be proper. Pushing the foot lever forces the 2 forks of the projection welding machine to come together and do the welding.
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SOME OTHER MAJOR OPERATIONS IN BIW SHOP Grinding
Dent Removal
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Buffing (This is same as grinding but we use soft tool mainly for polishing and removing scratches.)
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MACHINES AND EQUIPMENTS USED Spot welding guns
Spot welding
MIG welding machines
MIG welding
Hoist
For transfer of parts
Pencil grinder
Removes weld spatter and widens holes
Nut runner
For tightening nuts
Ratchet wrench
For tightening nuts
Miracle grinder
For fine grinding
Buffer
For buffing operation
Grinder
For grinding operation
Dent remover
Removes dents
Drill
For drilling operation
Screw runner
For tightening screws
Seam welding machine
For seam welding
Brazing machine
Welding
Cutter
For cutting operation
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Basics of World Class Quality (WCQ)
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What is WCQ? Achieving & excelling the world’s bench mark levels to manufacture and deliver the best Quality products to all the Customers.
The Culture:
Quality to be built into the process
Built In Quality to be made DNA of the Organization
Involve all People to strive for Quality Excellence
Prompt Actions for all abnormalities
Quality Culture building training to all the employees & suppliers
Execution Of WCQ Culture
Developing Quality Culture as DNA in the organization
WCQ pyramid
WCQ management system
BIQ migration strategy
WCQ pyramid
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WCQ Management System (5 Absolutes)
Definition of the Absolutes: People Involvement 1. Vision / Mission Statement 2. Values 3. Health & Safety Priority 4. Team Concept 5. People Involvement 6. Open Communication Process 7. Shop Floor Management 8. Qualified People Standardization 9. Workplace Organization 10. Management by Takt Time 11. Standardized Work 12. Visual Management Built in Quality (BIQ) 20. Product Quality Standards 21. Manufacturing Process Validation 22. In-Process Control & Verification 23. Quality Feedback/Feed forward 24. Quality System Management
Continuous Improvement 13. Problem Solving 14. Business Plan Deployment 15. Andon Concept 16. Lean Design of Facilities, Equipment, Tooling, Layout 17. Early Manufacturing and Design Integration 18. Total Maintenance System 19. Continuous Improvement Process Short Lead Time 25. Simple Process Flow 26. Small Lot Packaging 27. Fixed Period Ordering System Parts 28. Controlled External Transportation 29. Scheduled Shipping / Receiving 30. Temporary Material Storage 31. Internal Pull Delivery 32. Level Vehicle Order Schedule 33. Supply Chain Management
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BIQ Migration Strategy Right now Tata Lucknow is at the first stage of WCQ. TO reach the next levels the plant needs to achieve a certain goal which is show in the diagram:
Assessment of Quality System •
PPAP- Product Part Approval
•
Process •
Engineering Change
system •
Management •
Gauge calibration
•
Conformity of products
•
Control on disposal of non conforming parts
•
Quality control operating
Standard inspection procedure
•
Customer acceptance and review evaluation
•
Manufacturing related launch process
Health and safety issues 34
Operation Process Assessment •
Standardize work
•
Five
minutes
•
fixed
quality
Alarm and escalation (Quick Response)
break everyday
•
Health and Safety
•
People involvement
•
TPM / PPM / Calibration
•
Quality standard
•
System process monitoring /
•
Process control planning –
layered audit
Inspection resources
•
Back up process
•
Inspection scope and content
•
Repair
•
Inspection frequencies
•
Repair conformation
•
Error proofing
•
Containment
•
Process
•
validation
and
problem
solving
and
capability
•
Feedback and feed forward
Andon (Analyze how many
•
Work
times the line stopped and root cause analysis) •
Visual Management
•
Short time)
reaction
time
station
layout
and
condition •
Customer
oriented
quality
targets (Lead
•
The plant should be audited by the external auditors in regular intervals
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5 F Technique of Problem Solving
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Standardization: Layered Audits A layered audit is a standardized audit performed on a regular, frequent basis by all layers of the organization. Auditors check the adherence to standards and procedures by observing evidence in the workstation, and follow-up on deviations. Purpose: To keep close control over the manufacturing operations in order to ensure good business results. Complete audit process must include effective communication and follow-up on deviations
Plant Manager 1 /month
Shift Manager 1 time/week
Supervisor 2 times/week Team Leader (3 times/week)
found. The higher level auditor: •
always check if lower level audit has been performed
•
coach lower levels (invite them
•
perform occasional cross checks to ensure that established methodology
during check)
is applied correctly •
return to previous checked station to follow-up on open items
There are three kinds of results possible: O - No deviations are found X - Any deviation is found
∆ - No Evaluation done
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DRR (Direct Run Rate) Percentage of vehicles that made it through to the End-of-Line inspection processes with no defects. This is a common, global metric that is computed daily by all GM Assembly plants. DRR= Total Number of vehicles without defect x100 Total number of Vehicles
Group Leader’s Responsibility:
Understand the defects being detected by final inspection (End-of-Line through CARE Line).
Prioritize the problems.
Review and ensure standardized work is being followed.
Perform Problem Solving and implement countermeasures.
Plant Management’s Responsibility: Develop Direct Run Targets. Develop action plans to meet the desired targets. Provide necessary resources for effective Problem Solving. 38
DRL (Direct Run Loss) On a daily basis, total Direct Run Loss is computed as total number of defects that have reached a Quality station divided by the the total number of vehicles shipped through the Quality Station.
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Andon Operation Andon Help Calls, Faults and Events:
Scheduled Start or Stop
Team Member Help Call
Electronic Error Proofing Help Call
Run Stop
Manipulator Out-Of-Position and Over-Travel
Local Quality Verification Station Help Call
Downstream Quality Verification Station Help Call
Critical Check Reminder
Float Alarm
Equipment and Conveyor Faults
Entrance and Exit Conveyor Faults
Starved and Blocked
Status of Other Lines
Production Status Information
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Trolley Master List Generation (As per WCQ Level 1)
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Introduction After the recent audit of World Class Quality, Tata Motors plant has evolved from a typical Indian Assembly plant to a World Class Quality (Level 1) plant. New concepts of Build in Quality, Voice of Customer, 5F, 5S, and Personal Protective Equipment, Poka Yoke concepts have evolved from the Japanese industry and are now applied to the whole Tata plant in Lucknow.
The production has been streamlined with the motive of finding the root cause of an error to rectifying it from there and then auditing for several days to make the process error free.
The BIW shop complies with all of the WCQ level 1 rules. Its production have reached new standard while increasing the quality multiple times. Now there are very few cases of complaints from the Paint Shop or the Trim Shops of a fault (dents, holes, weld quality, gaps). This has been achieved by the hard work of the employees here towards a Built in Quality Concept.
This has been achieved by two processes: 1. Rectification of Errors 2. Reduction on Run Down time Rectification of errors includes remove the root cause of the problem which is rectified by small changes in the production process. This also includes removal of the error after it has been generated. Reduction of Run Down time includes the timely maintenance of all the equipments used in the plant which includes the Welding Machines, Brazing Machines, Hangers etc. 42
This would also include the timely maintenance of the trollies used for transportation of child parts in the factory itself.
What is a trolley at the BIW shop? A trolley is a container of different parts used in the assembly of a particular section/ loading unloading of the assembly. The division of the trolley is done on two bases: 1. Material Used for Trolley a. Modular, i.e., the newer types of trolleys which are light weight, more durable and contain minimum sharp edges. b. Iron, i.e., the older form of trolleys used which are heavier, prone to rust, contain more sharp edges which may/may not put scratches of the object. 2. Movement of trolley a. Static, which remain at a fixed place at a station all the time. Parts are brought to the station at regular intervals and are loaded onto them. b. Movable, which are taken to the storage room for loading and then to the station for assembly.
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Iron Type
Modular
` Movable
Static
My project comprises of: 1. Identification of the trolleys used at each station. 2. Creation of a master list of all the trolleys used, both Static and Movable. 3. Giving a unique name/number to the trolleys so that the audit can be done in a systematic manner. 4. Identification of the run down causes of the trolleys. 44
Identification Of The Trolleys Used At Each Station For example: CAB Roof Station 1: Trolleys Identified: a) Panel Roof b) Panel Front Roof c) Insert Stand
Quantity of each trolley is counted.
Identified whether the trolley is Movable or Static.
Identified whether the trolley is Modular (new) or Iron
CAB Roof Station 1: Panel Roof Trolley (Iron)
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CAB Roof Station 1: Panel Roof Trolley (Modular)
CAB Roof Station 4: Top Rail Side Inner (NS) 46
Creation Of A Master List A master list is now created for both the cab and the cowl line. This would help in knowing the total number of trolleys used in both the lines. The master list for the cowl is shown below: Sr. No.
Station
Trolley Description
Type
Quantity
Remark
Iron Modular Iron Iron Iron Iron Modular Iron Modular
14 10 4 4 1 1 1 1 2
Movable Movable Movable Movable Static Movable Movable Movable Movable
1 2 3 4 5 6 7 8 9
1 1 3 3 5 6.1 6.1 6.2 6.3
Cowl Assy Sub Structure Assy Bonnet Front Assy Wheel Arc RH Assy Wheel Arc LH AssyCrossframe Assy Frame LH Face Side LH&RH Assy Frame RH Assy Centre Panel
10
6.3
Assy Reinforcement Front Post LH
Modular
1
Movable
11 12 13 14 15 16 17 18 19 20 21 22
6.3 6B 7.2 8 8 11 11 11 11 12
Assy Reinforcement Front Post RH Front Wall Complete Assy Line Trolley Child Parts Stand Assy Centre Flap Assy Stay Rod And Nuts Assy Front Panel with Vent. Head Lamp Cover Nut Bolt Stand Assy Front Panel with Vent. Child Part Stand Faceless Line Stand
Modular Iron Iron Modular Modular Modular Modular Modular Modular Modular Modular Modular Total
1 6 64 2 3 1 2 1 1 1 2 5 128
Movable Movable Movable Static Movable Movable Movable Movable Static Movable Static Static
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The master list for the cab is shown below: CAB 23 24 25 26 27 29 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Roof1 Roof1 Roof1 Roof3 Roof4 Roof4 Roof4.1 Roof4.1 Roof4.1 Roof5 Rear1 Rear1 Rear1 Rear1 Rear1 Rear1 Rear1 SS1.1 SS1 SS1 SS1 SS1 SS1 SS2 SS2 SS3 SS3 SS3 FW1 FW1 FW1 FW1 FW1 FW1 FW1 FW2 FW2 FW2
Panel Roof Panel Front Roof Insert Stand Panel Outer Bottom Top Rail Side Inner (NS) Support Centre Top( Rear Wall) Top Rail Side Inner (S) Top Rail Rear Child Part Stand Assy Roof Trolley Assy Corner Panel RH (NS) Assy Corner Panel LH (NS) Assy Corner Panel RH (S) Assy Corner Panel LH (S) Assy Rear Wall (NS) Assy Rear Wall (S) Assy Rear Wall Complete Assy Sub Structure Trolley Assy Floor Panel Centre Floor Panel LH Floor Panel RH Wheel Arc + Reinforcement LH Wheel Arc + Reinforcement RH Child Part Stand Air Filter Assy Mud Guard RH Assy Mud Guard LH Floor Retainer Side Panel Face Side RH Panel Face Side LH Assy Face Support LH Assy Face Support RH Panel Outer Bottom Panel Side outer LH Panel Side Outer RH Assy Waist Rail Assy Door Post RH Assy Door Post LH
4 Iron 1 Mod Iron Modular Modular Iron Iron Iron Modular Modular Iron Iron Iron Modular Modular Iron Iron Iron Iron Iron Iron Iron Modular Modular Modular Modular Iron Iron Modular Iron Iron Modular Modular Modular Iron Iron Iron Iron Iron
5 2 1 1 1 1 1 1 1 4 2 2 4 4 2 2 4 6 1 1 1 1 1 1 1 2 2 1 3 3 1 1 2 2 2 2 2 2
Movable Movable Movable Movable Movable Movable Movable Movable Static Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Static Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable
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61 FW3 Waist Rail Support 62 FW3 Assy Frame Front LH 63 FW3 Assy Frame Front RH 64 FW3 Child Part Stand 65 FW4 Assy Toe Panel Front LH 66 FW4 Assy Toe Panel Front RH 67 FW5 Assy Bonnet Complete 68 FW5 Reinforcement Waist Rail 69 FW6.1 Panel Inner Bottom 70 FW6.1 Cover Panel 71 FW6 Assy Dashboard 72 FW6 Child Part Stand 73 FW7 AssyStepwell LH 74 FW7 AssyStepwell RH 75 FW7 Support Waistrail Trolley 76 FW9 Panel Innerside 77 FW9 Panel Innertop 78 FW10 Front Wall Complete Trolley 79 MainFramer Tackle Trolley 80 CabRespot1 Cab Trolley( for Line) 81 CabRespot1 AssyBearth Box 82 CabRespot1 Assy Cover( Step RH support) 83 FL1 Child Part Stand Assy Support Cross Member and 84 FL2 Assy angle support (Bearth Box)
Iron Modular Modular Modular Modular Modular Modular Modular Modular Modular Iron Modular Iron Iron Modular Modular Modular Iron Iron Iron Iron Modular Modular
2 1 1 1 1 1 2 1 1 1 2 1 1 1 2 1 2 10 1 32 1 1 2
Movable Movable Movable Static Movable Movable Movable Movable Movable Movable Movable Static Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Static
Modular
1
Movable
85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
Modular Modular Modular Modular Modular Modular Modular Iron Modular Iron Iron Iron Modular Iron Iron Total
1 1 1 1 1 1 1 1 2 2 2 1 2 1 3 167
Static Static Static Static Static Static Movable Movable Movable Movable Movable Movable Static Movable Movable
FL2 FL2 FL5 FL5 FL5 FL5 FL5 FL6 FL6 FL8 FL8 FL8 FL8 FL10 FL10
Assy Support (Bonnet Side) Brackets Trolley Brackets Stand 1 Nut and Bolt Stand 2 Brackets Stand 3 Assy Tie Member Front Stand 4 Assy Inner Corner Panel AssyBearth Box Complete Assy Centre Flap Assy Door Shell RH Assy Door Shell LH Assy Door Shell Rejected Nut, Bolts and Washers Stand Tackle Trolley Ladder
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Unique Naming System After creation of the master list all the trolleys are given a specific name. This would provide for the proper identification of each trolley for maintenance and auditing. For example the table below shows that if for example there are 5 trolleys for Panel Roof, each of them is given a specific name, i.e., Panel Roof 1-5, and a BIW Trolley Number “BIWCAB001-BIWCAB005”
Sr. No.
Station
Trolley Description
Type
Remark
Iron Iron Iron Iron Modular Iron Iron Modular Modular Iron Iron Iron Modular Modular Iron Iron Iron Iron
Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Movable Static Movable Movable Movable Movable
BIW Trolley No.
CAB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Roof1 Roof1 Roof1 Roof1 Roof1 Roof1 Roof1 Roof1 Roof3 Roof4 Roof4 Roof4.1 Roof4.1 Roof4.1 Roof5 Roof5 Roof5 Roof5
Panel Roof 1 Panel Roof 2 Panel Roof 3 Panel Roof 4 Panel Roof 5 Panel Front Roof 1 Panel Front Roof 2 Insert Stand 1 Panel Outer Bottom 1 Top Rail Side Inner (NS) 1 Support Centre Top( Rear Wall) 1 Top Rail Side Inner (S) 1 Top Rail Rear 1 Child Part Stand 1 Assy Roof Trolley 1 Assy Roof Trolley 2 Assy Roof Trolley 3 Assy Roof Trolley 4
BIWCAB001 BIWCAB002 BIWCAB003 BIWCAB004 BIWCAB005 BIWCAB006 BIWCAB007 BIWCAB008 BIWCAB009 BIWCAB010 BIWCAB011 BIWCAB012 BIWCAB013 BIWCAB014 BIWCAB015 BIWCAB016 BIWCAB017 BIWCAB018
Identification Of The Run Down Causes 1.
Damage/ Crack/ Broken members of trolley
2.
Loose Nut/Bolt
3.
Missing Nut/Bolt
4.
Wheel Jam 50
Final Result STATION: Roof 1, Panel Roof 1 IMPROVEMENT IN SYSTEM BEFORE
AFTER
STATION: Roof 4.1, Top Rail Side Inner (S) 1 IMPROVEMENT IN SYSTEM BEFORE
AFTER
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