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TATA MOTORS LIMITED, LUCKNOW


PROJECT REPORT


SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF
THE DEGREE OF

BACHELOR OF TECHNOLOGY
(Mechanical Engineering)

Submitted To
LOVELY PROFESSIONAL UNIVERSITY, JALANDHAR


Submitted By

Tanmay Sinha
(Reg. No.: 11104142)

Under the guidance of

Mr. Subhabrata Ghosh Mr. Sudeep Kulkarni
Manager, TATA Motors Senior Manager, TATA Motors



Lovely Professional University, Jalandhar
PUNJAB

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ACKNOWLEDGEMENT

It has been great privilege to undergo training at Tata Motors Limited,
Lucknow and the experience of working there has been highly enriching. My
interaction with the company personnel of varied designations and functions
provided valuable insight regarding Industry and functioning of the company.

I would like to thank Mr. Prashant Pandey for providing me the
opportunity to add a new dimension in my knowledge by getting training in this
esteemed organization.
It gives me great pleasure to express my regards and profound gratitude
to my Mentor Mr. Subhabrata Ghosh, Manager (TCF Line 2) for his expert
guidance throughout my training. I am also grateful to Mr.Sudeep Kulkarni,
Divisional Manager (TCF Line 2) for his moral support, intense knowledge of
corporate world and time to time guidance in every aspects. I am highly
indebted for his painstaking attention and giving me his valuable time towards
my projects and suggestions which helped shape my project to perfection.
The acknowledgement will not be complete without a vote of thanks to
the entire team of centre quality for their help and support at all times. There are
numerous other people whom I may not be able to acknowledge here but there
contribution is equally important in the success of my project.
Finally I want to thank all my friends with whom I had developed a
special bond for their helping attitude and co-operation during the course of this
project.
Tanmay Sinha
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CONTENTS

Introduction to TATA Motors
Products
TATA Motors Lucknow Plant
TCF Line 2
Project
Conclusion











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INTRODUCTION




Tata Motors Limited


Type Public (NYSE: TTM)
Founded 1945
Founder JRD Tata
Headquarters Mumbai, India
Key people Cyrus P Mistry, Chairman
Products Automobiles and Engines
Revenue
INR 448.58 billion (US$ 11billion)
(2011)
Net income USD $574 million
Parent Tata Group
Subsidiaries
Jaguar
Land-Rover
Tata Daewoo
Website http://www.tatamotors.com/
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Industry:
The automobile industry in India is the eleventh largest in the world with an
annual production of approximately 2 million units. India is expected to
overtake China as the world's fastest growing car market

in terms of the
number of units sold and the automotive industry is one of the fastest growing
manufacturing sectors in India. Because of its large market (India has a
population of 1.1 billion; the second largest in the world), a low base of car
ownership (25 per 1,000 people) and a surging economy, India has become a
huge attraction for car manufacturers around the world.
Though several major foreign automakers, like Ford, GM and Honda, have
their manufacturing bases in India, Indian automobile market is dominated by
domestic companies. Maruti Suzuki is the largest passenger vehicle company;
Tata Motors is the largest commercial vehicle company.
The automotive industry directly and indirectly employs 13 million individuals
in India. The industry is valued at about US$ 35 billion contributing about
3.1% of India's GDP (nominal). India's cost-competitive auto components
industry is the second largest in the world. In addition, India's motorcycle
market is also the second largest in the world with annual sales of about 5
million units. With the advent of development in engineering and technology,
a lot many significant changes have been taking place in industrial sector.
On the canvas of the Indian Economy, Auto Industry occupies a prominent
place. Due to its deep forward and backward linkages with several key
segments of the economy, automotive industry has a strong multiplier effect
and is capable of being the driver of economic growth. The growth curve of
India Auto Industry has been on an upswing for the past few years. India
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became the fastest growing car market in the world in 2004, with a growth rate
of 20%. Continuing the upswing, the sector posted an impressive 8.9% growth
in 2007-08.
Tata Motors, formerly known as TELCO (TATA Engineering and Locomotive
Company) a multinational corporation headquartered in Mumbai, India. It is
India's largest passenger automobile and commercial vehicle manufacturing
company. Part of the Tata Group, it is one of the world's largest manufacturers
of commercial vehicles. The OICA ranked it as the world's 20th largest
automaker, based on figures for 2006. It is the largest automobile manufacturer
in India and commands more than 70% of the commercial vehicle market in
India and has also increased its share of passenger vehicle market. It was
responsible for developing India's first indigenous vehicle, the Indica. It has
proved to be a success in the market after initial quality problems. The
company also exports the car to many countries. Tata Motors is considered to
be the flagship company of the Indian automobile industry.
TATA Motors
Established in 1945, Tata Motors presence indeed cuts across the length and
breadth of India. The company is the worlds fifth largest medium and heavy
commercial vehicle manufacturer and the world's second largest medium and
heavy bus manufacturer.
Over 3 million Tata vehicles ply on Indian roads, since the first rolled out in
1954. The companys manufacturing base is spread across Jamshedpur, Pune
and Lucknow, supported by a nation-wide dealership, sales, services and spare
parts network comprising about 1,200 touch points. The company also has a
strong auto finance operation, Tata Motor Finance. At the core of the
companys approach to doing business is the Tata Business Excellence Model.
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Incorporating sound business principles, like customer satisfaction, quality,
attention to detail, conservation of resources and protection of the
environment, this model shapes the way Tata Motors designs, manufactures
and markets its products.
History
Tata Motors is a part of the Tata and Sons Group, founded by Jamshetji Tata
and J. Baker. The company was established in 1945 as a locomotive
manufacturing unit and later expanded its operations to commercial vehicle
sector in 1954 after forming a joint venture with Daimler-Benz AG of
Germany.
1960-1986


Tata Motors launches its first truck in collaboration with Mercedes-Benz
Tata Motors started its commercial vehicle operations in 1960 with the
manufacturing of first commercial vehicle (a copy of a Daimler Benz model)
in Pune. It took five years for the company to begin the commercial production
of heavy commercial vehicles. Considering the road infrastructure of the
country which does not support heavy vehicles, the company adopted a route
for light commercial vehicles (LCV). It came out with its first LCV, Tata 407,
in 1986.
1987-1996
Post liberalization, in order to expand rapidly, the company adopted the route
to joint ventures. In 1993, it signed with Cummins Engine Co., Inc., for the
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manufacture of high horsepower and emission friendly diesel engines. It was
an effort made to reduce the pollution in the existing Tata engines and to
produce more environmentally friendly engines. Furthering the trail of JVs it
signed a joint venture agreement with Tata Holset Ltd., UK, for manufacturing
turbochargers to be used on Cummins engines.
1997-2006
In 2000, it launched compressed natural gas (CNG) buses and also filled the
product line gap through the introduction of the 1109 vehicle which is an
intermediate commercial vehicle and is useful for medium tonnage loads. Post
2000, the company introduced a variety of new models. It introduced the Ex-
series vehicles with high tonnage capacity and high pick up and also came out
with the entirely new LCV (207 DI) with direct ignition technology to cater to
the customers' requiring one and same vehicle for commercial as well as
personal use.
Tata Indica
After years of dominating the commercial vehicle market in India, Tata Motors
entered the passenger vehicle by launching hatch-back car, the Tata Indica.
Indica was the first car indigenously designed in India. Though the car was
initially panned by auto-analysts, the car's excellent fuel economy, powerful
engine and aggressive marketing strategy made it one of the best selling cars in
the history of the Indian automobile industry. A newer version of the car,
named Indica V2, was a major improvement over the previous version and
quickly became a mass-favorite. A badge engineered version of the car was
sold in the United Kingdom as the Rover CityRover. Tata Motors also
successfully exported large quantities of the car to South Africa. The success
of Indica in many ways marked the rise of Tata Motors.

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Daewoo acquisition


Tata Novus is one of the best selling commercial trucks in South Korea.
With the success of Tata Indica, Tata Motors aimed to increase its presence
world-wide. In 2004, it acquired the Daewoo Commercial Vehicle Company
of South Korea. The reasons behind the acquisition were:
Companys global plans to reduce domestic exposure. The domestic
commercial vehicle market is highly cyclical in nature and prone to
fluctuations in the domestic economy. Tata Motors has a high domestic
exposure of ~94% in the MHCV segment and ~84% in the light commercial
vehicle (LCV) segment. Since the domestic commercial vehicle sales of the
company are at the mercy of the structural economic factors, it is increasingly
looking at the international markets. The company plans to diversify into
various markets across the world in both MHCV as well as LCV segments.
To expand the product portfolio Tata Motors recently introduced the
25MT GVW Tata Novus from Daewoos (South Korea) (TDCV) platform.
Tata plans to leverage on the strong presence of TDCV in the heavy-tonnage
range and introduce products in India at an appropriate time. This was mainly
to cater to the international market and also to cater to the domestic market
where a major improvement in the Road infrastructure was done through the
National Highway Development Project
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On its journey to make an international foot print, it continued its expansion
through the introduction of new products into the market range of buses
(Starbus & Globus).
Joint ventures


MAN NG313-F; Hispano Carrocera "Habit"
In 2005, sensing the huge opportunity in the fully built bus segment, Tata
Motors acquired 21% stake in Hispano Carrocera SA , Aragonese bus
manufacturing company and introduced its high-end inter-city buses in the
country.
Tata Motors has also formed a 51:49 joint venture with Marcopolo S.A.,a
Brazil-based global leader in bus body building. This joint venture is to
manufacture and assemble fully-built buses and coaches targeted at developing
mass rapid transportation systems. The joint venture will absorb technology
and expertise in chassis and aggregates from Tata Motors, and Marcopolo will
provide know-how in processes and systems for bodybuilding and bus body
design.
Tata Ace
Tata Ace, India's first indigenously developed sub-one ton mini-truck was
launched in May 2005. The mini-truck was a huge success in India with auto-
analysts claiming that Ace had changed the dynamics of the light commercial
vehicle (LCV) market in the country by creating a new market segment termed
the small commercial vehicle (SCV) segment. Ace rapidly emerged as the first
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choice for transporters and single truck owners for city and rural transport. By
October 2005, LCV sales of Tata Motors had grown by 36.6 percent to 28,537
units due to the rising demand for Ace. The Ace was built with a load body
produced by Autoline Industries. By 2005, Autoline was producing 300 load
bodies per day for Tata Motors.
Tata Ace has also been exported to several European, South American and
African countries. Electric-versions of Tata Ace are sold through Chrysler's
Global Electric Motorcars division.
2007


Tata Pick Up, unveiled in 2007, is expected to enter European and American
market by 2009.
In 2007, Tata Motors launched several concept models and future designs of
existing models. It also formed joint ventures with various local companies in
several countries to assemble Tata cars. Tata Motors launched a re-designed
version of Tata Xenon TL during Motor Show Bologna which would be
assembled in Thailand and Argentina. A pick-up variant of Tata Sumo was
also launched under the program 'Global Pick-Up'. The company plans to
launch the new pick-up model in India, Southeast Asia, Europe, South Africa,
Turkey and Saudi Arabia. Tata Motors also unveiled newer model of Tata
Indigo and Tata Elegante concept-car during the Geneva Auto Show.
Tata Motors also formed a joint venture with Fiat and gained access to Fiats
diesel engine technology. Tata Motors is looking to extend its relationship with
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Fiat and Iveco to other segments like the 'Global Pick-Up' program. The
launch of the 'Global Pick-Up' will mark the entry of the company into
developed markets like Europe and the United States. The project was initially
collaboration between Tata Motors and its subsidiary Tata Daewoo
Commercial Vehicles, but later Tata Motors decided to work with Iveco as
Daewoos design was not in sync with the needs of sophisticated European
customers. The company has formed a joint venture with Thailands Thonburi
Company, an independent auto assembler, in which Tata Motors will hold a
70% stake.
Jaguar Cars and Land Rover
As of March 26, 2008, Tata Motors reached agreement with Ford to purchase
their Jaguar and Land Rover operations for US$2 billion. The sale is expected
to be completed by the end of the second quarter of 2008. Tata will also gain
the rights to the Daimler, Lanchester, and Rover brand names.

Business Overview:
Tata Motors has diversified in to a range of activities all related to the
automobile industry. Through its subsidiaries, the company is involved in
engineering and automotive products, construction equipment manufacturing,
automotive vehicle components manufacturing and supply chain activities,
machine tools and factory automation products, high-precision tooling,
electronic components for automotive and computer applications, and
automotive retailing and service operations. The company's manufacturing
base is spread across India. In the east they are based in Jamshedpur
(Jharkhand). Pune (Maharashtra) is their main centre for the west. In the north
Lucknow (Uttar Pradesh) and Pantnagar (Uttarakhand). A plant to manufacture
Nano which is in Sanand in Gujarat.
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TTM focuses on Research and Development and has over 2,500 engineers and
scientists working for the companys Engineering Research Centre. The
company has R&D centres in Pune, Jamshedpur, Lucknow, in India, and in
South Korea, Spain, and the UK. It has developed the first commercially
viable prototype of air power car. On 25th July 2008, It also announced to
launch the electric version of Nano in Europe by Dec 2009. The companys
dealership, sales, services and spare parts network comprises over 3500 touch
points; TTM also distributes and markets Fiat branded cars in India.

Joint Venture, Subsidiary and Associate Companies
Tata Motors has several joint venture, subsidiary and associate companies:
Jaguar Land Rover
Tata Technologies Ltd. (TTL) and its subsidiaries
Telco Construction Equipment Co. Ltd. (Telcon)
HV Axles Ltd. (HVAL)
HV Transmissions Ltd. (HVTL)
TAL Manufacturing Solutions Ltd. (TAL)
Sheba Properties Ltd. (Sheba)
Concorde Motors (India) Ltd. (Concorde)
Tata Daewoo Commercial Vehicle Company Ltd (TDWCV)
Hispano Carrocera
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Tata Motors Insurance Services Ltd. (TMISL)
Tata Motors European Technical Centre plc
Tata Motors Finance Limited
Tata Motors Thailand

INTERNATIONAL BUILDS UP:
Tata Motors, the first company from India's engineering sector to be listed in
the New York Stock Exchange (September 2004), has also emerged as an
international automobile company. In 2004, it acquired the Daewoo
Commercial Vehicles Company, Korea's second largest truck maker. The
rechristened Tata Daewoo Commercial Vehicles Company has launched
several new products in the Korean market, while also exporting these
products to several international markets. Today two-thirds of heavy
commercial vehicle exports out of South Korea are from Tata Daewoo. In
2005, Tata Motors acquired a 21% stake in Hispano Carrocera, a reputed
Spanish bus and coach manufacturer, with an option to acquire the remaining
stake as well. Hispano's presence is being expanded in other markets. In 2006,
it formed a joint venture with the Brazil-based Marcopolo, a global leader in
body-building for buses and coaches to manufacture fully-built buses and
coaches for India and select international markets. In 2006, Tata Motors and
Fiat Auto formed an industrial joint venture at Ranjangaon (near Pune in
Maharashtra, India) to produce both Fiat and Tata cars and Fiat power trains
for the Indian and overseas markets; Tata Motors already distributes and
markets Fiat branded cars in India. In 2007, Tata Motors and Fiat Auto entered
into an
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agreement for a Tata license to build a pick-up vehicle bearing the Fiat
nameplate at Fiat Group Automobiles' Plant at Crdoba, Argentina. The pick-
up will be sold in South and Central America and select European markets.
These linkages will further extend Tata Motors' international footprint,
established through exports since 1961.
While currently about 18% of its revenues are from international business, the
company's objective is to expand its international business, both through
organic and inorganic growth routes. The company's commercial and
passenger vehicles are already being marketed in several countries in Europe,
Africa, the Middle East, Australia, South East Asia and South Asia. It has
assembly operations in Malaysia, Kenya, Bangladesh, Ukraine, Russia and
Senegal.
Business segments
Tata Motors operates in four main automobile segments which cover the range
of products in the automobile segments in India.
Passenger Cars:(30.5% of total units sold) This segment accounts for 30.5%
of the total production volume During FY 2008, 182,292 units of gasoline and
diesel engine versions were manufactured and sold. This division also
distributes Fiat branded cars in India.
[
TTM has a presence in the compact car,
mid-sized car and station wagon segment of the market in the form of Indica,
Indigo and Indigo Marina and their variants. In FY 2008, the passenger car
industry grew by 11.9% in India, but the TTM sales in this segment declined
by 7.3% due to no new product launches. The market share of TTM in this
segment declined from 15.6% to 13.3%. All the passenger cars are
manufactured at plants at Pimpri and Chinchwad district in Maharashtra.
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Tata Motors has launched "Nano", an affordable family car with a price tag of
Rs. 1,10,000 (around $2200) for the developing world. The project was
delayed as the public opposition and political problems forced the management
to abandon the plant site at Singur, West Bengal and shift it to Gujarat.
Utility Vehicles :(8.4% of total units sold) TTM entered the utility vehicle
with the launch of Tata Sumo in 1994. Later it also entered SUV segment with
the launch of Tata Safari in 1998. This segment accounts for 8.4% of the total
production volume. The sales in this segment were 47,530 units, a decline
0.8% as compared to 47,892 units in FY 2007. The overall market share in this
category is 20.1%. TTM lost 2% of the market share due to lack of any new,
product or a variant of the existing product in this segment. All the utility
vehicles are manufactured at plants at Pimpri and Chinchwad district in
Maharashtra.
Light Commercial Vehicles :(29.1% of total units sold) TTM manufactures
light commercial vehicles including pickup trucks, trucks and buses with gross
vehicle weight(GVW) of between 0.7 ton and 7.5 tons. This segment grew by
17.2% growth to 147,316 units sold in the Indian domestic market in FY 2008
and constituted 29.1% of the total units sold. TTM entered this category by
indigenously developing a low priced product Ace(mini-truck) with a 0.7 ton
payload in fiscal 2006. In FY2008, TTM launched two other products, Magic a
passenger variant of Ace and Winger. It also announced to introduce CNG
variant of the Ace, the Tata Cargo Panel Van, a lifestyle pickup truck(Xenon
XT) and an office concept vehicle at the Auto Expo 2008 in India. TTM has a
market share of 64.2% in this segment. The light commercial vehicles are
manufactured at plants in Lucknow and Uttarakhand, Uttar Pradesh.
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Medium and Heavy Commercial Vehicles :(32% of total units sold) TTM
manufactures medium and heavy commercial vehicles which include trucks,
buses, dumpers and multi-axled vehicles with GVW of between 9 tons to 49
tons. In addition, through Tata Daewoo Commercial Vehicle Company
Limited, or TDCV, a wholly-owned subsidiary in South Korea, TTM
manufactures high horsepower trucks ranging from 220 horsepower to 400
horsepower, including dump trucks, tractor-trailers, mixers and cargo vehicles.
This segment constituted 32% of the total volumes in FY2008.. TTM has a
market share of 64.17% in this segment. In India, Tata motors manufactures
the Medium and Heavy Commercial Vehicles at manufacturing plants at
Jamshedpur, Chattisgard and Lucknow, Uttar Pradesh.









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PRODUCTS

Passenger cars and utility vehicles
Tata Sierra
Tata Estate
Tata Sumo/Spacio
Tata Safari
Tata Indica
Tata Indigo
Tata Indigo Marina
Tata Nano (September 2008)
Tata Xenon XT

Concept vehicles
2000 Aria Roadster
2001 Aria Coupe
2002 Tata Indica
2002 Tata Indiva
2004 Tata Indigo Advent
2005 Tata Xover
2006 Tata Cliffrider
2007 Tata Elegante

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Commercial vehicles
Tata Ace
Tata TL/Telcoline/207 DI Pickup Truck
Tata 407 Ex and Ex2
Tata 709 Ex
Tata 809 Ex and Ex2
Tata 909 Ex and Ex2
Tata 1109 (Intermediate truck)
Tata 1510/1512 (Medium bus)
Tata 1610/1616 (Heavy bus)
Tata 1613/1615 (Medium truck)
Tata 2515/2516 (Medium truck)
Tata 3015 (Heavy truck)
Tata 3118 (Heavy truck) (8X2)
Tata 3516 (Heavy truck)
Tata 4923 (Ultra-Heavy truck) (6X4)
Tata Novus (Heavy truck designed by Tata Daewoo)

Military vehicles
Tata LSV (Light Specialist Vehicle)
Tata 407 Troop Carrier, available in hard top, soft top, 4x4, and 4x2
Tata LPTA 713 TC (4x4)
Tata LPT 709 E
Tata SD 1015 TC (4x4)
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Tata LPTA 1615 TC (4x4)
Tata LPTA 1621 TC (6x6)
Tata LPTA 1615 TC (4x2)


Telco Construction Equipment (TCE)
TCE is a joint venture between Tata Motors and Hitachi, which focuses on
excavators and other construction equipment.
HV Transmission (HVTL) and HV Axles (HVAL)
HVAL and HVTL are 100% subsidiary companies of Tata Motors engaged in
the business of manufacture of gear boxes and axles for heavy and medium
commercial vehicles, with production facilities and infrastructure based at
Jamshedpur. The combined revenue of the two companies rose 38.7% yoy for
9MFY07 while the combined PAT rose 50.9%. Tata Motors plans a capex of
Rs2bn each for HVAL & HVTL and plans to raise funds for the same, most
probably by way of a strategic sale to a technical collaborator. The strategic sale
of either HVAL or HVTL or both is likely to be completed in the next one or
two quarters.

Tata Technologies Limited (TTL)
TTL provides Engineering and Design (E&D) solutions to the Automotive
Industry. Tata Motors holds 86.91% of TTLs share capital. TTL is based in
Pune (Hinjawadi) and operates in the US and Europe through its wholly owned
subsidiaries in Detroit and London respectively. It also has a presence in
Thailand. Tata Technologies is a software service provider in the IT services
and BPO space. Its global client list includes Ford, General Motors, Toyota and
Honda, to name a few. It bought over the British engineering and design
services company, Incat International Plc for Rs4b in August 2005. Incat
specializes in engineering & design services and product lifecycle management
in the international automotive, aerospace and engineering markets. With this
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acquisition, Tata Motors will have closer proximity to its global customers and
be able to provide a wider range of services.

Tata Daewoo CV (TDCV)
TDCV is a 100% subsidiary of the Tata Motors based in South Korea, which
was acquired in March 2004. TDCV is in the business of manufacture and sale
of heavy commercial vehicles. Tata Daewoo is Tata Motors 100% subsidiary in
Korea, with a market share of 30%.Tata Motors will use the Daewoo
technology to introduce higher tonnage trucks in the Indian market and use Tata
Daewoo for exports globally. In line with this strategy, it has already introduced
the Novus, a high-end tipper developed by Tata Daewoo for the Indian market

Future Challenges:
Competition In Heavy Vehicles:-
Mahindra and Mahindra: JV with ITEC, North American leader in
heavy trucks. M&M has formed a 51:49 JV called Mahindra
International with ITEC, USA (parent Navistar International), to
manufacture commercial vehicles and to bolster its position in the CV
business. ITEC is the leader in medium and heavy trucks and buses in
North America, and is the world's largest manufacturer of medium-duty
diesel engines. Mahindra International aims to have a presence across the
CV market (6-35 tonnes GVW) with variants of passenger transport,
cargo and specialised load applications and is likely to start producing
medium/heavy commercial vehicles from FY09.
Force Motors: JV with MAN for manufacturing high-tonnage vehicles
Force Motors has paired up with MAN in a 70:30 JV to manufacture
high-tonnage and specialty vehicles, such as long-haul trucks, tippers,
tractor trailers and multi-axle vehicles in the 16-32 tonne range at its
Pithampur plant, with an initial capacity of 24,000 units per annum and at
an investment of Rs7bn. The JV plans to sell nearly half of its production
in the domestic market, while the rest is to be exported to the Middle
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East, Turkey, Russia, Asia and Africa. Further, the two companies have
formed another JV to manufacture buses in India from end-2007.
Ashok Leyland: Acquisition of Czech Republic-based Avia Ashok
Leyland (ALL) recently acquired the truck unit of Czech Republic-based
Avia for US$35m. Avia manufactures 6-9 tonne LCVs and has a capacity
of 20,000 units per annum. The acquisition has given ALL direct access
to an entire range of Avia trucks, Avias press shop with dies and tools,
welding lines, state-of-the-art paint shop and R&D facilities. ALL has
also entered into technology agreements with Hino Motors of Japan and
ZF of Germany to complement its in-house R&D efforts and developing
complementary components and aggregates.
Bharat Benz: The newest competitor in the HCV segment for TATA
Motors is the famous German group Diamlers Indian segment of HCVs
called Bharat Benz to give their products and indigenous touch. The
trucks have been much appreciated for quality and aesthetic appeal over
TATA Motors. Also the name Diamler is associated to quality and
warranty worldwide thus proving to be a long term competitor for Indias
auto giant.
Competition In Passenger Cars: -
Maruti Suzuki India: Based in New Delhi, India. Maruti Suzuki India
Limited is a subsidiary of Suzuki Motor (SZKMF) Corporation. It was
formerly known as Maruti Udyog Limited. The Group's principal activity
is to manufacture, purchase and sale of Motor Vehicles and Spare parts.
The Group is a subsidiary of Suzuki Motor Corporation. The other
activities of the Group comprises of dealership network of Pre-Owned
Car Sales, Fleet Management and Car Financing. The Group also
provides services like framing of customized car policies, economical
leasing of cars, maintenance management, registration and insurance
management, emergency assistance and accident management. The
product range includes ten basic models with more than 50 variants. The
Group has operations in over 1220 cities with more than 2628 outlets and
also exports cars to other countries. It also exports its products to Asia,
Africa, and South and Latin America.
Hyundai Motor Company: Based in Seoul, South Korea, Hyundai
Motor Company manufactures and distributes motor vehicles and parts
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worldwide. It offers passenger cars, recreational vehicles and commercial
vehicles, including light commercial vehicles; medium and heavy duty
trucks; special vehicles, such as refrigerated van truck, dry van truck,
wing body truck, and trailer wing body/bottle carriers; medium and large
size buses; and bare chassis.
Honda: Headquartered in Tokyo, Honda Motor Co., Ltd., together with
its subsidiaries develops, manufactures and distributes motorcycles,
automobiles, and power products worldwide. Its motorcycle business
manufactures motorcycles, all-terrain vehicles, and personal watercrafts.
Hondas motorcycle line consists of sports, business, and commuter
models. Its automobile business offers passenger cars, multiwagons,
minivans, sport utility vehicles and mini cars. The company also offers
various financial services to its customers and dealers. In addition, it
manufactures various power products, including power tillers, portable
generators, general-purpose engines, grass cutters, outboard engines,
water pumps, snow throwers, power carriers, power sprayers, lawn
mowers, and lawn tractors. Honda sells its products through various
outlets, wholesalers, and independent retail dealers.
Toyota: Headquartered in Toyota City, Japan, Toyota Motor
Corporation operates in the automotive industry worldwide. It designs,
manufactures, assembles, and distributes passenger cars, recreational and
sport-utility vehicles, minivans and trucks, and related parts and
accessories. It also offers hybrid vehicles. Its products also comprise
conventional engine vehicles, including subcompact and compact cars,
mini-vehicles, passenger vehicles, commercial vehicles, auto parts, mid-
size models and luxury models. In addition, Toyota offers sports and
specialty vehicles, recreational and sport-utility vehicles, pickup trucks,
minivans and cab wagons, trucks and buses. Further, the company
provides finance to dealers and their customers for the purchase or lease
of Toyota vehicles. Additionally, it is also involved in the design and
manufacture of prefabricated housing and information technology-related
businesses, including intelligent transport systems and an e-commerce
marketplace, called Gazoo.com.

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TATA MOTORS, LUCKNOW PLANT



Year of commencement: 1991
Plant Area: 600 acres
Divisions Assembly Training Manufacturing

TATA MOTORS Lucknow is a 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) started which also included ITI's and Occupancy of
administration office of assembly shop in September 1992. First vehicle rolled
out from Lucknow plant on 20th October 1992 which was LP 1210 52.
Construction of MRS finished on 6th January 1993. It took approximately 9
years since the conception of the plan and to rollout the first vehicle from this
latest manufacturing facility of Tata Motors. Plant Head, Mr Alok Saxena,
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currently heads this Unit. The state of art plant is strongly backed by an
Engineering Research Centre and Service set-up to support with latest
technology and cater to the complexities of automobile manufacturing. Fully
Built Vehicle business, which is one of the fast growing areas of our business, is
also established in Lucknow.
Our plant, rolls out commercial vehicles and is specialized in the designing and
manufacturing of a range of modern buses which includes Low-floor, Ultra
Low-floor, CNG & RE Buses.
The Lucknow facility also specializes in manufacturing HCBS (High capacity
Bus System) buses. In light of Companys aggressive growth plans, we are
currently in expansion phase and production at Lucknow would grow manifold
in near future. The expansion shall be in the areas of painting, welding, vehicle
assembly & testing and utility services, driven by latest technology. To achieve
these plans we invite people who have good Technical Knowledge, seek
challenging opportunities and have a Drive for Engineering Excellence to come
and partner us in our journey.
Tata Motors Lucknow is one of the youngest production facilities among all the
Tata Motors locations and was established in 1992 to meet the demand for
Commercial Vehicles in the Indian market. The state-of-the-art plant is strongly
backed by an Engineering Research Centre and Service set-up to support with
latest technology and cater to the complexities of automobile manufacturing.
Fully Built Vehicle business, which is one of the fast growing areas of our
business, is also established in Lucknow

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Departments in TATA Motors Lucknow are:
Planning
Technical services
Central tool room
Central procurement
Dispatch
Central logistics
Factory logistics group-CV
Factory logistics gear-transmission
Factory logistics Gr-sumo
SQIG
Engineering services
Central maintenance
FPIG - CV factory
FPIG-transmission factory
Central quality (CQ)
Area office, Lucknow
Regional sales office (Lucknow)
Service dept., Lucknow works
Plant head office
Manufacturing head office
Human resources
Get training
Business excellence
Finance
Internal audit
ERC Lucknow
Administration
Construction


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Eastern Complex:
TATA Motors Ltd. Lko, has total plant area of 600 acres of which 280 acres are
covered in the Western Part called the Western Block which has a present
production capacity of 120 vehicles per day so they planned to increase its daily
production capacity to 520 vehicles by extension which is in the form of eastern
complex on the other side of Dewa road covering the remaining 320 acres.
The production capacity of this new assembly plant is roughly 320 vehicles per
day. The eastern complex has the longest conveyor line of India i.e. 375 meters.
This eastern complex has two conveyers formed by the combination of single
chain conveyor and double chain slat conveyor. These conveyors are named as
Line-2 and Line-3 (Line-1 is the name given to the conveyor at western
complex). There is also a provision of a future expansion in form of Line-4
and Line-5 and two more trim lines to cater their cowl/cab needs. Line-2 and
Line-3 are composed of 30 stations of 12.5 meters each in comparison to the
19 stations in the existing line.
The complete assembling activity for the vehicle chassis is
done in these 30 stations. The assembly of cowl/cab is catered by the two trim
lines, which are composed of 40 and 26 stations respectively. Apart from this, it
also have the biggest paint shop, which is dedicated for the painting of cowls
and cabs along with the BIW (Body in White) shop.
Moreover in the Eastern Complex there are many other changes
made for the efficient working on the line. Firstly the line accommodate the
assembling of chassis of various types of MCV`s and HCV`s up to the model
WORLD TRUCK of TATA. All the equipments and tools etc. operate over-
head so as to make the floor surface more available and reducing hindrance on
the shop floor. Platforms for accommodating different types of over-head
equipments and machines are hanged to the top with various beams and
hangers. Also the aggregates which are the heavy parts required during the
chassis assembly (Engine, Axles, and Cab etc.) are moved from storage to the
fitment station through EMS (Electric Monorail System) which freeze the
movement of fork-lifters on the shop floor. Moreover the docking stations are
built aside the wall to dock the material from outside in front of the station in
which that part go to the assembly line directly. Above all the main thing is that
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the flow of work is made in efficient & systematic way to enhance the
productivity with the increased safety.
Figure: Map of Eastern Complex- TML, Lucknow
TCF Line 2:
TCF Line 2 stands for Trim Chassis Frame Line and it is the second assembly
line in TATA Motors, Lucknow plant headed by divisional manager Mr.
Sudeep Kulkarni. Our department consists of five managers and the numerous
virtuoso operators on the assembly line. The line is responsible for the
production of three basic models of trucks from the plant namely: LPT3118,
LPT 2518, LPT 1613 and LPT 1512.
The line manages to match up to the production demands of the plant evenly on
all days. Many new additions are simultaneously done on the line as a part of
continuous improvement. I witnessed how the trucks are assembled from the
frame at station 1 to a fully built truck at the end of R2 area.
This line is divided into 30 Stations and total 110 Operations are performed in
this process.(from next page)



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STATION 1:

TROLLEY ADJUSTMENT- Trolleys are adjusted before the frame
drop. Correct flap position in the trolley -as per specified model


FRAME DROPPING- The frame is dropped on the trolleys. Frame
should be in the horizontal position at the time of transfer

NYLON CLUSTER PIPE FITMENT- They carries air to be supplied
to the whole truck. That air is used for braking.

WIRING HARNESS-They provide electricity to different harness
connection points of the truck.
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RELAY VALVE FITMENT- It controls the amount of air entering the
brake hose pipes, air tanks

BRAKE HOSE PIPE FITMENT- They carries air from relay valve to
brake actuators.

LIFT AXLE PIPE FITMENT- They carry air to the lift axle balloons.
PRV AND LOAD SENSING VALVE FITMENT- They sense the load
on the dead and live axles and accordingly gives command to the lift axle
control valve.
DDU FITMENT- The air enters the Dryer and Distributor Unit from Air
Compressor through AC head pipe. DDU has an inbuilt purge tank. It is
used in 52 WB only.
AIR DRYER & PURGE TANK - The air enters the Air Dryer and then
the extra air goes to purge tank. They both are used in 56WB.
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AC HEAD CONNECTING FITMENT- These AC head pipes connect
Air Compressor to the DDU in 52 WB or the Air Dryer in 56 WB.

EXTRA AIR TANK FITMENT (LARGE)-This tank is provided for
the clutch system.
EXTRA AIR TANK FITMENT (SMALL)- This tank is provided for
the Lift axle system




STATION 2:

FRONT SHOCK ABSORBER MTG BKT FITMENT- Front shock
absorber is mounted on this bkt.
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POWER STG PIPE MTG L BKT FITMENT- Power steering pipes
carries the power steering oil to the power steering gearbox and the used oil
again to the oil tank

SILENCER MTG BRACKET- The silencer unit is mounted on this
brkt. Basically the muffler.


FUEL LINE FITMENT- An I brkt is fitted in this fitment. And as we
move on to upcoming stations. The fuel lines are fitted.
CHASSIS NUMBER PUNCHING AND BAR CODING- Every chassis
has a different chassis no. that has to be punched on this station. Legibility
of the chassis number punches.


PROPELLER SHAFT DROPPING- The propeller shaft is dropped on
this station. The propeller shaft connects gearbox to the differential.
PROP SHAFT GUARD FITMENT- To avoid unnecessary movement of
prop shaft 2 different U guards are provided.

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LINK ROD FITMENT- Leaf springs to the rear axles are connected to
the link rod.


STATION 3:

LIFT AXLE KIT DROPPING,BALLOONS BKTS.FITMENT&
BALLOONS- This was the special kit which was provided to LPT
3118.This technology of lift axle was newly evolved.




STATION 4:

FRONT SHACKLE FITMENT- Shackle was only providing to the front
suspension system.

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LEAF SPRING FOR DEAD AXLE- The leaf spring is fitted to the link
rod .The Dead axle is to be dropped further on this leaf spring.


LEAF SPRING FOR LIVE AXLE- - The leaf spring is fitted to one end
of the link rod and other end was fitted to the welded joints .The live axle is
to be dropped further on this leaf spring.


STATION 5:

LEAF SPRING FRONT SIDE- Since approx. 40% weight is to be
supported by the front wheels. Front side leaf spring is thinner.

WEDGE SCREW & GREASE NIPPLE FITMENT- Wedge screw is
also called cotter joint. They in combination with the pin are used to fit the
leaf springs. Grease nipples are attached to pins. Grease can be easily
applied through them.
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STATION 6:

LIFT AXLE FITMENT- Lift axle is fitted to the lift axle kit.


FRONT AXLE FITMENT- Front axle is fitted to the front leaf spring.
They are joined by U-bolts.

LIVE REAR AXLE FITMENT- Live axle is fitted to the rear leaf spring.
They are joined by U-bolts.
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REAR ACTUATOR FITMENT- They are used for braking system.


DEAD REAR AXLE FITMENT- Dead axle is fitted to the rear leaf
spring. They are joined by U-bolts.


STATION 7:

FUPD BRACKET FITMENT- FUPD(Front Under Protection Device).


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REAR AXLE TIE ROD FITMENT- Tie rod is connected between the
dead and live axles. LSV senses the movement in the Tie rod. And
accordingly gives command to the lift axle control valve.
FUPD & BUMPER BKT FITMENT- FUPD Tube and Bumper brkt are
fitted.
FRONT AXLE TIGHTENING- Front axle U bolts are tighten through
runners. Torque set is 35kgfm.

STATION 8:

LIFT AXLE TIGHTENING- Lift axle is tighten through runners.



SHIMMY DAMPER- They are connected to the lift axle.

STATION 9:

FRONT SHOCK ABSORBER FITMENT. For shock absorbing they
are connected to the front axle.



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PROP SHAFT FITMENT ON REAR AXLE- Prop shaft is connected
to the differential.

STATION 10:

AIR TANK FITMENT LPT3118BS-2- The air tank is fitted.



GREASING- The process of grease application is called nissing.

SILENCER MUFFLER FITMENT- The muffler which is a part of
silencer unit is fitted.



STATION 11:

INVERSION- The whole chassis is inverted before engine, cowl and
other accessories fitment.
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STATION 12:

DEAD,LIFT AXLE AND FRONT AXLE BRAKE PIPE BRAKE
PIPE FITMENT AND CLAMPING- Brake hose pipe for dead and lift
axle is clamped on the L-Clamp.

REAR COWL MOUNTING BRACKET-Mounting brackets for the
cowl are fitted on the frame.

ENGINE MOUNTING PADS FITMENT-Both front and rear engine
mounting pads with torque support plate for front pad are fitted.


STATION 13:

POWER STEERING GEAR BOX AND DRAG LINK FITMENT-
Power steering gear box assembly with mounting bracket pitman arm and
spindle is performed and the whole assembly is fitted in the frame.
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POWER STEERING PIPE FITMENT- Power steering pipe kit
containing pressure and return pipe is fitted in the frame and are connected
with the power steering gear box.



STATION 14:

TAIL LAMP BCKT ASSY AND FITMENT- Tail lamp brackets (both
left and right) are assembled with the tail lamps and then fitted in the
frame.

ENGINE DROPPING AND TIGHTNING The one of critical
process. In this, engine from the engine assembly area is dropped on to
the frame (on engine mounting pads) and then tightened with the help of
the M-12 hex nut and bolt.
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LIFT AXLE CONTROL VALVE AND CONTROL SWITCH The
control switch and control valve for the movement of lift axle is fitted
into the frame.



FUEL TANK BRACKET PLATE AND BRACKET FITMENT- Fuel
tank bracket plates and fuel tank bracket assembly (Bracket and Strape)
are fitted on the frame.


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STATION 15:

SILENCER FITMENT - Silencer second and third pipe is assembled
with the help of pipe clamp and exhaust clamp and this assembly is fitted
to the muffler.

REAR AXLE BREATHER FITMENT An air breather assembly
(Assembly filter breather and Adaptor) is fitted to the live axle. Air
breather helps in removing the waste gases from the differential and
prevents the formation of sludge.



PROPELLER SHAFT CONNECTION WITH GEAR BOX Propeller
shaft is connected with the gear box with the help of 4 M-12 hex bolt and
Nalco Nut.

A/C HEAD PIPE FITMENT The outlet pipe with air compressor (A/C)
is fitted on to the frame.

FUEL MAIN LINE AND RETURN LINE Main fuel line through
which fuel from the tank enter the injector motor and the return fuel line
through which extra fuel from the injector motor returns back to the tank.

STATION 16:

CLUTCH PIPE AND BRAKE CLUSTER PIPE CLAMPING Clutch
pipe or clutch booster pipe is clamped with the help of assembly clamps
and coated clamp and then connected with the clutch assembly attached
with the cowl. Brake cluster pipe is also clamped with the help of coated
clamp.

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DUMBLE BKT AND RADIATOR FITMENT Radiator is dropped on
the frame and tightened.



STATION 17:

FUEL TANK DROPPING AND FITMENT A 400 l fuel tank is
dropped and fitted into the fuel tank bracket and the main fuel line and
return fuel line is connected.




STATION 18:

COWL DROPPING AND TIGHTNING One of the most critical
operations. Cowl from the trim assembly line is brought on the
overhanging conveyers and it is dropped on the frame. The cowl is then
tightened with the help of M12X50 and M12X55 bolt.
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DTV CONNECTION DTV (Dual Tube Valve) connections are made.

STATION 19:

STEERING SPINDLE FITMENT Steering spindle from the power
steering gear box is connected with the steering shaft attached in the cowl.


POWER STEERING PIPE CONNECTION AND CLAMPING
Power steering pipe kit (Pressure, Return and Suction) are clamped and
connected with the power steering oil container attached in the cowl
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.
AIR INTAKE PIPE AND HOSE FITMENT- Air intake pipe attached to
cowl is connected to the air intake of the engine unit with the help of the
reducer hose.


9 POLE CONNECTIONS These are the electrical connections.

STATION 20:

SPEEDO CABLE SEALING The speedometer sensor is sealed with the
sealing string.

WHEEL CHOKE FITMENT 2 Wheel chokes are fitted on the frame.

BUMPER SUB ASSY WITH THE HEAD LIGHT AND FITMENT
OF BUMPER Head lamp assy, Bumper cabbers are assembled with the
bumper and bumper is attached with the frame.
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STATION 21:

TOE PIN AND TOE PIN CHAIN FITMENT Toe pin and the pin
chain fitted.


AIR LEAKAGE Air leakage test is performed at all the possible leakage
joints.


STATION 22:

SPARE WHEEL CARRIER FITMENT Spare wheel carrier is fitted
on the frame.
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SPARE WHEEL FITMENT AND TIGHTENING Spare wheel is
fitted on the carrier and tightened.


STATION 23:

WHEEL FITMENT AND TIGHTENING Front and rear wheels are
fitted and tightened with the help of DC runner having torque of 80 m-kg.



STATION 24:

TYRE AND RIM NUMBER FEEDIN- Tyre and rim no. are feeded in
the system.


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STATION 25:

BATTERY BRACKET AND BATTERY FITMENT- Battery mounting
bracket is fitted on the frame on which two batteries are fitted which
provide electricity to the truck. These batteries are charged through
alternator fitted in the engine.


STATION 26:

CLUTCH OIL BLEEDING- Clutch oil is filled and is made to flow a
little so as to remove any air entrapped in the clutch oil pipe. The volume
of oil filled is 440 ml.
DIESEL FILLING- Diesel is filled in fuel tank for further test to be done
on the truck. The volume of diesel filled is 56 liters.

STATION 27:

POWER STEERING OIL FILLING- The oil is filled in the power
steering oil container which is used for power steering. The volume of oil
filled is 3.2 liters.
COOLANT FILLING- The coolant is filled in auxiliary tank fitted on
the intercooler. The volume of coolant filled is 24 liters. The water and
oil in coolant are in 50-50% ratio. The coolant is used to cool the engine
while its operation.


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STATION 28:

ENGINE STARTING
UNDERBODY
ACCELERATOR RPM SETTING

STATION 29:

INSPECTION
DATA FEEDING IN REGISTER
AIR PRESSURE BUILDUP CHECK





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PROJECT

Elimination of Maximum RPM Setting Process

Introduction to Project:
Before understanding the process of RPM setting and the problem faced due to
the setting process lets first understand the term RPM denotes. RPM is the
abbreviation used for the term Revolution per Minute. It tells you that how fast
the engine is moving in terms of revolutions in one minute. It's basically the
performance of the engine that you need to know when you rev it up by looking
at the odometer in the car's dashboard.
Basically for an IC Engine RPM can be of two types: Idle RPM and
Maximum RPM. Idle RPM is the rotational speed the engine runs on when the
engine is uncoupled to the drive train and the throttle pedal isn't pressed
(generally measured in revolutions per minute, or rpm, of the crankshaft) of a
combustion engine. At idle speed, the engine generates enough power to run
reasonably smoothly and operate its ancillaries (water pump ,alternator, and, if
equipped, other accessories such as power steering), but usually not enough to
perform useful work, such as moving an automobile. Whereas, the Maximum
RPM is set for the engine. If the speed of the engine is over the rated maximum
rpm then the performance of the engine detoriates. The various engine
parameters like specific fuel consumption, rated power and engine performance
are best when the engine speed is maintained within the range.
The project deals with the variation in the RPM observed at the time of starting
the engine for the first time a station 28 of TCF Line 2. According to the
company standards both the Idle as well as the maximum RPM must fall within
the standard range. The standard set by TATA Motors for the Idle and the
maximum RPM is:
For Idle RPM: 750100 RPM
For Maximum RPM: 275050 RPM
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Three major components of the entire Accelerator assembly are Fuel injection
pump (F.I.P), accelerator cable and accelerator pedal. The RPM of the engine
depend upon the amount of fuel delivered to the FIP through the valve. The
opening of the valve is controlled by the movement of the accelerator cable
which is in turn controlled by the accelerator pedal. In order to get the
maximum RPM the Accelerator pedal is pressed down to its full capacity,
which in turn pulls back the wire leading to the opening of the valve. Thus the
fuel is injected into the FIP. The control on the amount of the fuel entering the
FIP is done through the opening of the valve and hence the RPM of the Engine
is controlled. This is where the major problem starts. Almost all the vehicles
which are assembled on TCF Line 2 had their RPM out of the required range
which leads to the involvement of one more operator to adjust the RPM and
hence increasing the time taken at this station.
My objective was to eliminate this process of RPM setting and in order to
accomplish my task my first task was to understand the entire process of the
accelerator assembly. Shown below is the pictorial representation of the process
flow diagram of the entire accelerator assembly.













Grommet setting Accelerator pedal
and cable storage
Accelerator cable and
lock plate placement
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Ball joint connection Lock Pin Accelerator Paddle
setting
Hammering of clamps
Connection of accelerator cable to
the throttle valve
Clamping of cable at
the engine
Final assembly of accelerator cable at the
engine
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On observing it was found that number of probable causes were responsible for
this variation in the Maximum RPM. These causes were seen to be existing on
every station involve in the accelerator assembly. The probable causes can be
clearly represented by the Ishikawa Diagram or more commonly known as the
Fish Bone Diagram. Basically Fish Bone diagram shows the causes that occur
due to four major factors- Man, Method, Machine and Material.
After studying the probable cause responsible for RPM variation following Fish
Bone Diagram was prepared (on next page). :







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Causes found at Different Stations:


















At Trim Line (Station 12)







Storage
OBSERVATION:-
Slight deformation in the wires due to over hanging
of the surplus.
Wear and tear of the material and the threads due to
metal to metal contact causing deviation from the
required tolerances.
Surplus for the next 5-6 days already present.

ACTION PLAN:-
Proper tables, according to the length of the cable,
must be present for the storage in order to prevent
the unwanted deformation due to over hanging.
Unwanted metal to metal contact must be avoided
by maintaining a proper distance between the
cables. For example a different rack system must be
prepared to store the cables which is provided with
the cavity of the shape of the accelerator cable and
of the same dimension as specified in the drawing. In
this way al the cables which differ from the standard
drawing can be easily spotted.
Surplus must be reduced to 2-3 days.

OBSERVATIONS:-
Proper hammering was not done for
locking the lock plate with accelerator
cable which makes it necessary for the
lock plate to be adjusted at the time of
RPM setting.
Neither the alignment of the extension
arm of the accelerator pedal after
connecting it with the accelerator cable is
inspected, leading to the addition of this
step at the RPM setting station
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At Assembly Line 2(Station 18)

OBSERVATION:-
Excess tightening of nut at the clamp.

Required no. of threads to be left out
while tightening is 2, but due to human
error accuracy not achieved.

Generally no problem occurs in
Hammering of the clamps
holding the cable but sometimes
excessive hammering may cause
problem in the motion of the
internal wire.
ACTION PLAN:-
Hammering should be done in
order the lock plate into the
accelerator cable.
Proper hammering must be
carried out and it should be
made sure that clamps do not
press against the cable too
tightly.
Made sure that alignment of the
extension arm of the pedal is
done at the trim line itself.
ACTION TAKEN:-
Proper routing ensured as well
as proper placement of the cable
on the clamps also ensured.
IMPACT:-
No impact on the rpm, problem
of rpm setting still exist.
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Most of the threads not being used.

No proper reasons behind leaving 2
threads on the left side while the nut
tightening.

Positioning of the clamp on the engine is
not in accordance to the threaded
portion of the cable, due to which major
portion of the threaded region is not
being utilized.
According to some technicians the
threads are not of similar dimensions,
causing both side variations in the rpm.
No set pattern for setting the RPM is
achieved due to the variation in the
tolerances of different parts used in the
accelerator assembly.
Length of the cable may also be
considered as one of the factor. As every
cable is of different length, hence it can
play a major role in the altering the rpm
ACTION PLAN:-
Generally human err is unavoidable
required numbers of threads to be left
out must be made minimum (zero in this
case). In this way error of miscounting
the threads can be avoided.
The division of threads must be made in
such a way that while placing the wire
on the clamp, the threaded portion is
seated at its middle point.
The placement of the clamp should be in
such a way that most of the threads are
utilized, for example in the middle of the
threaded portion.


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Dimensioning of the Accelerator cable



ACTION TAKEN:-
No. of the threads to be left out while placing the cable on the clamp changed to Zero.
IMPACT:-
9 out of the 25 trucks with this adjustment found OK
OBSERVATION:-
Large variation in the length of the accelerator cable, even outside the tolerance limit.
One of the main factors responsible for the variation in the maximum RPM
.
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ACTION PLAN:-
Dimension of the wire must be in accordance with the drawing.
Variation in the wire must be checked at the suppliers end as well as in the storage
unit before fitting it in the Cowl
ACTION TAKEN:-
Improvement suggested to VQA Department.
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Suggested Improvements:

Improvements for the Storage Area










Improvements in the Accelerator Pedal


Before After
Proper tables, according to the
length of the cable, must be
designed for the storage in order to
prevent the unwanted deformation
due to over hanging.
Unwanted metal to metal contact
must be avoided by maintaining a
proper distance between the
cables. For example a different rack
system must be prepared to store
the cables which is provided with
the cavity of the shape of the
accelerator cable and of the same
dimension as specified in the
drawing. In this way all the cables
which differ from the standard
drawing can be easily spotted.
Before
A stopper must be provided to avoid
the unwanted downward movement of
the pedal.

The stopper must be placed at the
position depicted in the figure.

Proper placement of the stopper and
the height of the stopper is decided by
the angular displacement of the pedals
extension arm from the reference

After
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Improvements for the Routing of the Wire




Improvements in the Placement of Lock Nut






After Before
Initially excessive hammering was being
done on the clamps after placing the
wires.
This excessive hammering caused
problem in the motion of the internal
wire.

Before After
Required no. of threads to be left out
while tightening is 2, but due to human
error accuracy not achieved.
Generally this kind of err is unavoidable,
required numbers of threads to be left
out must be made minimum (zero in
this case). In this way error of
miscounting the threads can be
avoided.
Improvements in the final RPM were
observed after making this adjustment
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Improvements in the length of the Accelerator Cable














Improvements on the Instrument Cluster


Before After
Large variation in the length of the
accelerator cable, even outside the
tolerance limit.
This variation in length leads to the
variation in the final maximum RPM
observed at the time of RPM setting.
No instrument for verifying the length of
the accelerator cable.
Length must be in accordance with the
drawing in order to minimize the
variation in the RPM, hence reducing
the maximum RPM setting process.
The instrument shown below was
designed for the verifying the length of
the cables before putting it to use.
Before After
The instrument cluster and the sensors
giving the reading of the RPM must be
properly calibrated.
In order to achieve accuracy, the RPM
meter must be made digital.
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CONCLUSION

The purpose of this training was to give me the feel that the real industry is and
I feel that getting training in esteemed organization like TATA Motors is a
thing to be proud of. The most important thing that I have learnt in TATA
Motors is the power of WE. I have learnt great deal of team work here and the
sense of working as a team has enhanced my capabilities by huge amount.
On the whole, it has not given me an exposure to these
techniques but also has added a new dimension in my vision of knowledge. I
will always be grateful to TATA Motors, which has shown that how miracles
can be done by converting I into WE.

Apart from the allotted project I was able to work in an industrial environment,
which has provided a lot of value addition to me. Working with people in the
organization taught me a lot of managerial as well as personnel skill lessons
that definitely indispensable for my future carrier.


I observed and studied the various machining processes in the factory
and the work processes in the assembly line.
Working with different software helped me to enrich my computer skills
I observed various management and business protocols followed in
company and in its various
departments.

My experience in TATA motors has been really enriching and has provided me
a stepping stone for a prospective bright future in the industrial Sector.