SIX MONTHS

INDUSTRIAL TRAINING REPORT

AT

TATA MOTORS LIMITED

PANT NAGAR, UTTARAKHAND
Submitted in Partial Fulfilment for award of Degree of
Bachelor of Technology
In
Mechanical Engineering
From

Punjab Technical University, Jalandhar

Submitted By
GURMINDER SINGH
90491175388

Department of Mechanical Engineering

Ludhiana College of Engineering and Technology
Katani Kalan, Ludhiana.
JAN TO JUNE, 2012

Acknowledgment
I have taken efforts in this project. However, it would not have been
possible without the kind support and help of many individuals and
organizations. I would like to extend my sincere thanks to all of them.
I am highly indebted to my mentor, operators and other departments
for their guidance and constant supervision as well as for providing
necessary information regarding the project & also for their support in
completing the project.
I would like to express my gratitude towards my parents, Mr. S.S.
Wagh (Divisional manager), Mr. Ved prakash Yadav (Sr. Manager,
Engine), Mr. Manoj Vasistha (Manager, VQA) for their kind cooperation and encouragement which help me in completion of this
project. A big contribution and hard worked from both of you during
the eight week is very great indeed. The supervision and support that
he gave truly help the progression and smoothness of the internship
program. The co-operation is much indeed appreciated.
My thanks and appreciations also go to my colleague in developing
the project and people who have willingly helped me out with their
abilities. All projects during the program would be nothing without
the enthusiasm and imagination from department seniors. Not forget,
great appreciation go to the rest of staff that help me from time to time
during the project. The whole program really brought us together to
appreciate the true value of friendship and respect of each other.
1

DECLARATION
I hereby certify that the work which is being presented in this project report entitled Six months Training
report in the partial fulfilment of requirements for the award of degree of B-Tech Mechanical engineering
submitted in the department of Mechanical Engineering at LUDHIANA COLLEGE OF
ENGINEERING AND TECHNOLOGY under Punjab Technical University, Jalandhar is an authentic
record of my own work carried out during a period of Jan 2012- June 2012 under supervision of Mr.
MANOJ VASISTHA.The matter presented in this report has been submitted by us in any other
university/institute for the award of degree of B-Tech.

GURMINDER SINGH
90491175388 (M.E)
Certified that the above statement made by the student is correct to best of our knowledge and
brief

Mr. Manoj Vasistha

(Manager, Machine Shop)

Mr. S.S. Wagh

(Divisional Manager,
Engine & Gearbox)

Mr. Ved Prakash Yadav

(Manager, Engine shop)

CERTIFICATE
This is to certify that this is a bonafide record of Project Report entitled
IMPROVEMENT OF LEAKAGE IN THE ENGINE COMPONENTS
Carried out by
GURMINDER SINGH
Final Year B.E. (MECHANICAL ENGG.)
LUDHIANA COLLEGE OF ENGG. AND TECHNOLOGY,
PUNJAB.
Under the guidance of
Mr. MANOJ VASISTHA

Abstract
3

During my Project Trainee at Engine Shop, Power Train I have been

assigned three projects which are:
LOP (low oil pressure) improvement
EGR (exhaust gas recirculation)
Prepare manual for PCN machine
Replace some fixtures and machine parts.
The aims of the project are as follows:
To reduce the LOP problem in 475 engine from 5% to 1%.
To reduce the EGR leakage problem in 475 engine.
To make a working procedure for PCN machine.
They are a number of requirements for each project need to follow.
The requirement needed as:
Previous Data
Help from operators
Present Condition
Target to be attained
Guidance from Seniors

COMPANY PROFILE
4

INTRODUCTION TO TATA MOTORS

1.1 COMPANY

MR.JRD TATA

MR. RATAN TATA

Established in 1945, TATA MOTORS LTD. is India's largest automobile company,

with revenues of Rs. 32,426 cores (USD 7.2 billio5n) in 2006-07. It is the leader by far in
commercial vehicles in each segment, and the second largest in the passenger vehicles market
with winning products in the compact, midsize car and utility vehicle segments. The company
is the world's fifth largest medium and heavy commercial vehicle manufacturer, and the
world's second largest medium and heavy bus manufacturer.

RESEARCH AND DEVELOPMENT

The foundation of the companys growth is a deep understanding of economic
stimuli and customer needs, and the ability to translate them into customer-desired offerings
through leading edge R&D. TATA MOTORS LTD. invests approx. up to 2% of its annual
turnover on R&D The R&D establishment includes a team of 1400 scientists and engineers.
The company's Engineering Research Centre was established in 1966, and has facilities in
Pune, Jamshedpur and Lucknow. It was Tata Motors, which developed the first indigenously
developed Light Commercial Vehicle, India's first Sports Utility Vehicle and, in 1998, the
Tata Indica, India's first fully indigenous passenger car. Within two years of launch, it became
India's largest selling car in its segment. The ERC in Pune, among whose facilities are India's
only certified crash-test facility and hemi-anechoic chamber for testing of noise and
vibration, has received several awards from the Government of India. Some of the more
prominent amongst them are the National Award for R&D Efforts in Industry in the
Mechanical engineering Industries sector in 1999, the National Award for Successful
Commercialization of Indigenous Technology by an Industrial Concern in 2000, and the
CSIR Diamond Jubilee Technology Award in 2004.

1.3 AREAS OF BUSINESS

Tata Motors' presence indeed cuts across the length and breadth of India. Over 4
million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The
company's manufacturing base is spread across India -Jamshedpur (Jharkhand) in
the east, Pune (Maharashtra) in the west, and in the north in Lucknow (Uttar
Pradesh), Dharwad in Karnataka and Pantnagar (UK). A new plant is being set up in
Sanand (Gujrat) to manufacture the company's small car. The nation-wide
dealership, sales, services and spare parts network comprises over 2,000 touch
points.

MILESTONES
6

1945

1945 Establishment of Tata Engineering and Locomotive Co. Ltd. to manufacture

1948
1954

locomotives and other engineering products.

1948 Introduced steam road roller in collaboration with Marshall Sons (UK).
1954 JV with Daimler Benz AG (West Germany) to manufacture medium

1959
1961
1966

commercial vehicles. Within 6 months, the first vehicle rolled out.

1959 Research and Development Centre set up at Jamshedpur.
1961 In exports, the first truck shipped to Ceylon (now Sri Lanka).
Setting up Engineering Research Centre at Pune to give impetus to the

1971
1977
1983
1985
1986

automobile Research and Development.

1971 Introduction of DI engines.
1977 The first commercial vehicle manufactured in Pune.
1983 Commencement of manufacturing Heavy Commercial Vehicle.
1985 First hydraulic excavator produced with Hitachi collaboration.
1986 The first light Commercial Vehicle produced, Tata 407, indigenously

1989
1991

designed, and followed by Tata 608.

1989 Tata mobile 206 - 3rd LCV model introduced.
1991 Tata Sierra launched, TAC 20 crane produced and one millionth vehicle

1992
1993

rolled out.
1992 Tata Estate launched.
1993 JV with Cummins Engine Co. Inc. for manufacturing of high horsepower

1994

and emission friendly diesel engines.

1994 Tata Sumo and LPT 709 launched. JV with M/s Daimler-Benz/ Mercedes-

1995
1997
1998
2000

Benz and Tata Holset Ltd., UK.

1995 Launched Mercedes Benz car E220.
100,000th Tata Sumo rolled out.
Tata Safari and Indica launched. 2 millionth vehicles rolled out.
First consignment of 160 Indicas shipped to Malta. Launch of Indica with Euro II

2001

engine, CNG buses and 1109 vehicle - Intermediate commercial vehicle.

100,000th Indica wheeled out. Launch of CNG Indica. Exits JV with Daimler

2002

Chrysler.
2,00,000th Indica and 5,00,000th passenger vehicle rolled out. Tata Engineering

2003

signed product agreement with MG Rover of the UK.

Tata Engineering becomes Tata Motors Limited. 3 millionth vehicle produced.

2004

First City Rover rolled out.

Tata Motors and Daewoo Commercial Vehicle Co. Ltd. signed investment
agreement and Tata Daewoo Commercial Vehicle Co. Ltd. (TDCV) launched

2005

NOVAS, the heavy duty truck in Korea. Listed on NYSE.

Tata Motors rolls out the 500,000th Passenger Car from its Car Plant Facility in
Pune
The Tata Xover unveiled at the 75th Geneva Motor Show
7

Branded buses and coaches - Starbus and Globus - launched

Tata Motors acquires 21% stake in Hispano Carrocera SA, Spanish bus manu co.
Tata Ace, India's first mini truck launched
Tata Motors wins JRD QV award for business excellence.
The power packed Safari Dicor is launched
Introduction of Indigo SX series - luxury variant of Tata Indigo
Tata Motors launches Indica V2 Turbo Diesel.
One millionth passenger car produced and sold
Inauguration of new factory at Jamshedpur for Novus
Tata TL 4X4, India's first Sports Utility Truck (SUT) is launched
Launch of Tata Novus
Launch of Novus range of medium trucks in Korea, by Tata Daewoo Commercial
2006

Vehicle Co. (TDCV)

Tata Motors vehicle sales in India cross four million mark
Tata Motors unveils new long wheel base premium Indigo & X-over concept at
Auto Expo 2006
Indica V2 Xeta launched
Passenger Vehicle sales in India cross one-million mark
Tata Motors and Marcopolo, Brazil, announce joint venture to manufacture fully
built buses & coaches for India & markets abroad
Tata Motors first plant for small car to come up in West Bengal
Tata Motors extends CNG options on its hatchback and estate range
TDCV develops South Korea's first LNG-Powered Tractor- Trailer
Tata Motors and Fiat Group announce three additional cooperation agreements
Tata Motors introduces a new Indigo range

2007

Construction of Small Car plant at Singur, West Bengal, begins on January 21

New 2007 Indica V2 range is launched
Tata Motors launches the longwheel base Indigo XL, India's first stretch
limousine
Common rail diesel (DICOR) engine extended to Indigo sedan and estate range
Tata Motors and Thonburi Automotive Assembly Plant Co. (Thonburi), announce
formation of a joint venture company in Thailand to manufacture, assemble and
market pickup trucks.
Roll out of 100,000th Ace
Tata-Fiat plant at Ranjangaon inaugurated
Launch of a new Upgraded range of its entry level utility vehicle offering, the
Tata Spacio.
CRM-DMS initiative crosses the 1000th location milestone
Launch of Magic, a comfortable, safe, four-wheeler public transportation mode,
developed on the Ace platform
Launch of Winger, Indias only maxi-van
Fiat Group and Tata Motors announce establishment of Joint Venture in India
Launch of the Sumo Victa Turbo DI, the new upgraded range of its entry-level
utility vehicle, the Sumo Spacio
Tata Motors launches Indica V2 Turbo with dual airbags

COMPANY PROFILE
Tata

Motors

Limited

is

India's

largest

automobile

company,

with

consolidated revenues of Rs. 92,519 crores (USD 20 billion) in 2009-10. It

is the leader in commercial vehicles in each segment, and among the top
three in passenger vehicles with winning products in the compact, midsize
car and utility vehicle segments. The Company is the world's fourth
largest

truck

manufacturer,

and

the

world's

third

largest

bus

manufacturer.
Established in 1945, Tata Motors' presence indeed cuts across the length and breadth of India.
Over 5.9 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The
Company's manufacturing base in India is spread across Jamshedpur (Jharkhand), Pune
(Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and
9

Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set up an
industrial joint venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce
both Fiat and Tata cars and Fiat powertrains. The Company's dealership, sales, services and
spare parts network comprises over 3500 touch points; Tata Motors also distributes and
markets Fiat branded cars in India.
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. Through subsidiaries and associate companies, Tata Motors has operations in the
UK, South Korea, Thailand and Spain. Among them is Jaguar Land Rover, a business
comprising the two iconic British brands that was acquired in 2008. In 2004, it acquired the
Daewoo Commercial Vehicles Company, South Korea's second largest truck maker. In 2005,
Tata Motors acquired a 21% stake in Hispano Carrocera, a reputed Spanish bus and coach
manufacturer, and subsequently the remaining stake in 2009. Hispano's presence is being
expanded in other markets. In 2006, Tata Motors 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 entered
into joint venture with Thonburi Automotive Assembly Plant Company of Thailand to
manufacture and market the Company's pickup vehicles in Thailand. The new plant of Tata
Motors (Thailand)

10

has begun production of the Xenon pickup truck, with the Xenon having been launched in
Thailand in 2008.
In January 2008, Tata Motors unveiled its People's Car, the Tata Nano, which India and the
world have been looking forward to. The Tata Nano has been subsequently launched, as
planned, in India in March 2009.
In May 2009, Tata Motors introduced ushered in a new era in the Indian automobile industry,
in keeping with its pioneering tradition, by unveiling its new range of world standard trucks
called Prima. In their power, speed, carrying capacity, operating economy and trims, they will
introduce new benchmarks in India and match the best in the world in performance at a lower
life-cycle cost.
Tata Motors is equally focused on environment-friendly technologies in emissions and
alternative fuels. It has developed electric and hybrid vehicles both for personal and public
transportation. It has also been implementing several environment-friendly technologies in
manufacturing processes, significantly enhancing resource conservation.
Tata Motors is committed to improving the quality of life of communities by working on four
thrust areas employability, education, health and environment. The activities touch the lives
of more than a million citizens. The Company's support on education and employability is
focused on youth and women. They range from schools to technical education institutes to
actual facilitation of income generation. In health, our intervention is in both preventive and
curative healthcare. 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 our vehicles and operations for constantly enhancing environment
care.
With the foundation of its rich heritage, Tata Motors today is etching a refulgent future.

CORPORATE VISION & MISSION STATEMENT

0

VISION
To be best in the manner in which we operate, best in the products we deliver and best in our
value system and ethics.
MISSION
To become a world class automotive engineering and product development center, and enable
Tata Motors to become a world class automotive company.
BUSINESS UNIT WISE VISION & MISSION STATEMENTS
Tata Motors has two business units viz.
1. Commercial Vehicle Business Unit (CVBU)
2. Passenger Vehicle Business Unit (PVBU)

COMMERCIAL VEHICLE BUSINESS UNIT

VISION
To be a world class corporate constantly furthering the interest of all its stakeholders.
MISSION
Shareholders:

To constantly create shareholder value by generating returns in excess

of Weighted Average Cost of Capital (WACC) during the upturn and at
least equal to Weighted Average Cost of Capital during the downturn
of business cycle.

Customers:

To strengthen the Tata brand and create lasting relationships with the
customers by working closely with business partners to provide
superior value for money over the life cycle. Employees:

To create a

zseamless organization that inculcates and promotes innovation,

excellence and Tata core values.
Vendor & Channel Partners:

To foster a long term relationship so as to introduce a

broad range of innovative product and services, that would benefit our
customers and other stakeholders.
Community:

To proactively participate in reshaping the countrys economic growth

and to take a holistic approach towards environmental protection.

CORE VALUES

Integrity
1

Customer Focus
Corporate Citizenship
Passion for Engineering

Purpose:

To create economic assets for road transportation for bulk movement of goods
and people and participate in managing these over the life of assets in order to
create and capture economic value.

PASSENGER VEHICLE BUSINESS UNIT

VISION
To develop TATA into a world class Indian car brand for innovative and superior value
vehicles.
MISSION

To be the most admired multi-national car company producing vehicles that people

love to buy.
To create an organization that people enjoy working for, doing business with and
investing in.

KEY MANAGEMENT PERSONNEL

Mr. Ratan Tata

- Chairman

Mr. Carl-Peter Forster - Managing Director & Group CEO

Mr. P. M. Telang

- Managing Director - India Operations

Mr. C. Ramakrishnan - Chief Financial Officer

Mr. Ravi Pisharody

- President (CVBU)

Dr. Tim Leverton

- Head (Advanced and Product Engineering)

Mr. S. B. Borwankar

- Senior Vice President (Mfg Operations-CVBU)

Mr. Prabir Jha

- Senior Vice President (Human Resources)

Mr. R. Ramakrishnan - Vice - President (Commercial - PCBU)

Mr. Girish Wagh

- Head (Passenger Car Operations - PCBU)

Mr. R. T. Wasan

- Head (International Business - CVBU)

Mr. Johnny Oommen

- Head (International Business - PCBU)

2

Mr. H. K. Sethna

- Company Secretary

ORGANIZATIONAL CHART TATA MOTOR

Pantnagar Plant
Atul Renavikar

Director
Ralf Speth

Communications
Debasis Ray

Director
V K Jairath

Passenger Cars
R Ramakrishnan

Engineering Systems,
ERC
S Ravishankar

Director
Ranendra Sen

Head, Corporate Planning

N.S. Kulkarni

Jamshedpur Plant
P K Chobe

Chairman of the Board

Ratan Tata

Strategic Sourcing
B B Parekh

Manufacturing CVBU
Satish Borwankar

Vice Chairman of the

Board
Ravi Kant

Advanced & Product

Engineeri...
T Leverton

Manufacturing
Operations, CVBU
Shrikrishna Ambardekar

Director

Commercial Vehicles

ADD & Materials, CVBU

Raghunath Mashelkar

Ravi Pisharody

Uday Mishra

CEO

CFO

Finance Business
Planning

Carl-Peter Forster

C. Ramakrishnan

Abhijit Gajendragadkar
3

Director
Nasser Munjee

India Operations
P. Telang

CIO
Jagdish Belwal

Director
Subodh Bhargava

Secretary
H. Sethna

Internal Audit
N Pinge

Director
Jamshed Irani

Human Resources
Prabir Jha

Finance Accounts & Tax

Prakash Gurav

Director
N. Wadia

Legal
R. Bagga

Latin America Operations

S. Krishnan

Director
Sam Palia

Small Car
Girish Wagh

Car Plant, Passenger Car

Vikram Sinha

GOVERNANCE STRUCTURE AT TATA MOTORS

Tata Motors philosophy on Corporate Governance is founded upon a rich legacy of fair,
ethical and transparent governance practices. The Governance Structure and reporting
relationships among our Governance board, board Committees, senior leaders and
organization is as shown:

The Board of Directors along with its Committees provides leadership and guidance to the
Companys management and directs, supervises and controls the performance of the
Company. Tata Motors has various committees as shown above and also Management
Committee, Operations Committees and BU level Steering Committees to manage the
business and report the board on regular basis.

INDUSTRIAL PROFILE
Tata Motors owes its leading position in the Indian automobile industry to its strong focus on
indigenization. This focus has driven the Company to set up world-class manufacturing units
5

with state-of-the-art technology. Every stage of product evolution-design, development,

manufacturing, assembly and quality control, is carried out meticulously. Our manufacturing
plants are situated at Jamshedpur in the East, Pune and Sanand in the West and Lucknow and
Pantnagar in the North.
Jamshedpur Unit
Established in 1945, the Jamshedpur unit was the Company's first unit and is spread over an
area of 822 acres. It consists of four major divisions - Truck Factory, Engine Factory, Cab &
Cowl Factories. The divestments in March 2000 hived off the Axle and Engine plants into
independent subsidiaries viz. HVAL & HVTL, respectively. The Truck Division boasts of two
assembly lines. The main assembly line, measuring 180 m in length has 20 work stations with
a vehicle rolling out every 8 minutes. The other line is dedicated to special purpose vehicles
and for meeting the requirements of the Indian Army. The uniqueness of the Factory lies in its
possession of

Advanced facilities for manufacturing long members comprising of a set-up of 5000

Tones Hydraulic press line, cut-to-length line for strip preparation purchased from
M/s Kohler of Germany and a Camber Correction line.

Facility for hot forming of axle halves with a 3000 tone press and heating furnace.

Flexibility in manufacturing frames with an off line Proto-typing facility.

Pune Unit
The Pune unit is spread over two geographical regions- Pimpri (800 acres) and Chinchwad
(130 acres). It was established in 1966 and has a Production Engineering Division, which has
one of the most versatile tool making facilities in the Indian sub-continent. It houses a Vehicle
manufacturing complex which is one of the most integrated automotive manufacturing
centers in the Country producing a large variety of individual items and aggregates. It is
engaged in the design and manufacture of sophisticated press tools, jigs, fixtures, gauges,
metal pattern and special tools, as well as models for the development of new ranges of
automobile products. Its capabilities have enabled Tata Motors to
introduce new products and improve existing ones without resorting to
imports of dies or fixtures.
Lucknow Unit

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.
The plant, rolls out commercial vehicles and is specialized in the designing and
manufacturing of a range of modern buses
Sanand Unit
Built in record time of 14 months starting November 2008, Tata Motors plant for the Tata
Nano at Sanand, in Ahmedabad district of Gujarat, marks the culmination of the Companys
goal of making the Tata Nano available to hundreds of thousands of families, desirous of the
car a safe, affordable and environmental friendly mode of transport. The capacity of the plant,
to begin with, will be 250,000 cars per year to be achieved in phases, and with some
balancing is expandable up to 350,000 cars per year. Provision for further capacity expansion
has also been incorporated in this location.
Pantnagar Unit
The Company has set up a plant for its mini-truck Ace and the passenger carrier Magic (based
on the Ace platform) at Pantnagar in Uttarakhand. The plant began commercial production in
August 2007. This is the company's fourth plant, after Jamshedpur (commercial vehicles),
Pune (commercial vehicles and passenger vehicles) and Lucknow (commercial vehicles). The
plant is spread over 953 acres, of which 337 acres is occupied by the vendor park.
State-of-the-art facilities include weld shops, paint shops, engine and gear box shops and
assembly lines. The Company has invested over Rs.1000 crores in the plant. Vendors for the
vehicle have made additional investments to set up their plants in the vendor park adjoining
the plant. The operation has generated about 7500 direct and indirect jobs in the plant, among
vendors and service providers in the area.

PRODUCT PROFILE
This report consist the TM products that are launched in India. The two broad classifications
are:
7

1. Passenger Vehicles
2. Commercial Vehicles

PASSENGER VEHICLES CLASSIFICATION

1. Hatchbacks
Hatchbacks may be described as three-door (two entry doors and the hatch) or fivedoor (four entry doors and the hatch) carsand may range in size from city
cars and super minis to small family cars, mid-size cars
2. Sedans
A sedan seats four or more and has a fixed roof that is full-height up to the rear
window. Most commonly it is a four-door; two-door is rarer but they do occur (more
so historically).
3. Pickups
A small truck with an enclosed cab and open back.
4. Crossovers
A crossover is a vehicle built on a car platform and combining, in highly variable
degrees, features of a sport utility vehicle (SUV) with features from a passenger
vehicle
5. Utility Vehicles
Can be sports utility vehicle (SUV) or multi utility vehicle (MUV)

PASSENGERVEHICLE

COMMERCIAL VEHICLES

10

ABOUT THE PLANT

The company has set up a plant for its mini-truck Ace and the passenger carrier Magic (based
on the Ace platform) at Pantnagar in Uttarakhand. The plant began commercial production in
11

August 2007. This is the company's fourth plant, after Jamshedpur (commercial vehicles),
Pune (commercial vehicles and passenger vehicles) and Lucknow (commercial vehicles). The
plant is spread over 953 acres, of which 337 acres is occupied by the vendor park. This is the
first plant in India that has a vendor park attached to the main plant.
State-of-the-art facilities include weld shops, paint shops, engine and gear box shops and
assembly lines. The company has invested over Rs.1000 crores in the plant. Vendors for the
vehicle have made additional investments to set up their plants in the vendor park adjoining
the plant. The operation has generated about 7500 direct and indirect jobs in the plant, among
vendors and service providers in the area.
The various shops in the plant are as follows:

ASSEMBLY SHOP Also known as TCF Shop (TRIM CHASSIS FITTING). In this

shop, vehicle assembly operations take place and the vehicle is rolled out after the inspection
of the vehicle in the PDI section. There are presently 4 assembly shops TCF 1A, TCF 1B,
TCF 1C AND TCF 1D.

WELD SHOP Also known as BIW Shop (BODY IN WHITE).Here the sheet metal

moulded parts are welded together to make the chassis and the whole structure of the car is
built. The weld shop is divided into 5 sections namely, BIW 1A, 1B, 1C, 1D, 1E

POWER TRAIN SHOP This shop is divided into Gear Train and Engine shop.

This shop takes care of the assembly of the engine and the assembly of the gear box. The
engine and the gear box are assembled separately but are coupled at the end of the line.
Various testing related to engine performance and quality are checked here.

PAINT SHOP - The TAIKISHA shop is the paint shop of the car plant. This is the

most sophisticated shop of the plant. It uses world class technology for painting the vehicles.
The most interesting point of this shop is that all vehicles, no matter which type, are all
painted under the same shop together. Thus the paint shop has to work 4 times faster than the
TCF, so that body reaches each of the assembly shops.

12

All the shops are interconnected with the help of conveyors that run overhead. These
conveyors are used to transport the vehicle from one shop to another in sequence of
operation.

VARIOUS PRODUCTS MADE AT THE PANTNAGAR PLANT:

TCF-1A:

TATA ACE-EX

TATA ACE MAGIC

TCF-1B:

TATA ACE-GT

TATA SUMO GRANDE

TCF-1C:

TATA VENTURE

SUPER ACE

TCF-1D:

MAGIC IRIS

ACE ZIP

PLANT LAYOUT:

13

KITCHEN

PANTNAGAR PLANT [UK]`

The company has set up a plant for its mini-truck Ace and the passenger carrier Magic (based
on the Ace platform) at Pantnagar in Uttarakhand. The plant began commercial production in
August 2007. This is the company's fourth plant, after Jamshedpur (commercial vehicles),
Pune (commercial vehicles and passenger vehicles) and Lucknow (commercial vehicles). The
plant is spread over 953 acres, of which 337 acres is occupied by the vendor parts.

State-of-the-art facilities include weld shops, paint shops, engine and gear box shops
and assembly lines. The company has invested over Rs.1250 cores in the plant. Vendors for
the vehicle have made additional investments to set up their plants in the vendor park
14

adjoining the plant. The operation has generated about 7500 direct and indirect jobs in the
plant, among vendors and service providers in the area. It is also acting as a backup plant for
NANO. As the problem arise there in Singur it was decided to start production of NANO
from this plant in the meantime a full fledged plant is being constructed for nano at Sanand,
Gujarat .So, this plant is getting the opportunity to deliver peoples car to the people.

VARIOUS DEPARTMENTS AT THE PLANT:

1) Auto Projects
2) Finance
3) HR
4) Maintenance
5) Production
6) Material
7) CPED
8) Quality
9) APPC

Testing of engine
Purpose: To test the engines.
15

Responsibility: Manufacturing.
Procedure:
1) Shift the engine to test bed.
2) Clamp the engine test trolley with the test cell.
3) Fill the water in cooling system.
4) Connect the throttle wire in the engine.
5) Wait for the signal of bench ready.
6) Start the engine.
7) Select the auto cycle for the running test.
8) Save the engine no. in the desktop.
9) Take the reading of the running in test.
10) Check the engine for any abnormality i.e. abnormal noise, oil leakage,
diesel leakages, and water leakages.
11) After running in test, set the fly up speed of the engine to the tested.
12) Start the performance test of the engine i.e. record the performance
at 4500 and 2500 rpm.
13) Record and observe the engine power, fuel delivery, torque, smoke
value, oil pressure, water temp.
14) As per table of BS 2, BS3, BS4 compare the engine performance.
15) If parameters of the engine as per standard, declare engine to o.k.
parameters are not as per standard than reject the engine.
16) After performance set the idling speed of the ok engine. Then stop the
engine from the operator panel.

16

17) Drain the water from the engine and remove the trolley from the test
cell.
18) Unclamp the engine and remove the trolley from the test cell.
19) Record the engine testing status in register.

Safety instructions

Use knitted gloves.

Keep the floor oil free.

Use apron and desired ppe.

Problems

Engine rejected due to electronics problems i.e. sensors.

Less power engine rejected.

17

Engine performance testing

Ensure alignment of test bed trolley with dynamometer properly.

Ensure air filter clean before testing.

Ensure no pinches of hoses during testing.

Ensure no oil from intercooler.

Ensure no exhaust/inlet leakage during engine testing.

Ensure no oil on engine before testing.

ENGINE TESTING IN TEST BED

18

In
475 BS/BS

19

Objective:

To eliminate lop problem in 475 BS/BS

Present Condition:
9 Engines per day

Targets:
Reduce the rework time
Increase the production rate
Eliminate the lop problem

Duration:
1 April 2012 to Present

Faculty Coordinator
Mr. Ved Prakash Yadav(Sr. Manager ,Engine Shop)

Team Members
Gurminder Singh (Trainee)

20

Methodology Adopted:
Collect data.
Detail Study of the problem.
Analysis
Action
Check

Standardization
Recollection of data
Benefits to company
Lessons learnt from the project

21

Low oil pressure in engine

LOP defines as a low oil pressure in the engine. It effects the brake horse power of the engine
and decreases the engine cooling rate. Due to lop mainly damaged the engine oil filter, gear
oil pump, piston cooling nozzle, strainer, oil pressure switch, intercooler.

Low oil pressure

22

Affects of Blow by:

Loss of power

Pcn damage

Filter and pump damage

Engine Performance

Loss of fuel economy

Engine Damage

Piston rings damage

Child parts damage

Low Engine Oil Pressure Problem

Insufficient oil pressure is serious, since the oiling system must be properly pressurized to
keep the moving parts of the engine lubricated to prevent excessive wear. Most vehicles use a
visual indicator, which may be a light or gauge, mounted in the instrument panel to alert the
driver of low engine oil pressure.
The oil pressure indicator is connected with a pressure switch. The pressure switch sends a
signal when the oil pressure is below 5 PSI (3.5 kPa). This pressure is established by the
engine manufacturer based upon individual engine characteristics and requirements.
When the engine is not running and the ignition switch is turned on, the warning light
illuminates. If the vehicle is equipped with a gauge there will be no indication of pressure.
When the engine is started, oil pressure will compress the diaphragm in the pressure switch,

23

opening the contacts and cause the light to go out or, in the case of a gauge, a positive
pressure reading will be indicated.
If the warning light remains on, or the gauge fails to register a normal pressure several
seconds after start up, shut the engine off immediately. Check the oil level and fill as
necessary. If the warning light remains on or the gauge fails to register normally when the oil
level is correct, there are a number of possibilities that may be the cause of the problem:
1. The oil pressure switch could be faulty.
2. The wiring between the oil pressure switch and warning indicator could be
Grounded or disconnected.
3. The oil pump may have lost its prime.
4. The oil pump intake screen could be clogged.
5. The oil pump pressure regulating valve could be stuck in the open position.
If the warning light does not illuminate with the ignition switch in the on/run position, and
the engine is not running, then the bulb, pressure switch, and wiring should be checked and
repaired as necessary.
On some engines the filter is mounted in a position which could allow the oil in the filter to
drain back to the crankcase when the engine is shut down. This would be the case for the
filter shown in Figure 2 where the filter is horizontal and is above the level of the oil in the
crankcase. Normally, it takes less than five (5) seconds for the pump to fill the filter after the
engine has been started, during which time the warning device will indicate no or low oil
pressure.
Filters designed for these mounting positions contain an anti-drain back valve to prevent the
engine from operating without oil pressure for the period of time after start up. This valve is
usually in the form of a rubber gasket, which is visible through the inlet holes of the filter,
and allows the flow of oil through the filter in the correct direction. When the engine is shut
down, the anti-drain back valve prevents the oil in the filter from draining back to the
crankcase.
Under some conditions the warning light may fluctuate when the engine is running. This
usually happens when the vehicle is going around a corner or is on a relatively steep hill. If
24

oil pressure fluctuation occurs under these conditions, it is because the oil level is low and the
oil pump strainer is no longer fully submerged in the oil. The oil level should be immediately
filled to the proper level.
In summary, the oil pressure warning device provides vital information to the driver. If there
is an indication of low or no oil pressure when the engine is running, it should be shut off
immediately and the cause investigated.
OIL PRESSURE CHANGES
Users of diesel engine oils often note a change in oil pressure when they change from
monograde oil to a multigrade. Typically, oil pressure is lower with a multigrade, and the
uninitiated user can interpret the pressure drop as indicating a problem with the engine.
However, low oil pressure is not necessarily bad. In fact, it can be beneficial to a diesel
engine operating within normal limits. By the same token, high oil pressure is not
necessarily good. It can be caused by blocked oil galleries or a too viscous lubricant.
The following guidelines will help you decide whether the oil pressure readings you are
getting are reason for concern.
Oil pressure is caused by the oil's resistance to flow. Therefore, wide oil galleries and
low oil viscosity permit oil to flow freely. The results would be low oil pressure and
more reliable lubrication. Conversely, narrow oil galleries (either by design or blockage)
and high oil viscosity causes lower oil flow. While oil pressure would be high,
lubrication would not be as efficient. good" oil, therefore, has viscosity characteristics
sufficient to provide good hydrodynamic lubrication and also flows freely around the
engine to maintain a continuous supply of lubricant.
Under ideal conditions, oil pressure should be stable, and any large increase or decrease
should be investigated. The tables outline possible mechanical causes of low and high
oil pressure, and the corrective action that should be taken.
Cold start is one operating condition under which oil pressure should be checked. At
start up, all the oil is in the sump, and oil pressure is zero. The pump cannot begin to
deliver oil or generate pressure until it sucks cold oil through the filter screen and pick
up tube. Hence, cold start lubrication is improved by using a short, wide pick up tube
and an oil with good cold flow properties, such as a multigrade.
25

Cold oil generally has high flow resistance; therefore, oil pressure on start up is high. As
the oil circulates and warms up, it flows more freely and oil pressure drops to a stable
level. Only at this point is the engine being lubricated properly. Until oil pressure
stabilizes, wear rates are high because of insufficient oil delivery to the mating surfaces.
Therefore, good" oil is one that reaches a stable oil pressure quickly.
Thus, a user should be equally concerned about high pressure as low pressure.

Higher

pressure means more work must be done to pump the oil around the engine. This loss of
efficiency should be minimized. In general, high oil pressure does not equal good oil flow; in
many cases, it indicates just the opposite. Lower oil pressure, on the other hand, means that
the oil is flowing rapidly around the engine. In most cases, this condition is desirable to
minimize wear

CAUSES

Low oil level

Oil not flowing in to the pump at start up

Pump runs too slowly to deliver sufficient oil

Oil too hot, viscosity too low

Worn oil pump

Worn bearings allow oil to flow freely through increased clearance

Oil viscosity reduced by dilution

MAIN PARTS WHICH EFFECTS THE LOP

26

Piston cooling nozzle

Piston cooling nozzle is located in the cylinder of an engine. Its main
function is to cool the piston by spraying the coolant through the nozzle of
this piston cooling device in order to avoid overheating. The aluminum
piston cooling nozzle is manufactured by casting followed by secondary
Operations for drilling holes which leads to increase in production time. This
can be reduced by using plastic as the replacement of the metal apart from
the weight & cost reduction.

Piston cooling nozzle sketch fig.

27

Piston cooling nozzle fig.

Intercooler
An intercooler is any mechanical device used to cool
a fluid, including liquids or gasses, between stages of
a multi-stage heating process, typically a heat exchanger
that removes waste heat in a gas compressor. They are
used in many applications, including air compressors,
air conditioners, refrigerators, and gas turbines, and are
widely known in automotive use as an air-to-air or air
-to-liquid cooler for forced induction) internal combustion engines to improve their
volumetric efficiency by increasing intake air charge density through nearly isobaric
(constant pressure) cooling. Intercoolers increase the efficiency of the induction system by
reducing induction air heat created by the turbocharger and promoting more thorough
combustion. This removes the heat of compression (i.e., the temperature rise) that occurs in
28

any gas when its pressure is raised or its unit mass per unit volume (density) is increased. A
decrease in intake air charge temperature sustains use of a more dense intake charge into the
engine, as a result of supercharging. The lowering of the intake charge air temperature also
eliminates the danger of pre-detonation (knock) of the fuel air charge prior to time spark
ignition. Thus preserving the benefits of more fuel/air burn per engine cycle, increasing the
output of the engine. They also eliminate the need for using the wasteful method of lowering
intake charge temperature by the injection of excess fuel into the cylinders' air induction
chambers, to cool the intake air charge, prior to its flowing into the cylinders. This wasteful
practice (when intercoolers are not used) nearly eliminated the gain in engine efficiency from
supercharging, but was necessitated by the greater need to prevent at all costs the engine
damage that pre-detonation engine knocking causes.

Oil pump
The oil pump in an internal combustion engine circulates engine oil under pressure to the
rotating bearings, the sliding pistons and the camshaft of the engine. This lubricates the
bearings, allows the use of higher-capacity fluid bearings and also assists in cooling the
engine. As well as its primary purpose for lubrication; pressurized oil is increasingly used as a
hydraulic fluid to power small actuators. One of the first notable uses in this way was for
hydraulic tappets in camshaft and valve actuation. Increasingly common recent uses may
include the tensioner for a timing belt or variators for variable valve timing systems.
The oiling system addresses the need to properly lubricate an engine when its running.
Properly lubricating an engine not only reduces friction between moving parts but is also the
main method by which heat is removed from pistons, bearings, and shafts. Failing to properly
29

lubricate an engine will result in engine failure. The oil pump forces the motor oil through the
passages in the engine to properly distribute oil to different engine components. In a common
oiling system, oil is drawn out of the oil sump (oil pan, in US English) through a wire mesh
strainer that removes some of the larger pieces of debris from the oil. The flow made by the
oil pump allows the oil to be distributed around the engine. In this system, oil flows through
an oil filter and sometimes an oil cooler, before going through the engines oil passages and
being dispersed to lubricate pistons, rings, springs, valve stems, and more.

OIL PUMP FIG.

Oil filter
An oil filter is a filter designed to remove contaminants from engine oil, transmission oil,
lubricating oil, or hydraulic oil. Oil filters are used in many different types of hydraulic
machinery. A chief use of the oil filter is in internal-combustion engines in on- and off-road
motor vehicles, light aircraft, and various naval vessels. Other vehicle hydraulic systems,
such as those in automatic transmissions and power steering, are often equipped with an oil
filter. Gas turbine engines, such as those on jet aircraft, require the use of oil filters. Aside

30

from these uses, oil production, transport, and recycling facilities also employ filters in the
manufacturing process.
Early automobile engines did not use oil filters. For this reason, along with the generally low
quality of oil available, very frequent oil changes were required. The first oil filters were
simple, generally consisting of a screen placed at the oil pump intake.

ENGINE OIL FILTER FIG.

Strainer
Strainer is a simple device which is used to remove large particles in the sump. it is a
normal screen used to improve the impurities in the engine oil.
A screen used for trapping large and coarse particulate matter.

31

LOW OIL PRESSURE CORRECTIVE ACTION

Check the oil level

Replace pump

Replace bearings

Change oil

Check oil viscosity (correct grade)

TESTING FOR PISTON COOLING NOZEL

32

1. Switch on the pcn machine.

2. Switch on the heater and set the temperature at 40c.
3. Set the pressure at 3bar.
4. Insert the pc nozzle properly in the machine with gasket.
5. Tight the lock nut manually in correct position pc nozzle.
6. Press the timer button to reset.
7. Press the pressure pedal with foot.
8. Nozzle sprays the oil with pressure 3 bar in the beaker.
9. In the beaker, small 0.8 dia circle is required in the front of the nozzle.
10. If nozzle pressure sprays inside the 0.8 dia circle and one side of the circle surface
touches, then it is ok.
11. In the machine timer is used, in 1 minute 40 drops like small volume of liquid on the
machine surface.
12. There should no leakage from the joints of pc nozzle.
PRECAUTIONS
1. Nozzle should kept free from dust.
2. Nozzle handling should be proper.

33

PCN TESTING MACHINE FIG

Standard data
Temperature of the engine oil: 110

Pressure of the engine

RPM

oil at head: (bar)

1.3

850

2.5

2500

4.3

4500

34

Engine no. CXYS 57372

Pressure
1.3
2.4
3.9

Rpm
850
2500
4500

Pressure
1.4
2.7
4.2

Rpm
850
2500
4500

Problem: LOP becoz of improper suction at strainer.

Rework: Change the strainer.
Status: Engine ok

Engine no. CXYS 56761

Pressure
1.5
2.1
4.1

Rpm
850
2500
4500

Pressure
1.8
2.8
5.8

Rpm
850
2500
4500

Problem: LOP but at idling oil pressure at head is ok.

Rework: Change the PCN and strainer.
Status: engine ok.

Engine no. CXYS 63941

35

Pressure
1.1
2.0
4.0

Rpm
850
2500
4500

Pressure
1.2
2.2
4.1

Rpm
850
2500
4500

Problem: At idling oil pressure head is not ok.

Rework: Change the oil pump.
Status: Engine not ok in 1st trial.
Problem: Again lop after changing the oil pump.

Pressure
1.8
2.8
5.8

Rpm
850
2500
4500

Rework: To change PCN

Status: Engine ok.

Engine no. CXYS 58453

Pressure
1.3
2.1
4.1

Rpm
850
2500
4500

Pressure
1.8
2.7
5.0

Rpm
850
2500
4500
36

Problem: At idling oil pressure at head is ok.

Rework: Change the PCN.
Status: Engine ok.

Engine no. CXYS 60644

Pressure
1.4
2.3
4.0

Rpm
850
2500
4500

Pressure
1.5
2.7
4.2

Rpm
850
2500
4500

Problem: Lop at 2500 rpm and 4500 rpm.

Rework: Change the PCN and oil pump.
Status: Engine ok.

Engine no. CXYS 60645

Pressure
1.6
2.2
4.2

Rpm
850
2500
4500

Pressure
1.5
2.6
4.1

Rpm
850
2500
4500

37

Problem: Lop at 2500 rpm and 4500 rpm.

Rework: Change the oil pump.
Status: Again lop after changing the oil pump.

Pressure
1.5
3.5
5.3

Rpm
850
2500
4500

Rework: To change PCN

Status: Engine ok.

Engine no. CXYS 60644

Pressure
1.4
2.3
4.0

Rpm
850
2500
4500

Pressure
1.5
2.7
4.2

Rpm
850
2500
4500

Problem: Lop at 2500 rpm and 4500 rpm.

38

Rework: Change the PCN and oil pump.

Status: Engine ok.

39

Conclusion

Oil pressure

Countermeasures

s
P

< 1.3

at 850 rpm

To change the Oil pump & To do bearing

inspection

< 2.5

< 4.3

at

To change PCN & BI

2500rpm

inspection

at 4500

To change PCN

rpm

40

41

TATA PENGUIN OR MAGIC IRIS

The TATA Penguin or Magic IRIS is a totally new platform from the company. It comes in
the passenger carrier segment. It is a low cost solution for consumers who would like to buy a
four vehicle and use it for transporting people.
The Penguin has been specially designed for easy maneuverability around the city and for
taking high payloads while operating under a wide range of conditions. The compact design
of Penguin is enough to seat 5 adults. Provision has been given in the vehicle to increase its
capacity according to the requirement of the user.

42

Products Made in TCF-1D

ACE ZIP

MAGIC IRIS

43

Specifications:Ace Zip
Technical specifications:OVER ALL DIMENSION
Overall Length
Overall Width
Overall Height
(laden/unladen)
Wheelbase
Ground clearance
Min. Turning Circle Radius
Seating Capacity
Fuel Tank Capacity
Kerb Weight

3020mm
1480 mm
1800/1775 mm
1650 mm
140 mm
3.5 m
Driver+1.
10 Liters
1285kg

Wheel And Tyres

Tyre Type
Front Tyre size
Rear Tyre size
Spare Tyre size
Wheels

Crossply.
5.00-10 LT 8PR
5.00-10 LT 8PR
5.00-10 LT 8PR
MT 3.5*10

Engine:
Model
Type
No. Of Cylinders

Greaves 600W.
Watre Cooled.
1
611cc
11bhp@3000RPM
31Nm@ 1600-1800RPM

Capacity
Max. Engine Output
Max. Torque
Fuel Injection pump
Engine Oil Capacity
Compression Ratio

Plunger Type.
1.9ltr
18 :1

44

Layout and Transmission Rear wheel drive

Type
Transaxle constant mesh gears, 4forward,
1 sliding mesh reverse gear,
4-speed manual transmission
Steering
mechanical rack and pinion steering gear.
Turning radius: 3.5 meters
Performance
Max. Speed: 61kmph
Max. Gradeability at rated GVW: 16%.
Suspension & Brakes

Service Brakes: Hydraulically operated.

Front brake: drum 180dia
Rear brake: drum 180dia
Parking Brakes: At rear wheels (FLR mounted)
Front track: 1256mm
Rear track: 1316 mm
Front suspension: McPherson strut with lower A arm
Rear suspension: Coil Spring with Semi Trailing arm.

Tata Magic Iris

Specifications:ENGINE
Model

: Greaves 600W, BS-III

Type

: Water cooled diesel engine.

Max. Engine Output

Max. Torque
Displacement

: 11hp @ 3000 rpm

: 31Nm @ 1600-1800rpm
: 611 cc

45

Special Items

: catalytic converter (only in BS III)

CLUTCH
GEAR BOX

: Single plate dry friction diaphragm type

: TA 59

Type

STEERING

: Rack and pinion Steering gear, Mechanical

BRAKES
Type
Front
Rear

: Hydraulically operated.
: Drum brakes
: Drum brakes .

Parking Brake

: At rear wheels ( FLR mounted).

SUSPENSION:
Type
Shock absorber

Sliding mesh (4 forward gears), Sliding mesh (reverse

gear)

: Front:- Mc Pherson strut.

Rear:- Coil Spring with semi trailing arm.
: Hydraulic Shock Absorbers At rear.

WHEELS AND TYRES

Tyres

5.00-10 LT 8PR- cross ply.

FUEL TANK

Capacity 10 liters

PERFORMANCE
Max. Speed
Max. Gradeability

: 61 kmph
: 16%

DIMENSIONS:
Overall Length
Width
Wheel base
Overall height
Track Front
Track Rear

:
:
:
:
:
:

2960
1512
1650
1512
1256
1316
46

WEIGHTS
Max. GVW
Kerb weight
Seating capacity

: 1110 kg
: 685 kg
: Driver + 4

AUDITINVOLVEMENT
During my training period, I had joined two Audits in TATA MOTORS

B.S.C. Audit
BSC-Work Place Implementation
1. Stacking and Storage Systems
Purpose
Purpose of this procedure to have in Place, Good Stacking and storage practices
to maintain the proper upkeep of the good housekeeping. This procedure
describes stacking and storage practices followed in the TML Plant.
Objective
To avoid any incident/Accident due to improper Storage /Stacking
conditions in order to minimize incident rate to give safe working environment
Scope
It covers functioning of entire TML Pantnagar including contractual
Area.
47

Responsibility
All CX owners of their respective areas.
Procedure

Stacking has to be organized in such a manner so as to facilitate FIFO issues.

All goods should be protected from loss by fire, water and climatic conditions.
Paints & Thinners should not be stacked balanced to the walls. i.e. there should be some
distance between the walls and the stocks..
For stock movement between the bays or for delivery purpose mechanical trollies should
be used wherever possible.
Materials awaiting inspection/approved materials/rejected materials shall be clearly
identified.
6. Flammable liquids shall be stored in closed
containers and in limited quantities in
well ventilated rooms of fire resisting construction which are isolated from the remainder
of the building by fire walls and self closing doors.
7. Large quantities of flammable liquids shall be stored in isolated adequately ventilated
building of fire resistant construction or in storage tanks and at a distance from any
building as required in the Petroleum rules, 1976.
8. No Material is stacked beyond 1:3.5 Ratio where 1 is the base and 3.5 is the Height.
9. Material which are required to be stacked at height is bounded together.
10. No Material will be stored or stacked directly on ground.

Stacking improvement

Stacking has to be organized in such a manner so as to facilitate FIFO issues.

All goods should be protected from loss by fire, water and climatic conditions.
For stock movement between the bays or
For delivery purpose mechanical trollies
Should be used wherever possible.
The Oil storage Buildings should be of Non-Combustible construction.
All Oils, sealants & Lubricants storage buildings should have adequate ventilation
to prevent accommodation of flammable Vapors.

6. No Material is stacked beyond 1:3.5 Ratio where 1 is the base and 3.5 is the Height.
7. Material which are required to be stacked at height is bounded together.
8. No Material will be stored or stacked directly on ground.

48

Sheet Metal Component

Always keep fabricated items on Trolleys.

All fabricated loose parts should be stored vertically above the pallets if required.
The Turning radius of all the trolleys must be cleared.
Storage area should be well defined.
Space should be provided between Racks, Bins & Shelves.
Material shall not be stacked against the walls. Sufficient space should be
provided between the material & walls.
Empty Trollies/Bins should be kept in defined Area.
No Material is stacked beyond 1:3.5 Ratio where 1 is the base and 3.5 is the
Height.

Material which are required to be stacked at height is bounded together.

No Material will be stored or stacked directly on ground.

Racks, bins and pallets used for material storage shall be numbered and Safe
working load should be displayed as per BSC Norms.

Trim Parts, Engine & Gear Box aggregates

Propriety items received in Wooden Boxes should always be kept on Pallets.

Always Put Loose Items either on Racks & pallets.
Stacking height for material on pallet (Wooden & Cartoon Boxes)1m.
Always received parts from Vendors in Cartoons/Trolleys/Wooden Box &
Crates only.
Store parts as per nature wise.
Parts should be stacked as per station wise fitments.
All Line rejections should be kept separately with proper identification.
Line rejection should be again be stacked & Stored as per BSC Procedure.
Space should be provided between Racks, Trolleys and Bins.
Passages between piles of materials should be at least 90 cm wide.
While stacking the material, Ease of access & stability of stacking should be
ensured.
Material should not be stacked in front of Exist/Emergency Exist, Electrical
Panels & Fire Extinguishers
No Material is stacked beyond 1:3.5 Ratio where 1 is the base
And 3.5 is height.

Material which are required to be stacked at height is bounded

together.

49

Tyres
1. Tyres should always be stored in a well designed & maintained
Racking System.
2. The racking should always be kept at or below shoulder height to avoid
back arch pain.
Steel Coils, Sheets & tubes
1. All Steel Coil to be stacked on Steel Coil Stacker with two layers
2. All Steel CTS/CTL will be stacked on floor with the stack height max. 7~8
Feets,

T.P.M. Audit
Total Productive Maintenance (TPM)
An Introduction to Total Productive Maintenance (TPM)
In this competitive world, for our existence, we have to pay attention to
following factors;
1) High Quality of the product
2) Reasonable Cost
3) Prompt delivery to the customer.
To achieve this, TPM sets following objectives as a strategy.
Zero Accident
Zero Breakdown
Zero Defects

CONCLUSION

50

Doing my summer training (6 months) at TATA Motors was a highly enriching

experience for me. Seeing the practical implementations of the classroom theories
proved to be highly beneficial as well as innovating. My project was focused on
IMPROVEMENT IN BRAKE SYSTEM OF MAGIC IRIS/ZIP, To conclude, it was a
fine blend of theoretical knowledge and practical application. It shall be of great help
in shaping my future. Looking forward to more such experiences at TATA Motors.

REFERENCES
TATA MOTORS MANUAL AND OFFICIAL WEBSITE
WIKIPEDIA.COM
GOOGLE.COM

51