CHAPTER

CHAPTER NO.

PAGE NO.

1. INTRODUCTION
1.1 Company Profile..2-4
1.2 Various Sections & Departments.....5
1.3 Team SML ISUZU LIMITED....5
1.4 Models of SML ISUZU ..6-7
1.5 Plant Layout.8
1.6 Introduction to Bus Body Shop9-14
1.7 Introduction to Paint Shop15-21
1.8 Vehicle Assembly Shop22-30

2. PRODUCTION, PLANING AND CONTROL

2.1 Introduction to PPC...31-33
2.2 Technical Specifications of 3500-Series34-37
2.3 Department Alloted & job Assigned..38-40

3. PROJECTS

3.1 Analysis defect in chassis41-43

3.2 Proper placing of spare parts...44-45

4. KAIZENS
4.1 Conclusion46
4.2 Bibliography.47

CHAPTER NO. 1
INTRODUCTION
1.1

COMPANY PROFIL

Swaraj Mazda Limited is a joint venture of Punjab Tractors Limited (PTL) and Mazda
Motor Corporation of Japan. The agreement between the two was signed on 5 th October
1984. The Company decided on bringing the latest Mazda Products under the name
SWARAJ MAZDA T-3500.
The Swaraj Mazda Ltd. is collaboration between two giants in their own right-both
committed to quality and performance and showing profound development concern for
customers, stockholders, business partners and staff.
Swaraj Mazda found a very competent business partner in Mazda Motor Corporation of
Japan and enterprise of international repute. Founded in 1920 Mazda started
manufacturing trust way back in 1931. Today this enterprise has the distinction of being
the only company in the world producing reciprocator petrol and diesel engine in the
world & producing revolutionary rotary engines also. Mazda is every reputed company
in Japan. Mazda is ever seeing new areas of product excellence and innovation. It

adheres unflinchingly to a 2000 checkpoint inspection before declaring any vehicle

road worthy. The use of robots, sophisticated technology and production facilities
enable Mazda to produce vehicles of outstanding quality. No wonder Mazda have won
recognition all over the world for quality products with cars like Mazda 323 bagging
the most prestigious awards through the years.
Swaraj Mazda Plant is located near Ropar at Village Asron (About 45 kms from the
capital of Punjab State i.e. (Chandigarh Swaraj Mazda Plant is located near Ropar at
Village Asron (About 45 kms from the capital of Punjab State).The plant has a
captivating site. It spread over 100 acres of land surrounded by the Shiwalik Hills. The
barren silt hill has been leveled for construction, making it a beauty spot in the hills.
The construction of 100 crores plant, commenced on 16th January 1985.

1.1.1 Origin of the word SWARAJ

The word SWARAJ, in Hindi means freedom from bondage. Since P.T.L. was the
first largest tractor project in India, moreover fully based upon Indian technology. So
SWARAJ was appropriately chosen as its brand name. SWARAJ GROUP sells its
product under this brand name.

1.1.2 Units of SWARAJ Group

Originally, SWARAJ had set up its plant for the production of tractors. But with the
passage of time, to fulfill the requirements of Indian market, it diversified into other
fields, with the collaboration of foreign companies like Komatsu, Mazda etc. It is a fast
growing company; it opened its new Division near Chandigarh. Following are the five
divisions of SWARAJ GROUP:

SWARAJ COMBINE DIVISION

SWARAJ FOUNDARY DIVISION
SWARAJ ENGINE DIVISION
SWARAJ TRACTOR DIVISION
SWARAJ MAZDA DIVISION

1.1.3 MOTTO OF SWARAJ MAZDA ISUZU

PRODUCTS WHICH ARE BETTER THEN THEY HAVE TO BE

In the attainment of this motto the company follows the following codes which are:Seiri

Classify

things

into

necessary

and

unnecessary

ones.

Discard

what are unnecessary.

Seiton Put the things order so that they are available when needed.
Seiso Keep the work area and machine/tool clean so that abnormal
condition is detected.
Shitsuke Train, educate employees to follow rules, procedures & maintain standards.
Sieketsu Develop standards; implement them to maintain safe and hygienic
conditions at work.
The result of all this has been rapid increase in output of vehicles and sharp reduction
in each loss.
SML ISUZU Limited gives due attention to the marketing part and employees higher
qualified and trained personnel for job. It has already organized a widespread dealer
network. Zonal offices have been opened in Mumbai, Luck now, Chandigarh, Chennai,
Ahmadabad, and Calcutta. This helps substantially in sales promotion. Export
promotion, especially for hi-tech products is also being emphasized. It exports it
products to countries like Nepal, Zambia, Bangladesh, Kenya, Tanzania, Ghana, Ivory
Coast, Rwanda, Syria and Jordan.
The company's annual turnover for the year 2000-2001 exceeded 271 crores. It has a
dealer network of about 128 dealers spread throughout the country.
The corporate profile of SML ISUZU Limited projects a bright future for the company.
That is how it should be considering its importance for our economy. It is adding its
share to the real asset and job opportunities in the area both directly as well as
indirectly. Company changes its name on 4jan ,2011 which is implemented on 11 Jan,
2011. At SML ISUZU Ltd. {Ropar} there are mainly four shops as given below:-

Assembly Shop
Paint Shop

 Body Shop
Pre Delivery Inspection Shop
These shops are attended under the strict guidance of shop incharges and shop
engineers. On this training, I learn many things which I could not imagine in my
college labs.

1.2 VARIOUS DEPARTMENTS of SML-ISUZU LIMITED

1.2.1

Personnel Department

1.2.2

R&D Department

1.2.3

Quality Engineering

1.2.4

Technology Department

1.2.5

Accounts Department

1.2.6

Purchase Department

1.2.7

Maintenance Department

1.2.8

Marketing Department

1.2.9

Sales Department

1.3 TEAM SML ISUZU LIMITED

Mr. S.K. TUTEJA

Mr. HARKIRAT SINGH -

Chairman
Director

Mr. A.K THAKUR

Director

Mr. P.K NANDA

Director

Mr. K. MACHIDA

Director

Mr. M. SATO

Director

Mr. Y. WATANABE

Director

Mr. PANKAJ BAJAJ

Director

Mr. DONALD PECK

Director

Mr. STEVEN ENDERBY -

Director

Mr. YASH MAHAJAN

Managing Director

Mr. KEIJI NAKAJIMA

Whole-time Director

Mr. T. HASHIMOTO

Alternate Director

Mr. T.NAGASHIMA

Alternate Director

1.4 MODELS OF SML ISUZU

Work at the plant started at a great tempo. The first vehicle rolled off the production
line in record time of one year of laying the foundation stone. The installed capacity of
the plant is 10,000 vehicles per annum which are targeted to be achieved in five years.
The first 100 Swaraj Mazda T-3500 vehicles were flagged off from the plant on 14 th
August 1985. This sophisticated plant manufactures following models of light
commercial vehicles which are:-

1. 4.5 tonnes 14 ft Cargo Deck Commercial Vehicles.

2. 6 tonnes 10 ft Cargo Deck Commercial Vehicles.
3. 41, 32, 26, seater ordinary and Deluxe Buses.
4. Windshield chassis.
5. CNG Vehicles.
6. S7 (Standard School Buses)
Earlier known as Tokyo Kagyo Co. Mazda Motor Corporation of Hiroshima is the
seventh largest automobile company in the world. The company has the distinction of
developing the Wankel Rotary Engine in 1967.It produces on an average, 1.2 million
vehicles annually manufactured at its plant set up in sixteen countries which include
Korea, Malaysia, new Zealand, India & Pakistan.

Discipline and its right enforcement is an important hallmark of Swaraj Mazda. It is

great significance in evolving work culture. All the employees, irrespective of their
position or status, have to punch their cards when they report for duty.
Many effective steps are taken to bring this about and important among them are:Common canteen and mess for all and there is one dinning hall in which all the
employees dine together. Same meals served to all and in identical utensils. Everybody
has to stand in a queue and get his or her meals. Common toilets for all. No separate
cabins for all the members of higher hierarchy. All the members of a department or a
section sit and work in one hall with the manger facing the staff. Peons are conspicuous
by their absence. Every employee carries his or her files. Dignity or labour is thus
inculcated.

Figure 1.4.1

1.5 PLANT LAYOUT

ENGINE ASSEMBLY

CABIN WELDING CABIN & CARGO ASSY & PAINTING

BODY SHOP

CABIN PRE TREATMENT & BLACK DIPPING

PARTS FROM STORE
CARGO BOX FROM STORE

ENGINE COMPONENTS FROM WASHING MACHINE

LONG MEMBER STORAGE

TEMPORARY PART SETTING

ENGINE ASSEMBLY AND TESTING

FLOOR ASSEMBLY.

BAKING

CARGO BOX ASSEMBLY

SEALANT AND PRIMER APPLICATION

SLEEPER ASSEMBLY
TACK/FULL WELDING

CABIN ASSEMBLY

T/M ASSY LINE

CARGO BOX WELDING
STRAIN RELIEVING

DOOR WELDING & ASSEMBLY

TRANSMISSION COMPONENTS FROM WASHING MACHINE

CHASSIS PAINTING

BAKING

FINAL PAINTING
CARGO WASHING SEALANT APPL
FINAL FITTING AND FINISHING

TRANSMISSION ASSEMBLY AND TESTING

BAKING
BAKING

VEHICLE ASSEMBLY LINE

TO PAINT SHOP
INSPECTION
FINAL PAINTING

PAINTED CABIN TO VECH. ASSY.

FRONT/REAR AXLE & DIFFERENTIAL ASSY
PRE .DELIVERY INSPECTION
BAKING

ROAD/SHOWER TEST
AXLE COMPONENTS FROM WASHING MACHINE

CABIN DRESSING WITH SUB ASSEMBLY

INSPECTION

CARGO BOX MOUNTING

AXLE ASSY LINE

RUST PREVENTIVE APPLICATION

VEHICLE TO STOCK YARD

Figure 1.5.1 FLOW DIAGRAM OF THE SML & ISUZU PLANT

1.6 INTRODUCTION OF BUS BODY SHOP

Body shop consists of three lines known as Frame line, Cargo line and Cabin line. After
assembly, cabin and cargo sent to the paint shop and the frame to the vehicle assembly
shop. This shop involves the first of operations which finally result in production in
LCV.

This shop contains two lines

Line For Chassis Frame Assembly
Line For Bus Body Assembly Line

Figure: 1.6.1

 STRUCTURE SHOP:
In this shop make a structure of bus. In this shop GI tubes used to make a structure of
bus.
A. FIXTURE; This shop fixture are used to make a structure of bus. Many types of
Fixture are used in this shop. These are following;
I.
II.

FLOOR FIXTURE
ROOF FIXTURE

III.

L/S FIXTURE

IV.

R/S FIXTURE

V.

MAIN FIXTURE

After making all sides of structure then all sides attached each other. Also rear and front
structure Attached to this structure.
MIG weld used in this process 220-250A And 20-22V current used in this process.
TUBES: Tubes in this shop are GI. Because protect from rust,corrosion etyc.

Figure 1.6.2

SHELL SHOP:

Figure 1.6.3
After structure shop the structure of bus send to the shell shop. It is most important
shop of Bus body plant. In this shop inspection of structure and after this coading of
preemer at the Welding joints. The inspection are following:
I.
II.

Full Welding
Grinding

III.

Dents

IV.

Riveting

V.
VI.

Counting of screws
Wiper bush

VII.

Wiring of roof

VIII.

Driver window

IX.
X.

Wheel arcs front &rear

Lid cover, etc

In this shop Plasma cutter is used . After this wheel arcs are sealing and check The gap
in this. Lid cover also welded in this shop which is used for air cleaner . Foot step
alsoWelded in this shop.In this shop also fit GI panels . It panels fixed with the help of
MIG weld. In this shop Used two types of panels. Those are following:
GI PANEL
ALUMINIUM PANEL
``MIG weld current ; 150A20V

TYPE OF WELDING OPERATIONS IN BODY SHOP

Two types of welding operations are used in body shop these are:
1. Gas Metal Arc welding ( MIG)
2. Resistance Spot Welding

1. GAS METAL ARC WELDING

MIG is an arc welding process in which heat for welding is generated by an arc between a
consumable electrode and work metal. The electrode of M.S. Copper coated wire having
diameter 1.2 mm is continuously fed to the weld area by means of a D.C. Motor at speed of 9
12 m/min. This speed of feeding the electrode can be adjusted according to the requirement.
No flux is used but the arc and molten metal are shielded by an inert gas, which may be
argon,helium, carbon dioxide or gas mixture. The steam of CO 2 gas is to provide protection
from atmospheric contamination to weld puddle, arc, and adjusted area of base metal and the
electrode. The direct current with reverse Polarity (i.e. electrode is made positive and work is
made negative) is used.

Working Specifications of MIG welding instrument are

Voltage

32-36 Volts

Current

180-200 Amp.

High speed Co2 is used as inert gas.

Principle of Operation
Proper current and wire feed speed is set

and the

electrical connections are ensured. The

are

struck by any one of the two methods. In

the first

is

method current and shielding gas flow is

switched

on

and

the

electrode

is

scratched against the job as usual practice

for

striking the arc. In the second method,

electrode is made to touch the job, is
retracted and then moved forward to

carry

out welding; but before striking the arc,

shielding gas,

Figure

1.6.4

water and current is switched on. About 15mm length of the electrode is projected from
thetorch before striking the arc.During welding, torch remains about 10-12 mm away from the
job and arc length is kept between 1.5 to 4 mm.

EQUIPMENT
a) Welding power source and cables.
b) Welding torch and wire electrode coiled on a

spool.

c) Wire feed mechanism and controls consisting of

a pair of

driving rolls, electric motor, etc.

d) Shielding gas cylinder, pressure regulator and
meter.

flow
Figure 1.6.5

e) Controls for switching on and off the current, electrode wire and inert gas.

2. RESISTANCE SPOT WELDING

Resistance spot welding is a process in which surfaces are joined by the heat generation
by resistance to the floor of electric current through work piece that are held
togetherunder force by electrodes. The surface in contact is heated, in the region of
current concentration by short time pulse of low voltage, high amperage current to form
a fusednugget of weld metal. When the flow of current ceases, the force is maintained

while the weld metal rapidly cools and solidifies. The things which are used in this
process are
a. Hydraulic scissor gun.
b. Hydraulic C-gun.
c. Foot operated spot welding set.

Its specifications are

Weld time:

10 sec

Current:

8000-10000 Amp.

Voltage:

36-40 Volts

1.7 PAINT SHOP

In paint shop, cabin and cargo boxes are painted before these are sent to the vehicle
assembly shop. The painting of cabin is done after being pretreated. Therefore, we can
divide the total paint shop in the two lines. These are Pre-treatment Line and Paint
Line. Sheet metal painting is required to improve life and static appearance.

1.7.1 PRE- TREATMENT LINE

Pre-treatment line is having series of different operations are done on cabin which is
received from Body Shop. But Cargo Box is as it is received used in paint shop because
it is received pre treated from the vendor. Its production is 8 to 9 cargo box and 14-15
cabins daily. The detail of these operations is as follows:

A. KEROSENE CLEANING
It is done to remove dust, oil or any such impurities from the cabin

(received from

Body Shop) and also cleans the welding joint.

B.

DEGREASING

Chemical used in degreasing is caustic solution of quantage 22-25

The chemical in the tank is maintained at a temperature of 55 +5 oC

The dipping time for cabin in Degreasing Tank is 3-5 minutes.

The purpose of the degreasing is to remove dust and grease.

Alkaline chemical with 2-3 % strength is used.

Chemical
Bath Parameters

NIPAKLIN GN 360
Bath Specification

Temp (in c)
Fall (Point)
Oil Content (PPM)
Dipping time
Tank Cleaning

55 To 60
25 2
<3000
5 minutes
Once In a Month

Discard Frequency

Once in 4 months (100%)

C.

SIMPLE WATER TANK (WATER RINSING)

After dipping in degreasing tank, the cabin is dipped in a simple water tank for Water
Rinsing. This operation is used to clean the chemical, which is used in the Degreasing
Process.

Water
Bath Parameters

Industrial Water
Bath Specification

Temp (in c)
Fall (Point)
Discard Frequency
Tank Cleaning

Ambient
Max 9.0
Thrice in a Week
Once in a Week

D. DERUSTING TANK

The chemical used in the tank contains 30 % Phosphoric Acid Solution

This operation is done to remove the light rust.

Dipping time for cabin in Derusting Tank is 3-5 minutes.

For derusting process the chemical used is Nitric acid and 30 % Phosphoric
Acid Solution.

E. WATER RINSING TANK

Water Rinsing is done on the cabin so that all the derusting chemicals can be removed.
The specification of this tank is almost same as that of simple water tank.

F. SURFACE CONDITIONER
Chemical used in surface conditioner is Detonium Salt .The dipping time cabins 25
seconds. The process is to prepare cabin for phosphating.

G.

Chemical
Bath parameters

Nipafin GN ZS
Bath Specifications

Temp (c)
Ph
Discard frequency

Ambient
8.5 To 9.5
Once in 15 days (100%)

PHOSPHATE TANK (PHOSPHATING)

After surface conditioning operation, cabin is taken to phosphate Tank. The chemical
used in this Tank is Zinc phosphate. The chemical in the tank is maintained at a
temperature of 45 + 5oC. The dipping time in the tank is 3-5 minutes. There are another
four chemical used in this process given as below.
1. NIPAPHOS 3020 M & R
2. ADITIVE 4850
3. ADITIVE 4856
4. NIPACEL 4704 (DAILY 4 LITRE)

Bath parameter
Temp (c)
Dipping Time
Desludging
Discard frequency

Bath specification
45 To 50
3 mins
Daily
Once in a months (10%) due to sludge

H. PASSIVATION
The chemical used for passivation operation is chromic acid solution. This operation is
done to increase corrosion resistance of phosphate coating.

I.

D.M WATER RINSING

After passivation, no other chemical operation required. Therefore, DM Water rinsing is

done. Demineralised Water is used for DM Water Rising. This operation is used to
achieve acid neutralisation.The cabin is dipped 2 or 3 times. Water is maintained at
room temperature.

Water

D.M Water

Bath parameter

Bath Specification

Temp (c)
Ph
Discard frequency
Tank Cleaning

Ambient
6.5 To 7.5
Once in a week
Once in a week

J. BLACK DIPPING
Black dipping of the cabin is done to increase the strength of the part of the cabin to
increase the strength of the floor; only floor is black dipped in water-soluble black
paint, which is chemical resistant. The paint is maintained at a temperature of 30 oc.
With the help of hoists cabin or cowl is brought to the black paint tank which is filled
with Water Borne Black Paint. This paint is highly flammable liquid. Only the base of
the cabin or cowl is dipped in the black paint tank.

Paint
Paint parameters

Water Borne Black

Paint specification

Viscosity @ 25c
% Non volatile material (NVM)
Temp (c)
Ph
Black paint circulation
Tank cleaning

32 3
39 1%
26 2
8 To 9
Regular during production
Once in a Year

K. BAKING
After black dipping cabin is placed on the trolley and pushed inside the oven where the
temperature is maintained at 160 *C. After placing cabin for 30 minutes in the oven. It

is taken out of the oven and sends for next operation. Before this after dipping in the
black paint the cabin or cowl is go for washing zone where its washing can be done
with water so that the extra black paint that is stick to the component can be removed.
This will be a flour type mounted hot air convection type oven. The specifications
of the baking oven are given as below.

Baking Temperature (c)

Baking Time
Frame
Insulation
Fan Type

170 To 190
30 Minutes
Mild Steel
150 mm Rock Wool 40 kg/m
Centrifugal Type

Time of baking for sheet metal/component will depend upon Thickness of sheet,
Temperature, Time Taken to bake the component.

1.7.2 PAINT LINE

The Pre-treated Cabin is firstly coated with Thermosetting Primer surface spray. Then
sent for paint coating whereas cargo boxes are directly sent for paint cooling after
someoperations of cleaning and rubber sealing etc. The various operations in paint line
are as follows:

A. COATING OF SOUND DEADNER

Sound deadener is a rubber compound. Sound deadener layer is coated over the wheel
curvature of cabin and at the lower side of mudguard. Sound deadener destroys the
sound created by stone hitting the mudguard and prevents it from being transmitted to
the inside of the cabin. Sound deadner is applied in the booth between the pretreatment line and paint line.

B. CLEANING
Cabin is cleaned by using sand papers of different numbers and then using often cloth
pieces to remove dust particle from the cabin surface. The operation is done, for proper
adhesion of primer on the cabin surface.

C. PRIMER COATING
After cleaning operation cabin is then taken to paint booth. In the paint booth,
thermosetting primer surface spray is sprayed on the surface of the cabin. In paint shop,
all paint booths are given filtered air that flows from roof to the floor with pressure that
grinds the overspray paint particles to flow with the running water. Sufficient air
pressure is given within the booth so that painters feel comfortable during painting.

D. FLASH OFF
After painting operation cabin is kept for 5-10 minutes in another booth to enable the
primer to settle down to some extent. After 5-10 minutes, it is wheeled inside the oven
and exposed to oven temperature.

E.BAKING
Cabin is placed inside the oven which is maintained at a temp of 140 C for 30 minutes
so that Primer gets adhere properly to the surface of the cabin, Sealant is applied at all
joints of the cabin to make the cabin water proof. Then again, after sealant operation
cabin is wheeled inside the oven to allow the sealant to get hardened due to Baking.

F. CLEANING

Before painting operation, cabin is cleaned in order to remove a possible impurity on

the primer-coated surface of the cabin. This makes the surface ready for proper
adhesion of the paint on the cabin surface.

G. PAINT COAT
After cleaning operation, cabin is taken inside the paint booth. The paint booth has the
capacity of storing the cabin at a time. Topcoat paint is sprayed on the cabin surface.
This top coat has high glass, high weather durability and high chemical resistance.

H. FLASH OFF
After painting operation cabin is kept for 5-10 minutes to another booth to enable the
paint to settle down to some extent. After 5-10 minutes, it is wheeled inside the oven
and exposed to oven temperature.

I. BAKING
Cabin is placed inside the oven, which is maintained at a temperature. Of 140 oc fro 30
minutes. So that the paint gets adhere properly to the surface of the cabin. The paint
coat sequence for the cargo box is same as the above cabin.

1.8VEHICLE ASSEMBLY SHOP

IT BROADLY CONSISTS OF BUS BODY ASSEMBLY LINE

FLOOR ASSEMBLY LINE
WINDOW FRAME ASSEMBLY LINE
MAIN ASSEMBLY LINE
ELECTRICAL & SEAT ASSEMBLY LINE
PIT INSPECTION LINE

MAIN FUNCTION OF ASSEMBLY SHOP

The main function of assembly shop is to assembling of different types of
components/items on the four lines of the assembly shop which are stored on these
respective positions. Compressed air guns are used to tighten or loosen various nuts and
bolts in the product. Large hoists are used to carry object from one place to another as it
saves time and increases production.

BUS BODY ASSEMBLY LINE

In Cabin Assembly Line cabins received from the paint shop and various parts are
assembled to it. It has five stations. The stations are designated as S-1, S-2, S-3, S-4,S5,S-6,S-7 and S-8. This line has the workers of 17.

The different Stations are discussed as follows:S-1 Station

This station is further divided into three shops
BUS BODY ASSEMBLY SHOP
1.

PLYWOOD FLOOR SHOP

2. WINDOW FRAME ASSEMBY SHOP

Figure 1.8.1

1. PLYWOOD FLOOR ASSEMBLY SHOP

Figure 1.8.2
This is the first shop in station S-1. In this shop, brakes are assembled. The main parts
are as follows:In this shop plywood floor assemble to the bus floor. The thickness of this ply is about
12mm.It is firstly screwed in the frame. Pneumatic guns are used for this. In whole
industry used

mostly pneumatic

tools. After

this

floor

is

cleaned

with

pneumaticair.PVC carpet is fixed on the roofwith the help of adhesive. And plastic
beading screwed on it.
Applications: -This plywood floor in S7(standard school buses ) and Executive and
Staff Buses etc.

S-2 Station

Figure 1.8.3
This station is used to assemble window frames. In this station sealent is used to
assemble the window frames. Sealent spread around it by using pneumatic gun Sealent
protect the window from the shocks. After
windows.

S-3, 4 Station

this cleaned sealent from aroud the

The following accessories are fitted to the bus;

Vinyl matt
Glasses above the window frames
Grinding floor for smoothing
Beading fixed
Roof sealing.

PROCEDURE
1. First of all Window frames is fitted in the inner side below the front glass.
2. Then one air pipe or vent pipe is fitted in left hand side vent hole. It is
Made up of plastic and is fitted for the continuous circulation of air in cabin.
3. After fitting vent pipe toolbox is fitted with clamps at the rear side and is used to
keep the tools.
4. Then the Jack lever clamp, crack lever clamp are fitted on inner backside and are
used to hold Jack lever and lever.
5. Seat locker is fitted on inner backside and is used to hold the seats.
6. After lifting seat lockers, roof sealing is attached on the inner top of the cabin
up of plastic & foam and is used to keep the cabin warm.

Station S-5

In this Station, following attachments are fitted.

Dashboards

Side lamps

Head lighs

Gear lever cover

Wiper motor

Seats assemble

PROCEDURE

made

1. In this shop first dashboard is fitted on front of bus and fuse box is also fit in the
dashboard.
2. Then side lamp assembly is fitted just both sides of bus.
3. Head lights in this station and also adjustment of this lights. Head light tester is used
to test
the head lights.
4. Gear lever cover is also fit in this station..
5. The wiper motor is fitted. It is used to give back and forth motion to the wipers with
the help of a rod known as wiper linkage rod. After fitting the attachment, trolley is
passed to next station.
6. In this station also fit the passanger seats and driver s

Figure 1.8.4

STATION-S-6, 7
In Station S-6,7 following attachments are fitted:
A. Foot Step

B. Rear glass fitment

C. Front glass fitment
D. Left hand glass fitment
E. Right hand side door glass fitment
.

ASSEMBLEYES
Following jobs are performed at this station:
1. Propeller Shaft Yoke Greasing.
2. Silencer Fitment.
3. Centre Bearing Support.
4. Propeller Shaft Bolts.
5. Drum Centre Bolt
6. Joint Sealer.
7. Air Cleaner Fitment.
8. Air Intake Hose Fitment.
9. Fuel Tank Strap Fitment.
10. Packing Alignment.
11. Accelerator Wire Fitment.
12. Lower and Upper grill Fitment.
13. Model Plate Punching.
14. Antenna Hole Covering.

A-2 STATION
Following jobs are performed at this station:
1. Head Lamp Fitment.
2. Outer Mirror Fitment.
3. Horn Connection
4. Fender with Air Guide Fitment
5. Front Bumper Mounting
6. Number Plate Mounting.
7. Model Plate Fitment.
8. Jack plate Fitment.
9. Spare Wheel hinge Fitment.

10. Wiper Arm Nozzle Fitment.

A-3STATIONS
Following jobs are performed at this station:
1. Tyre Fitment
2. Spare Wheel Fitment.
3. Jack and Rod Fitment.
4. Brake Bleeding. 5. Engine Oil Level Checking

ASSEMBLY CARGO BOX

In this section Cargo Box for truck assembled as it is received Knocked Down form
vendor. Its components are side door, back door, load rest.
Mainly there are two types of cargo boxes
1. Standard Cargo Box
2. High Deck Cargo Box
Sleepers are also assembled to it here. After assembly cargo is passed for paint shop for
painting same as that of cabin line painting.

PIT INSPECTION
Operation of warning lights, functions of instrument panel and leveling of engine oil,
coolant, transmission oil and differential oil etc are checked. Toe in and toe out angles
of wheels are adjusted as 31o 1 o and 42 o 1 o respectively. RPM of the engine are
checked by magnet type tachometer. Vehicle is also checked for any defect of loose
fitment/ wrong fitment
Shower test is performed by sprinting water from all the sides on the cabin with
pressure to check leakage inside the cabin.
After shower test, the vehicle is taken for road test. The vehicle is taken to test track to
check brakes, emission, balance of vehicles, gears, steering control etc.
The details of this shop are given below:-

P.D.I (Pre-Delivery Inspection)

In the P.D.I Shop the no of tests are carried out on the vehicle, so that if there is any
fault in vehicle, it can be detected and then can be removed. The numbers of tests that
are carried out in P.D.I station are given below:

BRAKE TESTING
Brake testing machine is used to put braking force of the left and wheel of each one
axle at a time.

FORNT AXLE

LH: - 450K.G
RH: - 400K.G

REAR AXLE

LH: - 250K.G
RH: - 250K.G

SETTING OF TOE & TURNING ANGLES

Turning table is used to adjust toe-in & turning angles. Turning angles are given as

TURNING ANGLES
TOE-IN

LH

27 3

RH

38 2

1 to 6 mm

CHECKING OF R.P.M
A magnet type tachometer is used to check the rpm of the engine. The magnet of
tachometer is connected to the tappet cover according to standard, R.P.M at full throttle
& at normal idling should be 3800 and 640 respectively.

SHOWER TEST
After completion off all these vehicles is then taken to shower test, where water is
sprinkled on all the sides on the cabin with pressure to check leakage inside the cabin.

ROAD TEST
After shower test the vehicle is taken on the test track for road test. Vehicle is driven on
the road to check brakes, balance of vehicle, gears, steering control, operation of clutch.
After making a check list which contains the lines control of all stations and pit
inspection and road test record level of brake fluid, coolant, engine oil, transmission oil
the vehicle on the ramp for bottom sprayed with rust proof paint. Now vehicle is ready
for delivery or sale.

CHAPTER NO. 2
PRODUCTION,PLANING AND CONTROL(PPC)
2.1 INTRODUCTION of PLC
Abstract - Production planning and control (ppc) is a process that comprises the
performance of some critical; functions on either side, viz., planning as well as
control. PPC is a coordination between Marketing and Production process and its
ultimate goal is to customer satisfaction to increase the company profit or
company output and this job of PPC are done by separate PPC department of an
organization in effective manner. A Simple method to identify the Production
Planning of control process of Tata international Ltd. Dewas. In this Process we
have analysis the PPC process of an organization Tata international Dewas, In
which we have studied of different department of Tata International Dewas where
PPC process are going on and what is the factor effecting of PPC process in an
organization
Production, planning and control (ppc) department essentially consists of planning
production in a industrial undertaking before actual working starts. It establishes
the exact sequence of operations of each individual item ,part or assembly. It sets
starting and finishing dates for each important item, assembly. It covers the
procedures of releasing necessary order for production and their follow up to see
that they are completed in minimum adjustment. Thus it is a function of looking
ahead, anticipating difficulties and taking steps to remove them before they
materialize. In progressive industry, ppc department prepares maintains vital
information through elaborate systems and prepares plans by using sophisticated
planning techniques with the aim of bringing over all advantages to the company.

Figure 2.1.1

Relation to Other Functions

FUCTION;Good relationships with all the other functions in the enterprise are
essential to effective production planning and control. Full cooperation with the
marketing group is necessary, particularly in view of the importance of market
conditions and the goodwill of customers. Both product engineering and process
engineering must keep production planning and control informed as to their plans
to avoid the manufacture of goods either to incorrect specifications or by an
improper method

Figure 2.1.2
This deptt. Directly attached to the production. Firstly any component or item is
pass from thios deptt. Then issued from sore.In this deptt. Makes list of those
component which is issued.It keep record of all issued items.

FEEDING LIST:
Feeding list is the most important part of ppc department. It is the record of all
Issued component issue from department.

Feeding list of 20 buses;

Sr. no.
Item no.
Discription
UOM
Qty/Vehicle
Buffer

1
LZ15 2061
Reflector 80mm
00
2
30

Req. Qty
Line Stock
Bal. Req. Qty
Issue Qty
Station
Current Stock
SP
St. Loc.

40
30
40
40
5
100
21
SKS RACK

Figure 2.1.3
This is used to delivery of component from store to production line.these are following
type:
HAND PALLET
FEEDIN TROLLEY
FORK LIFTER

2.2 TECHANICAL SPECIFICATIONS OF SWARAJ

MAZDA T-3500 SERIES

Figure 2.1.4

SPECIFICATIONS
A. WHEEL BASE
B. OVERALL WIDTH
C. OVERALL LENTH
D. OVERALL HEIGHT
E. FRONT TRACK
F. REAR TRACK
G. FRONT OVERHNG
H. REAR OVERHANG

5100
2262
9280
2960
1674
1466
1180
3000

ENGINE TYPE
Type

No of Cylinder

Diesel Engine, Four Stroke Water cooled,

Direct Injection
Four Inline

CLUTCH
Clutch Operating Method
Type
Outer Diameter

Hydraulic
Single Plate Dry Diaphragm
260 mm

GEAR BOX
Type
No. of Gears
Oil Capacity

Diaphragm Type Synchromesh

5 Forward, One Reverse
3.6 lts

AXLES
Front Axle
Rear Axle

Heavy Duty Forged I Beam

Heavy Duty Pressured Beam With
Differential Carrier

STEERING
Steering Wheel Dia
Ratio

430 mm
32.0 ~ 54.5 (Variable)

FUEL TANK
Capacity

180 lts (For super Models)

90 lts (For Others)

SUSPENSION
Springs

Semi Elliptical Leaf Springs

Anti-roll Bar

Optional

Shock Absorbers

Hydraulic Double Acting, Telescopic

TABLE 2.2.1

BRAKES
Service Brakes

Dual Circuit Hydraulic, Vacuum Assisted

Front

Hydraulic Leading Sliding Shoes

Rear

Hydraulic Two Leading Shoes

Total Braking Area

2210 Sq.cm

Parking Brake

Mechanical Acting on Propeller Shaft

TABLE 2.2.2

WHEELS & TYRES

WHEELS & TYRES

Front 8.25 x16-16 PR

Rear 8.25 x 16 -16 PR

TABLE 2.2.3

ELECTRICAL SYSTEM
System Voltage

12 V

Battery Capacity

70 AH

Alternator Type

Built In Regulator with Vacuum Pump

Max. Output

12 V / 55 A

Wiper Motor

SRF Nippon Denso

Head Light

60/55 W, Halogen tube

TABLE 2.2.4

DIMENSIONS
Wheel Base

3335 mm

Overall Width

2200 mm

Overall Length

5454 mm

Overall Height

2070 mm

Front Track

1640 mm

Rear Track

1640 mm

Min.Ground Clearance

228 mm

Cargo Box (L X W X H)

3740mm x2080 mm x 1090 mm

Load Body Platform Area

3740 mm x 2080mm

TABALE 2.2.5

WEIGHT
Maximum GVW

6140 Kg

Maximum Permissible FAW

2460 Kg

Maximum Permissible RAW

3680 Kg

TABLE 2.2.6

PERFORMANCE
Max. Gradability in Ist Gear

27%

Min. Turning Radius

6.0 m

TABLE 2.2.7

2.3 DEPARTMENT ALLOTED AND JOB ASSIGNED

2.3.1 Spare Part Division:-

It basically deals with the:I.

To import the required spare parts needed for the vehicles manufactured.

II.

To control and manage the inventory

III.

To distribute the spare parts to different shops

IV.

To keep the record of all the inventory

V.

To deal with the vendor for raw material needed

Job Assigned:The spare part division deals with the control and management of inventory. It also
includes the proper space management and location of the spare parts. When I started
the training, the spare parts were not properly placed at required locations. Most of the
inventory was lying on the floors I was assigned a job to place the inventory at proper
locations in the racks present in SPD. My job was to give proper locations to spare
parts and also to note the locations of the spare parts according to their part numbers
and to enter them into the computer software.
My job was to place the spare parts in the racks according to their size and shape. The
heavy and large parts were stored in the lower rows while other in the upper rows.This
was my job in the Spare Part Division.

2.3.2 Body Shop:The Body Shop has further two lines which are as follows:
1. Frame Assembly Line
2. Cabin Assenbly Line
I was to work in Frame Assembly Line.

1. Frame Assembly line:In frame assembly line, six different chassis frames assembled. These are WT 48, WT
49, WT 50, WT50L and WV26, ELWB. The assembly of these six different chassis is
completed through five different stations, which are as follows:

A. Temporary Assembly Station

At this station, all cross members fitted to the side members placing these on the
special type of jig. Then the temporary assembly is taken to the next station, which is
known a Tack Welding Station. The temporary assembly is also known as Side Member
and Cross Member Assembly Jig.

B. Tack Welding Station

At this station other components like brackets, hangers for load springs etc are
positioned on this temporary assembly. At this station, small tacks are made to
temporary mount the various components like bracket, hangers for load spring etc.
Then this tack welded assembly is taken to the next station where full welding of the
frame assembly is done. This station is known as Full Welding Station.
C. Full Welding Station
The tack-welded assembly is mounted on rotating jig, which permits easy welding of
tubular cross members. At this station, full welding is carried out with the help of MIG
welding.
D. Strain Relieving Station
A special type of fixture is there in the strain relieving station .The fixture has clamping
arrangement along with hydraulic and mechanical operated jacks fitted on it. The
purpose of the jack is to relieve the assembly of the strain developed during welding. A
scale fitted on the hydraulic jig detects the distortion caused by welding. Then this
distortion is corrected by applying described pressure through the hydraulic jacks.

E. Black Painting Station

At this station, the complete frame assembly is cleaned by pressurized air and then
black paint is sprayed in the paint booth. From this station, the frame is taken to the
vehicle assembly shop sometime by the trolleys and sometime by the fock lifters.

F. Frame Rework Station

At this station finishing of frame is done like grinding, MIG welding and paint touch up
etc and location of components are checked with the help of gauges.

Job Assigned:In frame assembly line, the different parts of frame were assembled together with the
help of MIG welding. Then the strain from the welded parts is then relieved with the
help of strain relieving equipment. Then painting operation is done and then rework of
the frame is done.
In frame assembly line, after all the operations, some welding defects are imparted in
the frame. Also during rework operations like grinding and etc. some paint is also
missing on some parts on the frame. I was assigned a job to check the welding defects
and missing paint on the frame and to correct these defects before the frame is further
used. Approximately 20-30 chassis were checked for the welding and paint defects.
Further the parts were checked whether every part is present or not. If any defect was
found it was corrected and the frame is further used. This was my job in the frame line
assembly shop.

CHAPTER 3
PROJECTS
3.1 ANALYSIS DEFECT IN CHASSIS

Project:1
Aim:
To check the parts of the chassis that were not welded and painted properly and to find
out the solution of problem.

Objective:
1. To find out the defects in the chassis of trucks, and buses and to
countermeasure the defects.
2. To check the parts of the chassis those were not welded properly.
3. To check the parts of the chassis those were not painted properly.
4. To check whether all parts are present or not.

Introduction:
After all welding operations done in body shop, chassis come from the body shop to
frame line. We have to check that the parts attached to chassis are welded properly or
not.
Body shop consists of three lines known as Frame line, Cargo line and Cabin
line.
After assembly, cabin and cargo sent to the paint shop and the frame to the
vehicle assembly shop.

This shop contains two lines

Line For Chassis Frame Assembly
Line For Cabin Assembly Line (Cabin Fabrication)
Following are the parts which were checked for proper welding and painting:-

Chassis no.
Front Hangers 02
nos.
Front Brake hose
02 nos.
Front Stabilizer
Bracket
Brackets air bunch
Plate air cleaner (4
WD)
Side brim pipe
Bracket ALSV
Spindle Damper
DDU Bracket
Stiffener Hangers
Air Tank mounting
Brackets
Air holding
brackets LH side
Air bunch holding
bracket on CM-2

CA44
4
P

CA44
3
P

CA43
7
P

CA44
6
P

AC44
7
P

CA43
0
P

P
P
P
-

P
P
P
-

P
P
P
-

P
P
P
-

P
P
P
-

P
P
P
-

TABLE 3.1.1
These are the readings for only five Bus Chassis whose components have been welded.
Over 200 chassis were checked over the course of month. Chassis of BUS, TRUCKS,
etc.
We have seen that three major problems generally occur:
I.

Front stabilizer welding missing

II.

Spindle damper missing

III.

Side brim pipe miss

IV.

Paint missing on certain parts

To avoid these problems never happen we find out the following solution of the
problem:
On fixtures welding spots are not to be left behind, it should be cleared
after 10 chassis.

To give proper training to the people.

Poka yoke

Poka Yoke:
Japanese manufacturing engineer Shigeo Shingo developed the idea into a formidable
tool for achieving zero defects and eventually eliminating quality control inspections.
From the Japanese words:
yokeru To Avoid
poka
Inadvertent Errors /
Unintentional Error
This is based on the principle that the defects can be prevented by controlling
performance of a process so that it cannot produce the defects even when a mistake is
committed by humans.
The idea is to respect the intelligence of workers by taking over repetitive tasks
that depend on vigilance or memory.
Promotes Creativity and Value-Added Activities
Reduces Ego problem among employees.

The Ten Most Common Errors (Causes of Defects):

1.)
2.)
3.)
4.)
5.)
6.)
7.)
8.)
9.)
10.)

Processing Omissions
Processing Errors
Wrong Piece of Equipment
Operations Errors
Adjustment, Measurement or Dimensional Errors
Error in Equipment Maintenance
Handling Error
Error in Setting up the Equipment
Missing Parts
Inclusion of Wrong Part / Item

Five best Poka-yoke

Guide pins of different sizes

Error detection and alarms

Limit switches

Counters

Checklists

3.2 PROPER PLACING of SPARE PARTS

Project:2
Aim:
To place the spare parts at specific locations on the racks present in SPD (Spare Part
Division) Store.

Objective:
1. To place the spare parts at specific locations according to their weight,
shape and size.
2. To note down the locations of parts and enter them into the computer
software so that these locations can be retrieved when needed according
to their part number.

Introduction:
There are thousands of spare parts used in different types of trucks and buses. Proper
storage of these parts is very necessary so that these parts can be retrieved when
needed. A good storage is also necessary for long life and better working of the parts.
So the parts should be located at appropriate locations.
There are number of racks present in SPD store. These racks consist of number of rows
and columns in which the parts were to be stored. According to the size and shape of
the parts, these were stored in different racks and the location of parts was entered into
the computer software.
When a part is needed, the part number is entered in the computer software and we get
the location of the part from the database of the software. In this way the location of the
part is retrieved based on its part number. Hence in this way, it is very easy to find any
required part from the racks.

Following are the locations of parts which were located in Rack ZR-01:-

TABLE 3.1.2
This is the example of parts located in a single rack. In the same way hundreds of parts
were placed in the number of racks present in SPD store and their locations were noted
and were entered into the computer software. By entering the part number in the
computer software, we get the location of that specific part.

CHAPTER 4
KAIZENS
4.1 Conclusion

Got the practical knowledge of what I have learned in college.

Got a good experience to work in the industry.

Got a good conceptual knowledge by working on projects.

Learned to work with the employees and workers and maintain good human
relation.

Got to know how different levels of hirarchy in the industry are co-related and
work with each other.
Thus during my six week training,I got a good practical knowledge which
would help me in my future career.

Good judgment comes from experience, and often experience comes from
bad judgment.

4.2 Bibliography
a) Machine drawing by P. S. Gill
b) SML ISUZU MANUALS
c) Websites
a) www.Google.co.in
b) www.Amazon .com
c) www.Swarajmazda.net