A Project Report

On
Implementation of OHSAS 18001:2007
For
Automotive Stampings and Assemblies Limited
(A TATA Enterprise)

Table of Contents

Sr. No.

Content

Page No

Executive Summary

Company background & Introduction

Introduction and Scope of Project

Methodology

12

Definitions

13

Procedure of HIRA

17

Analysis

32

Conclusion & Recommendations

38

Bibliography

44

Annexure

45

List of Figures

Sr. No.

Name Of Figures

Page No

Pick and place shuttle Device

40

Swing Arm Robot

41

Pendulum Arm plane view

41

Pendulum arm Elevation View

42

Abbreviations

OHSAS

Occupational Health and Safety Assessment Series

HIRA Hazards Identification and Risk Assessment

OCP Operation Control Procedure
ERP

Emergency Response Plan

PMMPPerformance Measurement And Monitoring Plan

WIP

Work In Progress

BOP Brought Out Parts

ASAL Automotive Stampings And Assemblies Limited
PPEs Personal Protective Equipment Plans
CAD Computer Aided Design
BSI

British Standards Institution

NQL National Quality Assurance

EOT Electrical Overhead Travelling
MIG

Metal Insert Gas

ISO

International Organization for Standardization

RTB

Rear Twist Beam

1. Executive Summary

Automotive Stampings and Assemblies Limited (ASAL)being in the sheet metal

stampings and welded sub assemblies business. It is engaged in the supply of sheet metal
components, welded assemblies and the module for automobiles. It uses enormous welding
processes such as Spotwelding, Projection welding, MIG Welding, CO2 welding and it is
engaged with the press shop operations such as shearing, trim, pierce, blank, etc. Die
changing, shifting and raw material, WIP, BOPs handlings are carried out with the help of
EOT cranes, trolleys, forklifts and conveyors. The facilities like canteen, change room, office,
bus transport, securities are provided by the company. All these operations and facilities are
also maintained by the concerned departments. All these operations and activities are closely
associatedwith hazards, health and safety issues of staff, operators, visitors and workers.
Hence management has a target to achieve 4 zeros i.e.
Zero Accidents, Zero Defects, Zero Breakdowns, Zero Line Stoppage.
The aim is to become OHSAS 18001: 2007 certified company which will also meet a
specific requirements ofASAL customers and interested party who are Giant Automakers like
Tata Motors, GM, Fiat, Mahindra& Mahindra ,John-Deere, Piaggio, etc.
The project started with the study and identification of general requirements of
OHSAS certification. The first step was to list out the internal and external activities of
companyaffecting health and safety issues. and finalize the required equipments and
consumables. Then actual installation and training to the person. The next level was to make
HIRA (Hazard Identification and Risk Assessment) for each department. The outcome of all
these procedures are OCP, ERP, PMMP, PPEP, Training and Health plan for making apex and
procedures manual of the company.

The scope of my project was making of HIRA, and OCP etc. The remaining part was
out of time bucket and scope of the summer internship project. At the end of this project I am
glad to give good recommendations to the company.

2. Company background & Introduction

ASAL AT A GLANCE
Automotive Stampings and Assemblies Limited (ASAL) was incorporated as JBM
Tools Ltd. in 1990. In 1997, the Tata Group entered into a 50:50 Joint Venture with the
promoter. The Tata Group (Tata Industries & Tata Auto Comp) acquired 81.35% shareholding
in 2002 & the company was renamed Automotive Stampings and Assemblies Limited. Later,
in 2004, Tata Industries transferred its shares to Tata Auto Comp Systems Limited (TACO),
making the latter, the majority shareholder. Recently, in 2007, Tata AutoComp entered into a
Joint Venture with Gestamp Services S.L., Spain. The current share holding pattern is TACO
37.5%, Gestamp 37.5% and public 25%. The company is listed in both the BSE and NSE.

Main Products & Services & Delivery Mechanisms

ASAL is engaged in the supply of Sheet Metal Components, Welded Assemblies and modules
for automobiles. The product range includes Body-In-White (BIW) structural panels, Skin
panels, Fuel tanks, Oil sumps & Suspension parts, mainly for passenger and commercial
vehicles.

VISION

To be the preferred destination for sourcing automotive stampings, assemblies & modules, in
chosen geographies, creating benchmark value for investors
MISSION
Customers:

To develop strong bonding through Exceeding customer expectations in QCD

performance
Flawless new product launches (meeting all agreed program milestones)
Creating value through differentiated product offerings

Shareholders: To create benchmark value by delivering

TSR in top quartile of the Indian Automotive Stamping Industry

Employees: To create an organization that promotes excellence by providing

Pre-planned avenues for development and growth

Freedom to experiment
Work-life balance

Suppliers: To foster long term partnerships by

Delivering on transparent contractual terms

Ensuring enhancement of their processes and capabilities

Community: To make a difference in the community through

Sustained efforts in chosen felt needs

Creating a carbon neutral footprint

VALUES
Customer Focus

 Anticipating, understanding and focusing efforts on meeting customer needs and exceeding
expectations
Passion for Excellence
Relentlessly improving, continuously raising the bar
Integrity in all our dealings
All our actions and dealings should be capable of standing the test of public scrutiny
Respect and Understanding
We must be caring, compassionate, humane and respectful in all our interpersonal dealings
Responsibility
Take ownership for the consequences of ones decisions and actions

HEALTH, SAFETY AND ENVIRONMENT POLICY

We at Automotive Stampings and Assemblies Limited, reaffirm our commitment to
continually improve our Health, Safety and Environment and prevention of pollution.
To this we shall:
Comply with all applicable national and state environmental, health and safety regulations
and other requirements, related to environmental aspects and OH&S risks.

Conserve raw materials and energy.

Strive to achieve Zero accidents, Zero occupational diseases and Zero environmental
incidents.

Improve or upgrade our processes to institutionalize sound environmental, health and

safety practices.

Train and develop our employees and contractors to create awareness about good
environment, health and safety practices.
This policy will be communicated to all our employees and shall be made available to
public/ stakeholders.

Major Technologies, Equipment & Facilities

The organization has 4 manufacturing Plants, located at Chakan&Bhosari (Maharashtra);
Halol (Gujarat) and Pantnagar (Uttaranchal). Manufacturing facilities comprise of
(1)Mechanical and Hydraulic Presses (35 Nos.) ranging from 120T Single Action to 1500T
Double Action (2) Welding machines Spot / Seam /MIG (3) Lathe / Milling / Drill M/Cs (4)
Powder Coating Plant and (5) Autophoretic Surface Coating Plant. The Presses at Pantnagar
have robotic automation. Robotic Arms are used, at Chakan and Bhosari for critical-to-quality
operations in MIG / Spot welding and for material handling. The company has a Co-ordinate
Measuring Machine for component layout inspection & fixture calibration.Auto CAD,
Unigraphics, & CATIA softwares for 3D Surface Modeling, Arco CAD for CMM and Hyper
form CAE simulation for investigating formability of sheet metal parts and determining blank
size required for the part. SAP has been implemented to ensure process control and data
management.

3. Introduction and Scope of Project:

A) INTRODUCTION :Organizations of all kinds are increasingly concerned with achieving and
demonstrating sound Occupational Health and Safety (OH&S) performance by controlling
their OH&S risks, consistent with their OH&S policy and objectives. They do so in the
context of increasingly stringent legislation, the development of economic policies and other
measures that foster good OH&S practices, and increased concern expressed by interested
parties about OH&S issues. Many organizations have undertaken OH&S reviews or
audits to assess their OH&S performance. On their own, however, these reviews and
audits may not be sufficient to provide an organization with the assurance that its
performance not only meets, but will continue meet, its legal and policy requirements. To be
effective, they need to be conducted within a structured management system that is integrated
within the organization.
OHSAS 18001:2007 is an international occupational health and safety management
system specification. The system aims at enabling an organization to establish a
comprehensive framework for health and safety policy, setting of objectives and to assess
effectiveness the management system.
The OHSAS Standards covering OH&S management are intended to provide
organizations with the elements of an effective OH&S management system that can be
integrated with other management requirements and help organizations achieve OH&S and
economic objectives. These standards, like other International Standards, are not intended to
be used to create non-tariff trade barriers or to increase or change organizations legal
obligations. This OHSAS Standards specifies requirements for an OH&S management
system to enable an organization to develop and implement a policy and objectives which
take into account legal requirements and information about OH&S risks. It is intended to

apply to all types and sizes of organizations and to accommodate diverse geographical,
cultural and social conditions. The basis of the approach is shown in Figure 1. The success of
the system depends on commitment from all levels and functions of the organization, and
especially from top management. A system of this kind enables an organization to develop an
OH&S policy, establish objectives and processes to achieve the policy commitments, take
action as needed to improve its performance and demonstrate the conformity of the system to
the requirements of this OHSAS Standard. The overall aim of this OHSAS Standard is to
support and promote good OH&S practices, in balance with socio-economic needs. It should
be noted that many of the requirements can be addressed concurrently or revisited at any
time.
The second edition of this OHSAS Standard is focused on clarification of the first
edition, and has taken due consideration of the provisions of ISO 9001, ISO 14001, ILOOSH, and other management system standards or publications to enhance the compatibility of
these standards for the benefit of the user community. There is an important distinction
between this OHAS Standard, which describes the requirements for an organizations OH&S
management system and can be used for certification / registration and / or self declaration of
an organizations OH&S management system, and a non-certifiable guideline intended to
provide generic assistance to an organization for establishing, implementing or improving an
OH&S management system. OH&S management encompasses a full range of issues,
including those with strategic and competitive implications. Demonstration of successful
implementation of this OHSAS Standard can be used by an organization to assure interested
parties that an appropriate OH&S management system is in place.

Occupational Health and Safety Assessment Series (OHSAS) has been developed
with the developed with the assistance of standard bodies, certification bodies and specialists
consultancies such as,

National Standards Authority of Ireland.

South African Bureau of Standard.

British Standards Institution.( BSI )

Bureau VERITAS Quality International. ( BVQI )

Det Norske VERITAS.( DNV)

Lloyds Register Quality Assurance ( LRQA )

National Quality Assurance ( NQA )

SFS Certification

SGS Yarsley International Certification Service

International Safety Management Organization Ltd.

International Certification Service

B) SCOPE OF PROJECT:As mentioned earlier, ASAL being a stamping industry, it deals with sheet metals and
uses welding as a special process.All these operations and related activities are closely
associated with hazards, health and safety issues of staff, operators, visitors and workers.
The root of this project lies in being to become OHSAS 18001:2007 certified company and to
achieve management target i.e. 4 Zeros. (Zero Accidents, Zero Defects, Zero Breakdowns,
Zero Line Stoppage.)The project scope defines the identification of PotentialHazards(HIRA)
and Risk associated(OCP) in the activities and processes at ASAL, Chakan.
The project will come up with the proposal of analysis of hazards in company,
probable solutions and new technology to tackle the accident problems.
At the end of proposal, this report will give project execution schedule which will
define the time period necessary for the implementation of the project.

4. Methodology
The methodology followed while completing the HIRA and SOPs, PPE plan other
essential plans and analysis.

Identify and list out the all the activity, process, operations and their sequences carried

out in ASAL chakan plant.

Prepare the check list/work place hazards.
Visit to the diff department concern persons.
Finalize the responsible person for finding hazards.
Identify the all hazards in company.
Assess the risks which are identified.
Analysis the collected informations.
Project Implementation schedule.

5. DEFINITONS
1 Acceptable Risk:-Risk that has been reduced to a level that can be tolerated by the
organization is having regard to its legal obligations and its own OH&S policy.

2 Audit:-Systematic, independent and documented process for obtaining audit evidence

and evaluating it objectively to determine the extent to which audit criteria are fulfilled.

3 Continual Improvement:-Recurring process of enhancing the OH&S management system

in order to achieve improvements in overall OH&S performance consistent with
organizations OH&S policy.

4 Corrective Action:-Action to eliminate the cause of a detected nonconformity or other

undesirable situation.

5 Documents:-Information and its supporting medium.

6 Hazards: - Source, situation, or act with a potential for harm in terms of human injury or ill
health, or a combination of these.

7 Hazard Identification: - Process of recognizing that a hazard (3.6) exists and defining its
characteristics

8 Ill Health: - Identifiable, adverse physical or mental condition arising from and / or made
worse by a work activity and / or work-related situation.

9 Incidents:-Work-related event(s) in which an injury or ill health (3.8) (regardless of

severity) or fatalityoccurred, or could have occurred.

10 Interested Party:-Person or group, inside or outside the workplace, concerned with or

affected by the OH&S performance of an organization.

11 Nonconformity:-Non-fulfillment of a requirement.

12 Occupational Health and Safety (OH&S):-Conditions and factors that affect, or could
affect the health and safety of employees or other workers (including temporary workers and
contractor personnel), visitors, or any other person in the workplace.

13 OH&S Management Systems:-Part of an organizations management system used to

develop and implement its .OH&S policy and manage its OH&S risks.

14 OH&S Objective:-OH&S goal, in term of OH&S performance that an organizations sets

itself to achieve.

15 OH&S Performance:-Measurable results of an organizations management of its OH&S

risks.

16 OH&S Policy:-Overall intentions and direction of an organizations related to its OH&S

performanceas formally expressed by top management.

17 Organizations:-Company, corporation, firm, enterprise, authority or institution, or part or

combination thereof, whether incorporated or not, public or private, that has its own functions
and administration.

18 Preventive Actions:-Action to eliminate the cause of a potential nonconformity or other

undesirable potential situations.

19 Procedures:-Specified way to carry out an activity or a process . Procedure can be

documented or not.

20 Records:-Document stating results achieved or providing evidence of activities

performed.

21 Risk:-Combination of the likelihood of an occurrence of a hazardous event or exposure(s)

and the severity of injury or ill health that can be caused by the event or exposure(s).

22 Risk Assessments:-Process of evaluating the risk(s) arises from a hazard(s), taking into
account the adequacy of any existing controls, and deciding whether or not the risk(s) is
acceptable.

23 Workplace:-Any physical location in which work related activities are performed under
the control of the organization.

6. Procedure of Hazard Identification & Risk Assessment standard

6.1 Purpose

This work instruction defines the steps to conduct risk assessments so as to provide a
safe working environment and a safe system of work for employees, Contractors,
Visitors and anyone else they might reasonably expect to be affected by activities
carried out in the plant.``
Risk Assessments will be a formal method for identifying hazards and risks
associated with proposed and existing working practices. They will also be used to
identify fire hazards and evaluate risks associated with other emergencies in order that
management precautions can be put in place to preventive measures or limit the
potential danger posed to people.
The success or failure of any Health, Safety & Environmental Management
System depends upon its having in place an adequate system for identifying and
controlling risk. Therefore Risk Assessment will form the basis of all safety
management Standards.

6.2 Scope

This Standard will apply to all activities undertaken at the Plant and will take account
of all hazards associated with the process or activity being assessed; a guide to assist
with hazard identification is detailed below.
Specific Risk Assessments will be required for;

a) Routine Activities like

Raw Material Unloading

Shearing Operation

Press Operation

Die Setting

Welding Process in Weld Shop e.g. Spot, CO2(Manual, Robotic), Projection,

Seam Welding ,etc.

Tool Maintenance

Die movement using EOT crane

Material Movement using pallet with the help of forklift/mobile crane

Leak Testing

Powder Coating

Autophoretic

RTB / Sub Frame Assembly

Dispatch

Office Activities etc

Canteen

Pallet Fabrication

Milling and machining

Scrap handling

b) Non Routine Activities like

Welding in Press Shop

Wall Painting

Digging / Excavation

Unloading of the dies through EOT Crane

Erecting and Commissioning

New Project Activity

Layout Change

Welding Cutting on line

Machine Maintenance

Contractor activity etc.

Oil cleaning of components (Rousting)

Risk Assessments will be reviewed if

A new operation is introduced.

New / changed working methods, equipment, substances or environments are

introduced

Following an accident, major incident or any emergency.

Once in a year the HIRA to be revised & updated

6.3 Risk Assessment Process

1 Risk Assessment is essentially a three-stage process:

Identification of all hazards associated with an operation or process

Evaluation of the risks of those hazards actually causing harm.

Management of the Risks by identify measures to limit the exposure to harm,

and for monitoring and controlling their effectiveness.

Non Routine Activities- Contractor Activities, Visitor, and Facilities provided at the
work place. Impact of external activities

a. Hazards created in the vicinity of the workplace by work

Human behavior, capabilities and other human factors

Infrastructure, equipment and materials

Changes or proposed changes

Modification

Applicable legal requirements `

Design of work areas processs, installation

`
b. Management of Change

Changes or proposed changes in the organization

Activity changes (eg. Changes to processes, equipment, infrastructure,

software)

Materials (e.g.new chemical, packaging)

Change to the OH&S management system (e.g. Procedure)

c. Hazards are identified on the Occupational Health, Safety, Fire and

Ergonomics Hazard Identification Form.
The Plant HSE Coordinator, responsible for identifying Hazards will;

Retrieve any previous assessments for the activity or process being assessed
for reference.

Refer Process Flow Diagram, FMEA, Control Plan and SOPs, as appropriate

Conduct the assessment based on current identified hazards in accordance with

this Standard.

Ensure that any precautions identified are put in place.

Make the significant findings of the assessment known to those who are
affected.

d. Risk Rating
Risk Priority Rating (RPR) = Regulatory x Consequences x Likely hood
The Risk Assessment form appended to this Standard enables the
competent individual to assign numerical risk factors to the hazards identified
from work activities; these numerical factors are detailed below. The risk rating
will give the necessary priority to risks, which must be considered when
allocating resources.
The initial assessment on each process or activity will be done taking
account of control measures that are already in place. Once the risk factors have
been determined, the competent person should consider each identified hazard,
estimate the severity of any incident and its likelihood, determine whether the

existing controls are adequate or whether additional control measures are

required. Existing and additional controls must be recorded on the Risk
Assessment form.

Risk of any activity will become Significant if the rating is as following.

Legislation (4 Regulated)
Total Risk value is more than 50

Having applied additional control measures the risk rating should be reviewed,
the additional control measures should have the function of reducing the risk
rating to less than 50 wherever practicable and in any case as low as possible.
Where a risk is above 50, it should be reviewed if the work activity or location
changes or as a minimum once per annum.
Risk assessment for new process have to be completed before SOP, including
process change, & if any accident take place the HIRA to be revised within one
week.
When carrying out a Risk Assessment, the following must be considered;
The location, hazards arising from the surrounding environment
The task to be carried out, hazards, including occupational health hazards,
arising from the task
The trades involved, including tools, equipment and the activities they will
undertake
Other persons who may be affected

e. Assessment Method
1. Identifying the Process or Activity
Each process activity must be considered to establish which hazards apply
to it.
Below is a list of activities generally associated with Automotive
Stampings and Assemblies Limited work activities, the list is intended as a
guide and is not exhaustive.

Press Operators

Welders

Manufacturing Team Members (Press Shop & Weld Shop)

EOT crane / Mobile crane / Fork Lift Operators

Finished Goods Auditors

Electricians

Fitters

Storemen

Maintenance Engineers

Manufacturing Engineers

Process Engineers

Cleaners

Support

2. Identifying the Hazard

Below is an indicative list of hazards, which may be inherent in the

companys workactivities, the list is intended to be a guide, and is not
exhaustive.
a)

b)

Mechanical

Entanglement

Friction / Abrasion

Crushing /Collapse / Overturning

Fluid Injection / Ejection

Trapping fingers

Trapping Hands

Trapping Feet

Trapping Body

Impact on body

Impact to eye

Cuts to Fingers

Cuts to hands

Cuts to Body

Ejection of tool

Ejection of particles

Ejection of work piece

Transport

Overturning of vehicle

Collapse of load

Crushing by vehicle

Poor visibility

Speed

Overloading of vehicle

Working adjacent to edges

Damage to feet

Entanglement in moving belts

Crushing hands

Poor housekeeping

c) Access
Slips /Trips / fall
Falling or moving objects
Obstruction or projection
Height
Entrapment

d) Confined Spaces
Chemical / Process Residues
Fumes / Gases
Fumes / Gases from Maintenance Activities
Oxygen Deficiency
Oxygen Rich Atmospheres
Flammable Atmospheres

Access / Egress
Emergency Escape
Effects from Other Processes

e) Manual Handling
Repetitive Movement
Work Related Upper Limb Disorders
Back Injuries
Cuts, Abrasions
Strains, sprains
Injuries to Feet
Human behavior, capabilities & other human factor.

f) Electricity / Power
Hydraulic

High Pressure,Low Pressure

Pneumatic

High Pressure, Low pressure

Electricity

High voltage above 240 volt

Medium voltage up to 240 volt
Low voltage up to 110 volt

Thermal

Hot / Cold surfaces

g) Chemicals / Substances
Skin Irritation

Biological Effects
Sensitization
Industrial Diseases

h) Fire and Explosion

Flammable Liquids, Gases, Dusts.
Combustible materials
Sparks
Heat
Explosive Atmospheres
Exothermic Reactions
Storage of flammable substances
Maintenance and Contractor activities
Use of Electrical appliances and machinery
Housekeeping

i) Major Accident Hazards

Process Leak or Spillage
Storage Facility Rupture or Leak
Traffic Accident (Vehicle Carrying Hazardous Substances)
Fire
Explosion
Bomb Scare

Structural Damage to Facility

Major Industrial Injury

j) Particles and Dust

Inhalation
Ingestion
Impact (eyes)
Abrasion (skin)

k) Radiation
Ultra violet light, IR light

l) Environmental
Noise
Vibration
Light
Humidity
Ventilation
Temperature
Climate
Pressure / vacuum
Wind
Plant movement
Traffic

m) Other Work Related Hazards

Stress
Excessive Working Hours
Fatigue
Out side the workplace

f. Evaluating the Risk

A risk-rating guide has been produced to assist in making an assessment of
the risks associated with a work activity. The risk rating is based on an
evaluation of those at risk, the severity of the possible harm and the
probability of the hazard actually causing harm. As described below.
Operational control to be consider for the operation / activity as current
control while evaluating risk.

1) Regulated:1 = Not regulated

2 = Company policy
3 = Potential to become regulated
4 = Regulated (permitted, part of govt. mandated programmed, defined
regulations)
2) Consequences
1 = Negligible, No Injuries or minor First Aid required

2 = Marginal, Moderate, injury. Minor Medical treatment required

3 = Critical Severe injury. Extensive Medical treatment required
4 = Catastrophic Single or multiple Fatalities

3) Likelihood
1 = Very Rare / Almost impossible
2 = Remote
3 = Occasional
4 = Frequent
g. Hierarchies for Determining the Control
Following hierarchy should be implemented to control the risk
Elimination
Substitution
Engineering Controls
Singes/warning/ Administrative controls
Personal Protective equipment

h. Records
HIRA Form (Annex)

7. Analysis

8. Conclusion & Recommendations

ASAL has taken steps within its own industry parameters to negate these risks, and action
serves as a working example of how the issue can be approached and tackled. There are
several key areas of the ASAL in which, safety on the production plant floor has been
distinctly improved by automation.
Several modern production lines are automated. Operation, ranging from packaging to
dispatching, in which handles large dangerous sheets of steel for product, is always moving.
In ASAL mostly accident occurs during sheet metal handling, so we must focus on it. For this
we can use method like, Sheet metal automation such as a turret punch press or robotised
press brake handles this product quite rapidly, so the objective is to keep employees well
clear of these active zones. It could be as sophisticated as some which have optoelectronic
sensors or laser beams, which switch off a machine the moment they are triggered, so for the
operator there is complete safety.
There are several key areas of the ASAL in which, safety on the production plant floor has
been distinctly improved by automation. Blank sheet metal is not only sharp, it has
cumbersome dimensions for manual movement, plus the edges and corners always carry the
potential to cause serious cuts. By incorporating into the systems such technologies as
elevating platforms, suction cups, robotic arms, and conveyor movements, manual
involvement has been all but removed from the fabrication equation by automation, and
allowed the operator to slot into a role, where he or she oversees the operating software
component of the system.
A completely integrated automation system seems to hold the key to production plant safety
requirements. The less manual handling involve in all the steps from procurement to dispatch

the lesser likelihood of personal injury. Modern flexible manufacturing systems (FMS) are
known for working metal sheets, (such as punching/shearing, bending and the like), that
allow the production of unitary lots of finished metal sheets (pieces) with a proven
technology

consisting

of

"nesting",

that

is,

the

optimized

jointing

of sheets.

In modern working areas, in order to feed the metal sheets to the machine tool and in order to
collect and stack the finished pieces, an anthropomorphous robot can be used instead of or in
addition to traditional devices. The anthropomorphous robot is provided with an arm having a
plurality of rotational joints and one or more sliding joints. Preferably, the rotational joints are
five or more than five. The robot anthropomorphous allows an easy handling of the metal
sheets, especially if they have shapes and dimensions that are not very suitable for
conventional handling.In order to set up the trajectories for handling the metal sheets a "selflearning" procedure is commonly used. In this "self-learning" procedure, operator by
operating a pendant control, guides the robot to execute the desire trajectory or evolution in
space. The path executed in this way is memorized in a control unit of the robot for use in an
autonomous manner (i.e.) without the intervention of the operator at a later time, for the
handling of the metal sheets from a feeding site to the machine tool and/or from the machine
tool to an unloading site. The self-learning method greatly reduces the flexibility of the
working area. In particular, if the production lots are unitary, flexibility becomes nil due to
the fact that the self-learning process performed for each individual piece of a unitary lot is
not used again. An automatic blank feeder is integrated for first double action press. Loading
and unloading of panels from one press to the next are carried out through various systems.
Some use mechanical arms mounted on individual presses with a shuttle conveyor between
the presses. The system uses independently mounted robots to unload from a press and to
load on the next press without any interference between the presses.

1. Pick and place shuttle devices that include:

One press mounted linear or cam driven extractor

One press mounted linear or cam driven loader

One floor mounted part transfer

2. Swing arm robot,amounted to a slide or track (unless the presses are with special side slide
bolster); with a six-axis articulated arm style robot mounted to an auxiliary swing arm
seventh axis to reach large centre to centre distances of the press lines.

3. Pendulum arm,( with optional 5th axis) articulated robot that uses a single pick up transfer
between large press centre distances without the robot being relocated for die change.
Pendulum arm is mounted off to one side of the press line.

LASERS FOR TRIM /PIERCE

Laser cutting machines with 3-axis, 5-axis movements are finding application in sheet metal
component manufacturing and are being used to do number of complimentary operations.
Biggest advantage is its flexibility and the torch path can be changed as per the component
design and manufacturing requirements. Blanking, piercing, trimming, notching can be easily
performed for varied components. With improved cutting speed, the time cycle achieved may
be viable for low volume requirements. The laser may be the most efficient manufacturing
technique for the smaller holes in odd positions because of its flexibility. Generally, the punch
life becomes critical or die design becomes complex. A number of additional dies may be
required. The process may be easily integrated in the existing manufacturing system to
increase production and efficiency, and to cut down tooling, maintenance and setup cost. For
holes with less than 2:1 hole/thickness ratios, laser provides the best solution. For
components such as doors, bonnet with complex holes and contours, a laser system may
improve part quality and reduce hazard.
As the panels are being designed mostly using CAD system, CAM software can develop the
laser working program for the process by starting from the description of component

geometry. Laser cutting is destined to get effectively integrated in stamping plant for
automotive components. 5-axis laser cutting machines are already being used for all trimming
and piercing operations particularly for low/medium volume operation such as proto-typing
or after sales market requirements. Laser capability to combine several processes such as
cutting, shearing, and welding into one work station will provide immense opportunity to
improve overall part quality, and will ultimately reduce hazards.

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3.
4.
5.

www.finn-power.com
Report from Brook heaven National laboratories
OHSAS Manual from Tata Johnson
www.lincolnelectric.com
Safety Management Manual (SMM), International Civil Aviation Organization

6. Hand book SHEET METAL STAMPING IN AUTOMOTIVE INDUSTRY

7. NSLS OHSAS Management System Manual
8. BSI Management Systems Manual
9. www.irca.org
10. Manual, Tata code of conduct
11. Manual, Tata business Excellence model

Annexure

Sr. No.

Name

Project Execution schedule.

General Manufacturing Process.

Accident Investigation Report.

Hazard, Consequence and Control form.

HIRA for press shop.

OCP.

1) Project execution schedule :

KEY WORK PROCESSES IN ASAL

C
U
S
T

C
Business
Business
Development
Development

Program
Program
Management
Management

Manufacturing Operations
Stamping
Coating

Welding Assembly

Module Assembly

M
E
S
R
U
S
P
P

O
Material Procurement
M
Bought out parts
(brackets, fasteners)

Tool
Maintenance

Plant
Maintenance

HR & CR Sheets

I
Finance

HR

IT

R
S

E
R
S

Consumable & Spares

Key Work Processes

Key Support Processes

Continuous
Improvement

GENERAL MANUFACTURING PROCESS