PROJECT REPORT

Development of Automatic ON-OFF System for various Electrical Equipments of Paint Touchup Zone
TATA MOTORS LIMITED, LUCKNOW
at

Submitted by

KAANCHAN KRISHNA
B.Tech. 3 Year Electrical & Electronics Engineering Northern India Engineering College, Lucknow
rd

Summer Trainee Cowl-Cx Assy

Under the Guidance of Mr. Ritesh Srivastava

Div. Manager [Cowl-Cx Assy]

13

th

Project Duration June 2012 11th July 2012

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TABLE OF CONTENTS S. No.

1 2 3 4 5 6 7 8 9 10 11 12 13

Content
Declaration Certificate Acknowledgement TATA MOTORS- An Introduction TATA Journey-Year by year TATA MOTORS (Lucknow Plant) Organization Structure of Lucknow Plant
Organization Structure Of Trim cx Divisions of Tata Motors Lucknow

Page No.
3 4 5 6 7 10 11 12 13 17 18 21 35

My department Cowl Shop Process Flow for Manufacturing of Cowls Project: Development of Automatic ON-OFF System for
various Electrical Equipments of Paint Touchup Zone Summary

DECLARATION
I KAANCHAN KRISHNA hereby declare that the project work entitled Development of Automatic ON-OFF System for

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various Electrical Equipments of Paint Touchup Zone is an authentic record of my own work carried out at TATA MOTORS, LUCKNOW as requirements of 4 weeks project during training under the guidance of MR. RITESH SRIVASTAVA DIV. MANAGER (COWL-CX-TRIM ASSY).

KAANC HAN KRISHNA (SUMM ER TRAINEE) COWLDate: 11

TH

CX ASSY. -JULY-2012

I certify that the above statement made by the student is correct to the best of our knowledge and belief. I wish him every success in life.

Mr. Ritesh Srivastava (DIV. Manager, COWL-CX ASSY) Tata Motor Ltd., Lucknow

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CERTIFICATE I, RITESH SRIVASTAVA (Div. MANAGER TRIM LINE), HEREBY of DECLARE B.Tech. 3rd HAS THAT Year KAANCHAN Electrical & HIS KRISHNA Electronics

Engineering

COMPLETED

PROJECT ON Development of Automatic ONOFF System for various Electrical Equipments of Paint Touchup Zone DURING THE ACADEMIC YEAR 2012-13.THE INFORMATION SUBMITTED IS TRUE AND ORIGINAL TO THE BEST OF MY KNOWLEDGE.

Mr. RITESH SRIVASTAVA (Div. Manager, COWL-CX ASSY.)

Ms. JASNEET RAKHRA (Manager, HR)

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ACKNOWLEDGEMENT
Industrial training is a crucial period in

engineering curriculum since it exposes a student to the real world which he or she is going to enter after the completion of the Diploma. This is the period during which an engineer actually becomes an engineer by gaining the Industrial experience. I am extremely happy that I was given the opportunity to get training in TATA MOTORS, LUCKNOW one of the most renowned organization of India. I would like to take the opportunity to thank my Project Head MR. RITESH SRIVASTAVA (Sr. Manager, CX TRIM ASSY) for having provided me with the wonderful & conductive environment to work in. He has been ever helpful and supportive. I would like to thank Ms. JASNEET RAKHRA (Manager HR) for providing me the opportunity to add a new dimension to my personality. I will remain indebted to her for her generous way of dealing with industrial trainees.

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Kaanchan Krishna (Summer Trainee) Cowl-Cx Assy

AN INTRODUCTION
Type : Industry: Founded: Founder(s): Headquarters: India Key people: Chairman Carl Peter Forster, CEO
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Public (BSE: 500570) Automotive 1945 JRD Tata Mumbai, Maharashtra, Ratan Tata, Chairman Ravi Kant, Vice

(NYSE: TTM)

Prakash Telang, MD (India Operations) Ravi Pisharody, President (CVBU) Products: * Automobiles * Engines Services: Engineering and Design Revenue: Net income: Total assets: Total equity: Employees:
Parent:

Outsourced $20.572 billion (2010) $844 million (2010) $20.192 billion (2010) $2.224 billion (2010) 50,000 (2010) Tata Group

TATA JOURNEY YEAR BY YEAR:

1868: Jamsetji Nusserwanji Tata starts a private trading firm, laying the foundation Of the TATA group. 1874: The Central India Spinning, Manufacturing Company are marking the Group's entry into textiles. Weaving set and up,

1902: The Indian Hotels Company is incorporated to set up the Taj Mahal Palace and Tower, India's first luxury hotel, which opened in 1903. 1907: The Tata Iron and Steel Company (now Tata Steel) is established to set up India's first iron and steel
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plant in Jamshedpur. The plant started production in 1912. 1910: The first of the three Tata Electric Companies, The Tata Hydro-Electric Power Supply Company, and (now Tata Power) is set up. 1911: The Indian Institute of Science is established in Bangalore to serve as a centre for advanced learning. 1912: Tata Steel introduces eight-hour working days, well before such a system was implemented by law in much of the West. 1917: The Tatas enter the consumer goods industry, with the Tata Oil Mills Company being established to make soaps, detergents and cooking oils. 1932: Tata Airlines, a division of Tata Sons, is established, opening up the aviation sector in India. 1939: Tata Chemicals, now the largest producer of soda ash in the country, is established. 1945: Tata Engineering and Locomotive Company (renamed Tata Motors in 2003) is established to manufacture locomotive and engineering products. Tata Industries is created for the promotion and development of hi-tech industries. 1952: Jawaharlal Nehru, India's first Prime Minister, requests the Group to manufacture cosmetics in India, leading to the setting up of Lakme. 1954: India's major marketing, engineering and manufacturing organization, Voltas, is established. 1962: Tata Finlay (now Tata Tea), one of the largest tea producers, is established. Tata Exports is established. Today the company, renamed Tata International, is one of the leading export houses in India.

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1968: Tata Consultancy Services (TCS), India's first software services company, is established as a division of Tata Sons. 1970: Tata McGraw-Hill Publishing Company is created to publish educational and technical books. Tata Economic Consultancy Services is set up to provide services in the field of industrial, marketing, statistical and techno-economic research and consultancy. 1984: Titan Industries - a joint venture between the Tata Group and the Tamil Nadu Industrial Development Corporation (TIDCO) - is set up to manufacture watches. 1991: Tata Motors rolls out its millionth vehicle. (The two-million mark was reached in 1998 and the third million in 2003.) 1995: Tata Quality Management Services institutes the JRD QV Award, modelled on the Malcolm Baldrige National Quality Value Award of the United States, laying the foundation of the Tata Business Excellence Model. 1996: Tata Tele services (TTSL) is established to spearhead the Group's foray into the telecom sector. 1998: Tata Indica - India's first indigenously designed and manufactured car is launched by Tata Motors, spearheading the Group's entry into the passenger car segment. 1999: The new Tata Group corporate mark and logo are launched. 2000: Tata Tea acquires the Tetley Group, UK. This is the first major acquisition of an international brand by an Indian business group. 2001: Tata-AIG - a joint venture between the Tata Group and American International Group Inc (AIG) marks the Tata re-entry into insurance. (The Group's

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insurance company, New India Assurance, was nationalized in 1956). The Tata Group Executive Office (GEO) is set up to design and implement change in the Tata Group and to provide long-term direction. 2002: The Tata Group acquires a controlling stake in VSNL; India's leading international telecommunications service provider Tata Consultancy Services (TCS) becomes the first Indian software company to cross one billion dollars in revenues. Titan launches Edge, the slimmest watch in the world. Idea Cellular, the cellular service born of a tie-up involving the Tata Group, the Birla Group and AT&T, is Launched. Tata Indicom, the umbrella brand for telecom services from the Tata Tele services stable, starts operations. 2003: Tata Motors launches City Rover Indicas fashioned for the European market. The first batch of City Rovers rolled out from the Tata Motors stable in Pune on September 16, 2003. 2004: Tata Motors acquires the heavy vehicles unit of Daewoo Motors, South Korea. TCS goes public in July 2004 in the largest private sector initial public offering (IPO) in the Indian market, raising nearly $1.2 billion. 2005: Tata Steel acquires Singapore-based steel company NatSteel by subscribing to 100 per cent equity of its subsidiary, NatSteel Asia. 2009: Tata Motors launched Tata Nano, worlds cheapest family car. 2010: Tata Ace becomes India's first 1-lakh brand in goods commercial vehicles. Appointment of Mr. Carl-Peter Forster as Managing Director of Tata Motors. Jaguar Land Rover announces opening of its Dealership in New Delhi. Tata Motors to construct heavy truck plant in Myanmar under Government of India's Line of Credit.

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Tata Motors declared as the Commercial Vehicle Maker of the Year. Chief Minister of Punjab inaugurates Tata Motors supported State Institute of Automotive and Driving Skills. Jaguar Land Rover announces Dr. Ralf Speth as Chief Executive Officer. Tata Motors appoints Mr. Carl-Peter Forster as Group CEO. Tata Motors Group displays the widest range of products and environment-friendly technologies at Auto Expo 2010. Tata Motors launches Magic Iris. On 26th April 2010, Tata Motors sold its 4 millionth Commercial Vehicle. Tata Motors Passenger Car Division launches Tata Motors Service Edge' for leading edge customer service. Tata Motors displays Tata Nano EV at the 80th Geneva Motor Show.

TATA MOTORS LTD. (LUCKNOW PLANT)

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Year of commencement: Plant Area: Number of employees Divisions

1991 600 acres 835 BIW, Assembly Paint, Training

TATA MOTORS Lucknow Works is a third manufacturing unit of Tata Engineering and Locomotive Company. This unit covers an area of 600 acres. In this unit the assembly of chassis and spare parts takes place. On 14th January 1992 the recruitment of operators started in Lucknow plant. On 25th June induction of Engineers (first phase) started which also included ITI's and Occupancy of administration office of assembly shop in September 1992. First vehicle rolled out from Lucknow plant on 20th October 1992 which was LP 1210 52. Construction of MRS finished on 6th January 1993. It took approximately 9 years since the conception of the plan and to rollout the first vehicle from this latest manufacturing facility of Tata Motors.

ORGANIZATION STRUCTURE (Lucknow Plant)

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Alok Saxena PLANT HEAD Umair Tauheed A.G.M Trim Assy/Weld Shop

Alok Saxena Plant Head

S.N.Verma A.G.M Manufacturing

Ritesh Srivastava Process Owner Trim CX-1

Mandar Puranik Umair Tauheed Process Owner CVA.G.M Trim CX Assy./Weld Shop

Sunil Kumar Process Owner Frame CX

Ritesh Srivastava Process Owner

SHANTI SHAW / N.L.Mishra

UMESH SHUKLA MANAGER

NARENDRA KUMAR/ D.Chaudhary

NALIN KUMAR ASST..MANAGER

Navyug

Navodaya

Navshakti

Navjeevan

1. Vijay Kumar 1. A.K.Sahi 1. Nand Kishor 2. Abraham K.G. 2. Man Singh 2. Gauri Dutt 3. A.K.Shukla 3. A.K. 3. D.Mathpal 4. Anand Singh Srivastava 4. Chhabi Nath Organization Structure Of Trim 5. Chanden 4. V.S.Nagi 5. Mahesh Duttcx Singh 5. Jai Kishor 6. Krishna Kumar 6. G.D.Bhatt 6. D. 7. B.S.Sajwan 7. Rajendra Vishwakarma 8. Moti Lal Singh 7. M.S. Rawat 9. Rakesh 8 B.N.Godwami 8. P.K.Singh 10.Vikash 9. U.P.Singh 9. A. N. Dubey Chandra 10.Bagisg Prasad 10.P.C. Ram 11. Ram Taj

1.Ramesh Chandra 2.Balendra Singh 3.M.K.Mishra 4.M.K.Sharma 5.Mukesh Katyer 6. Budh Singh 7. A.K.Tripathi 8. R.K.Chaudhary 9. Rajesh Kumar 10. Sanjay Kumar 11. Arvind Kumar 12.J.C.Gupta

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Divisions of TATA Motors Lucknow: Training division

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The Training Center at the Lucknow plant aims at providing high quality Apprenticeship Training. In addition, the Centre provides both internal and external training, support to operators, supervisors and managers in areas like special skills and technology, safety, personnel practices etc. The Lucknow plant, after a major restructuring exercise, executed a smooth transition from function-based to process-based structure. By this structure, process owners are required to meet stretched targets, and in order to do so, are required to encourage individual learning and development of employees. A structured process is being followed to establish and reinforce an environment that encourages innovation.

Assembly division
Lucknow Plant started with the assembly of Medium Commercial Vehicles (MCVs) to meet the demand in the Northern Indian market. However, in 1995, the unit started manufacturing bus chassis of Light Commercial Vehicles (LCVs) and SUMOs. The facilities for manufacturing the spare parts were set up and started supply of Crown wheel & pinion (CWP) in 1994. Subsequently, G-16 & G-18 Gear Parts started in 1998. With the availability of G-16 gear parts manufacturing facility, the Plant also started assembly of G-16 Gear Box to meet in-house requirement for SUMO vehicles in the year 2000.Now TATA Motors Lucknow has started assembling of CNG MCV`s to meet the

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consumers demand. TATA Motors is also producing Rear Engine CV`s.

Manufacturing Division
In TATA Motors Lucknow Crown Wheel and Pinion are manufactured by various gear cutting process. Machining (grinding and heat treatment) of Gear Box parts is Aalso done here. These gears are used in gear boxes or as spares. Now TATA Motors is assembling Gear Box of ACE (Newly launched small CV) in Lucknow itself. The Manufacturing unit of Tata Motors at Lucknow is the latest manufacturing facility of Tata motors and is located towards East of Lucknow plant.

There are five factories in Tata Motors, Lucknow:

- CV-CX (Commercial Vehicle) Factory - Transmission Factory - TATA MARKOPOLO MOTORS Limited - Integral Bus Factory (IBF) - RECON Factory

Departments in TATA Motors Lucknow are:

Planning Technical services Central tool room

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Central procurement Dispatch Central logistics Factory logistics group-CV Factory logistics gear-transmission Factory logistics Gr-sumo SQIG Engineering services Central maintenance FPIG - CV factory FPIG-transmission factory Central quality (CQ) Area office, Lucknow Regional sales office (Lucknow) Service deptt., Lucknow works Plant head office Manufacturing head office Human resources

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Business excellence Finance Internal audit ERC Lucknow Administration Construction

COMMERCIAL EXCELLENCE

VEHCILES

CENTER

OF

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Over the last fifty years, Tata Engineering has built up an impressive line up of commercial vehicles that can match international benchmarks. Today Telco is Indias largest and among the worlds top ten commercial vehicles manufactures. They have over 130 models and variants of vehicles designed to transport almost anything. Their commercial vehicles can haul loads ranging from 0.75 tones to 49 tones. They have mini buses that can seat 12 people and buses that can accommodate as many as 60.Tippers, tractors trailers, and 4x4off road vehicles.

ABOUT VEHICLE CLASSIFICATION

In the Commercial Vehicle Business Unit, the models are classified on the basis of GVW as under: HCV: MCV: LCV: Heavy Commercial Vehicles Medium Commercial Vehicles. Light Commercial Vehicles.

The HCV segment can be further classified into three segments based on gross vehicle weight as follows: ICV: MCV: to 15 ton. HCV: Heavy Commercial Vehicle with GVW of 16 ton and above. MCV & HCVs can also be classified into two categories depending on their usage as Trucks and Buses. Buses are passenger carriers. Trucks include goods carriers along with specialized vehicles like dumpers, tractor-trailers etc. the ICVs fall in the load category of 8 to 10 ton GVW and are Intermediate Commercial Vehicle with GVW Medium Commercial Vehicle with GVW of 10 of 8 to 10 ton.

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often substituted for medium or heavy commercial vehicles in trunk routes or cities. EICHER Motors and SWARAJ MAZDA are two manufacturers operating in this segment.

About Cowl CX
Cowl is the front portion of the Chassis, which has driving seat, engine hood, lights, blinkers, dashboard, different meters, indicators and other electrical connections to regulate the vehicle. Bare Cowls are being received from Tata Motors, Jamshedpur as well as from Eastern Complex and are assembled here. Bare Cowls are put on the trolley with the help of 0.5 ton (JIB) hoist and different fitments are made. Cowls trimmed on the floor slat conveyor. Cowls of all the vehicles are firstly assembled at Cowl CX and then it is finally bolted to the Chassis at the Chassis assembly line (cowl dropping station). The Cowl CX is divided into two areas: 1. Bare Cowl Rectification Area 2. Trim CX Assembly Area

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Process Flow for Manufacturing of Cowls

Whole process of manufacturing cowls is divided into 19 stages as under after which the cowl is transferred to main assembly line where it is assembled with the Chassis: Stage 0 (bare line): Unloading, tapping, washing, inspection and welding (if required) Filling of sealant at open joint Denting cowl where dents are observed Grinding, emery paper sanding and application of putty Centre panel alignment and knob fitting and stopper fitting Stage 1: Dropping of the cowl Model determination by facing mascot Fitment of the L bracket/Maxi Fuse bracket Stay rod and sleeve attachment

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 Pasting of the inspection card Stage 2: DTV mounting and fitment Fitment of the rubber bellow Fitment of accelerator paddle Acc pedal stopper bolt Fitment of retaining plate Stage 3: Hand brake fitment Connection of hand brake with W/H main cable Placing clutch container with pipe above the rubber grommet Fitment of the wiper motor Fitment of the high temperature buzzer Stage 4: Insulation and fitment of elbow in flange tube Fitment of flange pipe and service indicator Fitment of the footrest in LHD vehicles Stage 5: Assembly of jaali Engine hood beading Fitment of the stay rod Pasting of BS2, BS3 and caution stickers Stage 6: Fitment of the letter TATA

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 Fitment of the T-emblem Fitment of reflector triangle bracket Fitment of Auxiliary water tank Stage 7: Harness layout and routing, placing grommets over the holes Horn fitment & connection Stage 8: Routing of bottom harness Place speed cable inside clamps and holes provided Stage 9: Placing of W/H cable wire inside hole of dome and tighten screws of dome Fitment of the head lamp Tighten blinker with screw Stage 10: Fitment of power steering tank Fitment of combi switch Stage 11: Panel wiring Instrument cluster connection Stage 12: Fitment of beeper Driver seat stand fitment Thrust rod fitment Stage 13:

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 Mounting of air filter assembly on the bracket with straps Fitment of air filter bracket Mount and connect air intake pipe assembly to flange pipe Stage 14: Mounting of driver seat Tightening of wiper motor Stage 15: Instrument cluster fitment Ammeter fitment Stage 16: Mounting of steering column assembly on the bracket Steering wheel fitment Hydraulic Jack fitment Stage 17: Electrical testing Stick OK marked Stage 18: Inspection of the cowl and its parts Remove the cowl from the conveyor with the help of tackle Finished cowl palletizing on empty pallet

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PROJECT Development of Automatic ONOFF System for various Electrical Equipments of Paint Touchup Zone

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Development of Automatic ON-OFF System for various Electrical Equipments of Paint Touchup Zone
OBJECTIVE: To reduce wastage of electricity in Paint
Touchup Zone in Bare Line by designing automatic shut down system for blowers and other electrical equipments.

APPROACH OF THE PROJECT:-

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Problem Identification Current State

Proposed Ideas

Selection of best alternative

Solution Development

Plan Implementation

Benefits

PROBLEM IDENTIFICATION:
The Paint Touchup Zone in the Bare line section is used to touch up the paint of cowls whenever necessary. The Paint Touchup Zone has many electrical equipment necessary for painting such as Blowers, Exhaust, Halogen Lamps and Tube lights etc. These equipments are kept ON in the whole shift of 8 Hrs. but it is used occasionally according to need. So a large amount of energy is being wasted. This is not suitable on financial ground as well as for company policy of eco-friendliness. This is the problem.

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CURRENT STATE:
The layout of Paint Touchup Zone and current energy consumption study is as following:

The Paint Touchup Zone in Bare Line in Cowl Cx. Contains following electrical equipments1. Blowers 2. Halogen Lamps -4 -2

3. Industrial Tube Lights - 16 The arrangement of these equipments is shown in the following plan layout of Paint Touchup Zone.

Layout of Paint Touchup Zone:

The following figure shows the top view of Paint Touchup Zone

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Energy Consumption Study of Paint Touchup Zone: The following table shows the energy consumption of the Paint ZoneS. No. 1 2 3 Equipme nt Blower Halogen Lamp Industrial Tube Light Power Rating 7.5 hp = 5.6 KW 400 W 40 W No. of Units Used 4 2 16 Working Hours 8 8 8 Power Consumed 179.2 kWh 6.4 kWh 5.12 kWh

Total

190.72 kWh

Proposed Ideas:
For the above said problem following solutions are proposed1. Off Delay Timer Circuit - 29 -

2. Sensor Based System 3. Manual System These solutions are explained in detail as following-

1. Off Delay Timer Circuit:

In this system an Off Delay Timer is made using IC-555 and this is used to control a relay which in turn controls the various electrical equipments. The following Flow chart shows the plan.

Block Diagram:

Limiting Switch

Delay Timer Circuit

Relay

Power Equipments

Contactor coil

Working:
According to this plan a limiting switch senses the entry of cowl in the paint booth and sends a trigger signal to the off

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delay timer circuit. Limiting switch is of Pushbutton type so after the entry of cowl the off delay timer starts its count down. After a predetermined time the timer goes off which is controlling a relay so relay turns off which turn off the equipments connected to it through contactor coil. Thus the equipments of Paint touchup Zone are turned off after a predefined time after cowl entry. This circuit keeps off until another cowl comes in the zone.

Merits:
Simple and Cheap construction of system Large saving of power Fully automatic System

Demerits:
Installation is Difficult Timing not very accurate

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2. Sensor Based System:

In this system sensors are employed at entry and exit of the paint zone which gives triggering signal to a switching circuit which turns on and off a relay on receiving trigger signals from sensors which in turn controls the various electrical equipments. The following Flow chart shows the plan.

Block Diagram:

Entry Sensor

Switching Circuit

Exit Sensor

Relay

Power Equipments

Contactor coil

Working:
According to this plan input and output sensors are used. When a cowl comes in the booth the input sensor sends signal to switching circuit which turns on a relay and on exit the exit sensor senses the cowl exit and sends trigger to switch off relays. Thus power is on only for the period when it is being used to paint.

Merits:
Large saving of power Fully automatic System

Demerits:

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 booth

Costly system On busy days frequent ON-Off can cause breakdown of equipments Interference due to workers passing through

3. Manual Operation:
A very simple and basic solution of our problem is that the worker manually switches off the equipments from electrical panel but this is not very suitable because its not automated and increases strain on workers.

Merits:
Large saving of power No additional cost

Demerits:
Not automatic Increased burden on workers Safety Threat

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Selection of best alternative:

In above explained proposals the Selection of best alternative is done on the basis of effectiveness of system and applicability. The most suitable alternative is selected to be the Delay Timer based system because Its cheap and simple to construct Helps to save considerable amount of power

Solution Development:
According to our need an OFF Delay Timer Controlled Relay based system is developed. The entry of cowl in booth is sensed by an pushbutton limiting switch and the trigger signal is sent to an off delay timer circuit which starts its countdown as soon as cowl enters the booth. After a predetermined time the timer goes off and turns off all equipments. The suitable delay time is selected to be around 5 minutes by interaction with workers and technicians as well as considering fatigue to equipments. Thus following circuit is developed.

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Circuit Diagram:

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The above circuit shows the developed system for

Automatic ON-OFF for various Electrical Equipments of Paint Touchup Zone.

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The circuit uses an IC-555 with various other components to make an off delay timer circuit. The circuit contains following components-

S. No. 1 2 3 4 5 6 7 8

Part IC- 555 Resistor Resistor Capacitor Diode- 1N1004 Relay Battery Push Button Switch

Rating

100 Kohm, watt, 12 v 2 Mohm, watt, 12 v 100 F, watt, 12 v watt, 12 v 12V DC, 230V AC, 12V 12V, watts

Working:
The circuit is triggered by a switch between pin 1 and pin 8. In actual case we use an limiting switch. When this switch is pressed and released the circuit turns ON which energizes a relay coil which inturn turns on all equipments. After a pre calculated time delay of around 250-300 seconds the circuit turns off automatically.

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Plan Implementation:
The above discussed plan is made and implemented. The circuit is made on a matrix PCB. The images of actual circuit are following-

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Circuit Developed

Back View

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Closer View Benefits Achieved:

The plan for automation of Equipments of Paint Touchup Zone has the sole purpose of saving electricity being wasted. The following study shows how much energy could be saved by this projectAverage number of cowls in an fair day Total ON time per shift mins. 3.5 hrs. Energy consumed per shift with our system 190.72 = 667.52 kWh Energy consumed per shift without our system = 0 8 x 190.72 = 1525.76 kWh = 3.5 x = 40 = 200 System on Time per cowl through our system = 5 mins.

Total energy saving per shift = 1525.76 667.52 = 858.24 kWh Thus our system offers a energy saving upto 56% which is very good for company as well as environment.

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SUMMARY
The sole motive of this four weeks project training is to give an idea what a real industry is all about and getting training in such an esteemed organization is definitely a thing to be proud of. I got the chance to learn much more than I expected before I came here. In my training I learnt how to plan the activities regarding different work and develop the techniques to solve the problem. I also learnt the power of team work that how onerous tasks can be accomplished easily with the help of team work. By working in the Cowl shop, I learnt about the different processes which are being carried out in the Cowl line and more specifically about the Electrical and Electronic Systems used in industry, sensors and controllers, safety systems, automation etc. During training I was given a project to develop an Automatic ON-OFF System for various electrical equipments of Paint Touchup Zone which were kept ON continuously during whole shift causing lots of wastage of energy. I have designed,

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developed and built an Auto On-OFF system for the Paint Zone. The system designed by me saves upto 56% of energy. Apart from the allotted project, I also learnt a lot about Organizational Culture. Working with people from different areas taught me a lot of managerial as well as personal skills that are definitely very helpful for my future. My experience in TATA motors has been really enriching and has provided me a stepping stone for a prospective bright future in the industrial Sector. I wish that every engineer should get a chance to get associated with such a giant and reputed group.

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