SHOWER LEAKAGE REDUCTION/ELIMINATION

INDEX
S. No.
1.
2.
3.
4.
4.1
4.2
4.3
4.4
4.5
4.6
5.
5.1
5.2
5.3
5.4
5.5
6
6.1
7
7.1
7.2
7.3
7.4
7.5
8
9
9.1
9.2
9.3
9.4
9.5
9.6
9.7
10

Page No.

Acknowledgement
World and Automobile
India and Automobile
Tata Group of Companies
Tata Motors Ltd.
Area of Business
Joint ventures, Subsidiaries and Associates
Research and Development
Location
Tata motors Hierarchy
Tata Motors Pantnagar

Shower Leakage Elimination

Wind shield leakage
Main harness leakage
LH/RH leakage
Head lamp joint Leakage
Sticker missed

Proposed Solution
Possible further aspect in Project

In Tata Motors
BIW
Paint shop
TCF shop
PDI shop
Powertrain shop

By the End of Training Period

Learning at Tata Motors
Kaizen
Just In Time Manufacturing
Just In Sequence
Just In Sequence is Just In time
Elimination of Waste
Bill of Material
Work Experience

Bibliography

2
4
5
7
9
10
10
11
12
13
15
16
20
22
23
24
25
26
26
28
28
29
29
30
31
31
31
32
33
33
33
34
35
36
37
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SHOWER LEAKAGE REDUCTION/ELIMINATION

1) World & Automobile

During the 1670s, Father Ferdinand Verbiest (Flemish Jesuit

missionary, China) designed the first ever self-propelled vehicle
many claim this as the world's first automobile but lack of evidence
that it was actually built, in spite of its small size it could only
operate for 12-15 minutes before running out of steam, and its
tremendous weight and poor balance made it very difficult to steer

The first car was built by Joseph

Cugnot in 1769. It was powered
by a steam engine and was very
slow.

Notable Personalities of Past :

1 cylinder IC engine

J.J. tienne Lenoir

4 cylinder IC engine

N. August Otto

1st 4-wheel automobile &

v-slanted engine

Gottlieb
(1886)

Automobile powered by IC engine

Over 15 million Model Ts by 1927
Hybrid cars

Karl Benz
Henry Ford
Since the 1900s.

1st hybrid commercial truck

in 1910

Daimler

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SHOWER LEAKAGE REDUCTION/ELIMINATION

2) India & Automobile

Automobile:
o
o
o
o
o
o
o
o
o

Public Transport
Personal Transport
War-fare
Law and order
Trade
Emergency Services
Public Hygiene
Sea Transport
Aero planes

Indian Automobile has 12 % share in Indian economy

AUTOMOBILE COMPANIES making the Dream Machines in India:

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SHOWER LEAKAGE REDUCTION/ELIMINATION

The forecast of various type of 4-wheelers production in India:

GRAPH 2

GRAPH 3

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SHOWER LEAKAGE REDUCTION/ELIMINATION

Passenger Vehicles

Commercial Vehicles

3) TATA GROUP OF COMPANIES

Tata Group, an Indian multinational conglomerate company, headquartered in
the Bombay House in Mumbai, India, in terms of market capitalization and
revenues, it is the largest private corporate group in India.
The Tata Group comprises 114 companies and subsidiaries in
eight business sectors, 27 of which are publicly listed. 65.8% of
the ownership of Tata Group is held in charitable trusts. The
group takes the name of its founder, Jamsedji Tata, a member
of whose family has almost invariably been the chairman of the
group. The current chairman of the Tata group is Ratan Tata.
The Tata Group has operations in more than 80 countries across six continents
and its companies export products and services to 80 nations.
TATA Group's 114 companies are held by its main Company Tata Sons. The
2009 annual survey included 600 global companies by the Reputation Institute
ranked Tata Group as the 11th most reputable company in the world.

TATA GROUP of COMPANIES

Information technologies

CMC
Computational Research Labs
Nelito Systems
Tata Advanced Systems

Tata
Business
Support
Services
T ata Consultancy Services
Tata Elxsi
Tata Interactive Systems
Tata Technologies

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SHOWER LEAKAGE REDUCTION/ELIMINATION

Comunication

TRL Krosaki Refractories

Tata Sponge Iron

Tata Steel
Tata Steel KZN
Tata Steel Processing and
Distribution
Tayo Rolls
The Tinplate Company of India
TM International Logistics

Indian hotel
Root Corp.
Taj Air
Tata Housing
Devlpmnt Co.
Tata Realty &
infrastructure

Financial Services
Tata AIG General
Insurance
Tata
AIG
Life
Insurance
Tata
Asset
Management

T ala Capital
T ala Financial
Services
Tata Investment
Corporation

Energy

North Delhi Power

Powerliks Transmission
Tata BP Solar
Tata Petrodyne
Tata Power & Tata Power Trading

Consumer Product

Hooghly Met Coke & Power

JAMIPOL
Jamshedpur
Utilities
and
Services
Mjunction services
NatSteel Holdings
Tata BlueScope Steel
Tata Metaliks

Hotels Property Developement

Metals

Hispano Carrocera
Jaguar Land Rover
Tata AutoComp Systems
Tata Cummins
Tata Daewoo Commercial
Vehicle Company
Tata Motors
Tata
Motors
European
Technical Centre
Telco
Construction
Equipments
Engineering
TAL Manufacturing Solutions

Automotive

Tata Communication
Tata Teleservices
Tata sky
Tata Net
Nelco

Tata Consulting Engineers

Tata Projects
TRF
Voltas

Casa Decor
Infiniti Retail
Landmark
Tata Ceramics
Tata Global Beverages
Titan Industries
Trent
Westland

Chemicals

Advinus Therapeutics
Rallis India

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SHOWER LEAKAGE REDUCTION/ELIMINATION

Tata Chemicals
Tata Chemicals Europe
Tata Chemicals Magadi
Tata Chemicals North America
Tata Pigments

Other services

Drive India Enterprise Solution

Tata Industrial Services
Tata Quality Management Services
Tata Services
Tata Strategic Management

4) TATA MOTORS
Tata Motors Limited is a multinational automotive corporation. A
part of the Tata Group, it was formerly known as TELCO (TATA
Engineering and Locomotive Company).
Established in 1945 by J.R.D.Tata, Tata Motors' presence indeed cuts across
the length and breadth of India. Tata Motors is India's largest automobile
company, with consolidated revenues of Rs. 1, 23,133 crores ($ 27 billion) in
2010-11.
Through subsidiaries and associate companies, Tata Motors has operations in
the UK, South Korea, Thailand and Spain. Among them is Jaguar Land Rover,
the business comprising the two iconic British brands. It also distributes Fiat
cars in India, and has an industrial joint venture with Fiat in India. With over 5.9
million Tata vehicles plying in India, Tata Motors is the country's market leader
in commercial vehicles and among the top three in passenger vehicles. It is also
the world's 4th largest truck manufacturer and 3rd largest bus manufacturer. Tata
cars, buses and trucks are being marketed in several countries in Europe, Africa,
the Middle East, South Asia, South East Asia and South America

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SHOWER LEAKAGE REDUCTION/ELIMINATION

4a) Areas of business:

Tata Motors makes passenger cars, multi-utility vehicles and light, medium
and heavy commercial vehicles.

Passenger cars: compact Tata Indica in 1998, the sedan Indigo in

2002 and the station wagon Indigo Marina in 2004. Tata Motors also
distributes Fiats cars in India.
Utility vehicles: The Tata Sumo was launched in 1994 and the Tata
Safari in 1998.
Commercial vehicles: The commercial vehicle range extends from
the light two-tonne truck to heavy dumpers and multi-axled vehicles in
the above 40-tonne segment.
Passenger buses: The Company also manufactures and sells
passenger buses, 12-seaters to 60-seaters, in the light, medium and
heavy segments.

4b) JOINT VENTURES, SUBSIDIARIES, ASSOCIATES

Tata Motors has joint ventures with MARCOPOLO, the Brazil-based maker
of bus and coach bodies, and with FIAT-AUTO (to build a commercial
vehicle at Fiat's facilities in Crdoba, Argentina).
Other associates include:
Tata Daewoo Commercial Vehicle Co.: heavy commercial vehicles
Tata Motors European Technical Centre: design engineering and
development of products.
Telco Construction Equipment Company: construction equipment and
allied services.
Tata Technologies: design services, product lifecycle management and
product-centric IT services.
Tata Motors (Thailand): Tata Motors (70%) and Thonburi Automotive
Assembly Plant Co (30%).
Tata Cummins: manufactures high horsepower engines.
HV Transmissions and HV Axles: make gearboxes and axles for
commercial vehicles.
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SHOWER LEAKAGE REDUCTION/ELIMINATION

TAL Manufacturing Solutions: provides factory automation solutions

and provides machine tools.
Hispano Carrocera: Spanish bus manufacturing company.
Concorde Motors: retailing Tata Motors range of passenger vehicles
Tata Motors Finance: the business of financing customers and channel
partners of Tata Motors

4c) Research & Development

The companys
Engineering Research Centre (ERC), in Pune (which has 1400
scientists and engineers),
Tata Daewoo Commercial Vehicle Company
Hispano Carrocera at Gunsan in Korea and Zaragoza in Spain.
These three facilities together enable the company to share and access
knowledge and technology for designing and developing world-class
products which are environment-friendly technologies in emissions and
alternative fuels.
It was Tata Motors, which developed
the first indigenously developed Light Commercial Vehicle,
Indias first Sports Utility Vehicle
Tata Indica, Indias first fully indigenous passenger car (Indias largest
selling car)
Tata Ace, Indias first mini-truck.
The ERC in Pune, among whose facilities are Indias only certified crash-test
facility and hemi-anechoic chamber for testing of noise and vibration has
received several awards from the Government of India.
Some of the more prominent amongst them are:
National Award for Research and Development Efforts in Industry in
the Mechanical Engineering Industries sector in 1999,
National Award for Successful Commercialization of Indigenous
Technology by an Industrial Concern in 2000
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SHOWER LEAKAGE REDUCTION/ELIMINATION

CSIR Diamond Jubilee Technology Award in 2004.

Adopting the principle of Kaizen or continuous learning, versatile yet simple
5S approach to process improvement which helps to optimize various
operations of the company and conserve precious resources is the way of life
at Tata Motors.
The company introduced emission-friendly engines in its products in India
even before such norms were made statutory. It ensures that its products are
environmentally sound by reducing hazardous materials in vehicle
components, developing extended life lubricants, fluids and using ozonefriendly refrigerants.

4d) Location
Tata Motors' plants are located at
o Jamshedpur (eastern India),
o Pune and Sanand (western India),
o Lucknow and Pantnagar (northern India).
o Tata Motors and Fiat have a common manufacturing facility at
Ranjangaon, near Pune.
being marketed in several Europe,
South East Asia,
countries
assembly operations

Malaysia,
Ukraine,
Senegal..

Africa,
Middle East,
South Asia and Australia
Kenya,
Russia,

Bangladesh,
Spain and

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SHOWER LEAKAGE REDUCTION/ELIMINATION

4e) TATA Motors Hierarchy

Board of Directors
Mr. Ratan N. Tata
(Chairman)
Mr. Ravi Kant
Mr. Nusli N. Wadia
Mr. S. M. Palia
Dr. R. A. Mashelkar
Mr. Nasser Munjee

Mr. Subodh Bhargava

Mr. V. K. Jairath
Mr. Ranendra Sen
Dr. Ralf Speth
Mr. Carl-Peter Forster
Mr. P. M. Telang

Senior Management
Mr. Carl-Peter Forster

Managing Director & Group CEO

Mr. P. M. Telang
Mr. C. Ramakrishnan
Mr. Ravi Pisharody

Managing Director - India Operations

Chief Financial Officer
President (CVBU)

Dr. Tim Leverton

Mr. S. B. Borwankar

Head (Advanced and Product Engineering)

Senior Vice President (Mfg Operations-CVBU)

Mr. Prabir Jha

Mr. R. Ramakrishnan

Senior Vice President (Human Resources)

Vice - President (Commercial - PCBU)

Mr. Girish Wagh

Mr. R. T. Wasan

Head (Passenger Car Operations - PCBU)

Head (International Business - CVBU)

Mr. Johnny Oommen

Mr. H. K. Sethna

Head (International Business - PCBU)

Company Secretary

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SHOWER LEAKAGE REDUCTION/ELIMINATION

FIG. 2: Fuel type- Diesel, Gasoline and CNG

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SHOWER LEAKAGE REDUCTION/ELIMINATION

4f) TATA MOTORS (Small Car Division) Pantnagar

This plant came into existence in 2007. TATA
MOTORS LTD. Pant Nagar has four shops for
manufacturing of vehicles.

DESCRIPTION OF SHOPS
ASSEMBLY SHOP
Also known as TCF Shop(TRIM CHASSIS FITTING). In this shop all the
assembly works like Engine,
Suspension, Tyres, Lights, Dashboard etc. fitting is carried out.

WELD SHOP
Also known as BIW Shop(BODY IN WHITE) .
Here the different parts are welded together and the whole structure of
the car is built.

POWER TRAIN SHOP

o This shop is divided into Power Train and Engine shop. Here various
operations related to Engine, Gear Trains etc. are performed.

PAINT SHOP
The TAIKISHA paint shop is the beauty parlors of the car plant. This shop
paints the car in various shades. It takes 18 steps spread over less than 10
hours to accomplish the task.

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SHOWER LEAKAGE REDUCTION/ELIMINATION

TATA MOTORS
SUMMER INTERNSHIP PROJECT (SIP)
SHOWER LEAKAGE ELIMINATION IN
TATA ACE ZIP & TATA MAGIC IRIS

5)Shower test
The shower test is used for checking the leakage of water into the vehicle.
It is also known as water testing.

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SHOWER LEAKAGE REDUCTION/ELIMINATION

The nozzles spray the water on both right hand and left hand side of the
vehicle at a pressure of 1.3 bar ( greater than the atmospheric pressure i.e.
1.01325bar).
The pressure in the nozzle is controlled by the flow regulating
arrangement.
The following tests are conducted on the shower.

Windshield leak
Head lamp moist/ bezzle leak
Air vent leak
Canopy leak
Door pad leak
Weather strip leak
Floor leak
Tail lamp leak
Corner trims
Roof leak
Door seal leak
Window glass run leak
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SHOWER LEAKAGE REDUCTION/ELIMINATION

HMSL leak
STG gear grommet leak
Fire wall grommet leak
Repeater lamp leak

Shower defect monitoring sheet

Defects

6june 7june
A B A B
5 12 3 2

8june
A B
5 5

9june
A B
4 1

total

1.wind shield leakage

4June 5June
A B A B
4 3 3 6

2.main harness leakage

75

3.LH/RH door leakage

11 13

9 15 7 10 9 14 6

111

4.dome nut leakage

5 13

48

5.cabin joint leakage

34

6.head lamp joint leakage

56

7.head lamp grommet

leakage
8.rear glass leakage

33

39

9.sticker missed
10.LH/RH fender leakage

2
4

0
6

2
3

2 2
7 4

2
5

5
2

5
1

7
4

8
2

6
1

12 53
2 41

Total vehicle tested

Ok vehicle after test

57 44

44 50

50 61 51 41 51 39 39 48

FSO15

FSO-17

FSO-30

FSO-32

FSO-18

53

FSO-16

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SHOWER LEAKAGE REDUCTION/ELIMINATION

Major shower leakages

Wind shield leakage-53
Main harness leakage-75
LH/RH leakage-111
Head lamp joint leakage-56
Sticker missed-53

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SHOWER LEAKAGE REDUCTION/ELIMINATION

5.1)Wind shield leakage

Glass- it has two layers which are fabricated by adhesive such as poly
vinyl beautyl (PVB).the thickness of glass is generally taken about
4.56mm and the adhesive is 0.76mm.
The glass can be used in wind shield leakage is of two types.
a) laminated
b) tempered
laminated- the laminated glass is cheaper and having cost about 200rs.
It has the property not to create sharp edges when it breaks so that it
will not harm the driver during accident.
Tempered- the tempered glass is manufactured by heating it above recrystalization Temperature and hold it for some time and cooled in some
cooling medium. It has the property not to scatter when it breaks. It is
costlier than laminated glass about 5times i.e. 1000Rs.

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SHOWER LEAKAGE REDUCTION/ELIMINATION

Robot timing- The sealant, used to make the surface nonporous is

provided by the robot from the sealant drums. The process is repeated in
about 2min.

Problem concerning with robot-

a) priming- when the air stuck between the sealant pipes. It does

not allow the sealant to flow by creating an air pressure head.

b) Voltage fluctuation- if the fluctuation of light takes place in very

short period of time, the robot does not sense it and the sealant
flow rate vary that creates problem like porosity, leakage etc.

S.
Wind shield Causes
No. leakage
Fender leakage B.I.W , human, welding
1.
error.

2.

Profile leakage

Human, robotic and

manufacturing problem.

Remedies
Automation and precise
machinery
Advanced manufacturing
processes, training of
workers

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SHOWER LEAKAGE REDUCTION/ELIMINATION

5.2)main harness leakageIt is the leakage due to improper tightening of grommet.

S.
No.
1.

Harness leakage

Causes

Treatment

Grommet leakage

Improper tightening

Inspection

2.

Fitting leakage

Improper sealing or
fittings

Testing and
inspection

The leakage is due to improper size of grommet and

imperfection in fitting. This can be eliminated by the providing
a washer there.

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SHOWER LEAKAGE REDUCTION/ELIMINATION

5.3)LH/RH Door leakage

It is the leakage in the right hand and left hand door of the vehicle due to
some misalignment and improper fitting of glasses.

This is the major leakage in the shower test, so it must be eliminated by

overcome the above problems.

S.
No.
1.
2.

Door
leakage
Door pad
leakage
Fitting
leakage

Causes

Remedies

Misalignment of fittings.

Testing and
inspection.
Hammering the
door.

Improper fittings of doors and

rubber pads.

In door pad, membrane is used.

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SHOWER LEAKAGE REDUCTION/ELIMINATION

5.4)Head lamp joint leakageIt is the leakage in head lamp portion of the vehicle due to improper
fittings and some BIW problem.

The bezel gap must be within certain limit of range so that proper fitting
and no leakage can be achieved.

S.
No.
1.

2.

Head lamp
leakage
Bezel gap
leakage

Causes

manufacturing
inaccuracy(bezel gap must be
controlled)
Fitting leakage Due to improper fitting
,human error

Remedies
Precise
machinery
Testing and
inspection

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SHOWER LEAKAGE REDUCTION/ELIMINATION

5.5)sticker missedsticker is used to prevent leakage due to some unwanted holes.

It has the property to sustain the high pressure at high speed

(80km/hr).

Precautiona) sticker must be placed effectively.

b) It must have high plasticity.

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SHOWER LEAKAGE REDUCTION/ELIMINATION

6) Proposed Solution:
Here at TCF-1D, I was trained by the Line-supervisor to identify the
shower leakage which can be reduced by proper functioning during
fitment process.
During fitment due to human error or by some other way in trim section,
shower leakage can occour.so proper care need to be to eliminate it.

Hence I observed that:

Testing and inspection should be carried out at every quality gate.
Tightening of nut and bolt should be proper.
By using automation and precise machinery.
The assembly parts should be manufactured by advanced
manufacturing processes in vendor company.
The training and motivating policy should be applied to workers.
Kaizen should be applied.
Job rotation policy should be applied.

6.1) Possible further aspects in the project:

WHAT CAN GO WRONG ANALYSIS: By doing this one can also
find the root cause of the untraceable line problems and take suitable
steps towards its elimination and thus TML TCF-1D shop can assure
nearly perfect fitment for the car .

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SHOWER LEAKAGE REDUCTION/ELIMINATION

CONCLUSIONS

After analyzing the problem, in the trim section (magic iris and tata
ace) the leakage can be eliminated within accepted limit of standards.

So, the leakage is eliminated as well as quality is also improved.

1) The quality of vehicle is obtained within accepted limit of

standards.

2) The leakage will be eliminated.

3) Rating of vehicle will be improved.

4) As the fouling is eliminated, the life will be improved.

5) Due to reduction in leakage , engine work properly and heat loss

will be minimum.

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SHOWER LEAKAGE REDUCTION/ELIMINATION

7) In TATA MOTORS:
PRODUCTION SYSTEM

MANUFACTURING

PRODUCTION PLANNING

BIW(Body in white)

PAINT

TCF(Trim chassis fitment)

PDI (Pre-Delivery Inspection)

POWERTRAIN

MATERIAL SUPPLY

MES(Manufacturing
execution system)
SAP

(JIT,KAIZEN,JIS)

QUALITY MANAGEMENT

7a) BIW
This shop plays very important role in framing the body shell of Nano. The press panels are
transported from Bhuj and Pune plant.
It has three main assemblies, which includes-UB(under body), ML(Main line or main frame)
and MF(metal finish) where different welding processes of
Projection welding
CO2 welding
Stud welding
MIG welding
Spot welding
are done and after that the parts are attached to the main assemblies

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SHOWER LEAKAGE REDUCTION/ELIMINATION

SUB ASSEMBLIES
MAIN
FRAME
LINE

UNDER BODY
LINE

METAL
FINISH
LINE

PAINT SHOP

SUB ASSEMBLIES

9b) PAINT shop:

Here in Paint shop:
Colour and appearance
Covering of gaps between the weld joints
Corrosion resistance
Smoothening of sharp corners
SHOP LAYOUT:

WELD
BODY
COOLING

DRY SANDING

TCF

PRETREATMENT

ELECTRODEPOSITION

UNDERCOAT
OVEN

UNDER COAT

INTERMEDIATE
COAT (I/C)

TOUCH UP
AND
INSPECTION

ED OVEN

SOL
SEALING(UB)
SEALANT

I/C OVEN
COOLING

T/C
OVEN

TOP COAT
(T/C)

DRY
SANDING

7c) TCF (Trim Chassis Fitment) shop:

SHOP LAYOUT:

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SHOWER LEAKAGE REDUCTION/ELIMINATION

TRIM LINE
(TR1, TR2)

UNDER BODY LINE

(UB1, UB2, UB3, UB4)

MECHANICAL LINE

CANOPY TEST

ROLL AND BRAKE

TEST

WHEEL ALIGNMENT

NOK

OK

REWORK

PRE DISPATCH
INSPECTION (PDI)

PAD

To
costumer

7c) TCFShop
It is the biggest of all the shops in TML,Pantnagar.
Here the painted chassis delivered from the Paint shop is accessorized
from scratch to a finish car ready for dispatch and also tested.
The car delivered by the TCF shop is completely checked with reference
to products utility quality and manufacturing quality. After several
inspections made by line operators for operational conformance and
ethical looks the Car is permitted to be dispatch from TCF shop by the
assurance of Line supervisors and operators.
The cart dispatched from the TCF shop is delivered, through drive test to
the PDI (Pre-Delivery Inspection) shop where final touching to looks is
given and the conformance of working of all the accessories is done.

7d) PDI Shop:

PDI is the final quality check, in this the overall checking of the vehicle
takes place, in this the fitment is not done, only the outward checking is
completed. The final QA OK of the vehicle is done here and after this the
vehicle is sent for dispatch.
Parts which are checked are mentioned below:
1.

Brake, Brake oil.

21. Inner handle.

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SHOWER LEAKAGE REDUCTION/ELIMINATION

2.

Carpet fitment.

22. Instrument cluster.

3.

Central lock

23. Keys.

4.

Coolant filling

24. RH front door.

5.

Dents

25. Roof lamp.

6.

Door pad

26. Roof lining.

7.

Drive shaft

27. Rear bumper.

8.

Engine oil .

28. Rear door LH, RH.

9.

Engine wiring harness.

29. Rear door lock LH

10. Front bumper.

30. Rear door lock RH.

11. Front door LH

31. Rear seat

12. Front door lock LH

32. Seat. Belt

13. Front door lock RH

33. Spare wheels

14. Front seat

34. Scratches on whole body

15. Fuel.

35. Steering wheels.

16. Gear shifter.

36. Tail lamp.

17. Head lamp.

37. Washer jet.

18. Hood LH.

38. Window glass.

19. Hood RH

39. Wind shield washer.

20. Horn

40. Wiper.

7e) POWERTRAIN shop:

It consists of
Engine Assembly Shop
Transaxle Assembly Shop
Engine Dressing Line
In Engine assembly the various components of the Engine are assembled
into a single unit and sent for the various tests.

8) By the end of training period:

If this plan can be implemented then there is considerable change in the
trim line. With kind consultation and guidance of authority, department
managers and Line supervisors I was able to analyze the remedies of
shower leakage reduction.

9) Learnings at Tata Motors

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SHOWER LEAKAGE REDUCTION/ELIMINATION

Being one of the most technically sound and having few of the costliest technologies
among the Asian automobiles, the culture in the Tata Motors is free, motivating and
appreciative.
Here the culture of Equality is fully nurtured all the people operator to senior level are
given equal respect through all the possible manner like same Canteen facility, same
transportation facility, same uniform among various levels.
The lesson of Time is Money & Creativity is thinking up new things Innovation is
doing new things. is taught from day 1 to all employees.
The lesson of Appreciate your colleagues work is well taught from senior level
manager to all the man-force in TML, Pantnagar.
Other nice and unique things which I observed in the Plant were:

9.1KAIZEN
The Japanese refer to Kaizen as a simple parts-movement system that
depends on cards and boxes/containers to take parts from one work
station to another on a production line.
The essence of the Kaizen concept is that a supplier or the warehouse
should only deliver components to the production line as and when they
are needed, so that there is no storage in the production area.
Within this system, workstations located along production lines only
produce/deliver desired components when they receive a card and an
empty container, indicating that more parts will be needed in production.
In case of line interruptions, each work-station will only produce enough
components to fill the container and then stop. In addition, Kaizen limits
the amount of inventory in the process by acting as an authorization to
produce more inventories.

ADVANTAGES OF THE KAIZEN PROCESS:

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SHOWER LEAKAGE REDUCTION/ELIMINATION

A simple and understandable process

Provides quick and precise information
Low costs associated with the transfer of information
Provides quick response to changes
Limit of over-capacity in processes
Avoids overproduction
Is minimizing waste
Control can be maintained
Delegates responsibility to line workers

9.2 JUST IN TIME MANUFACTURING

JIT is a philosophy of continuous improvement in which non-value-adding activities
(or wastes) are identified and removed for the purposes of:
Reducing Cost

Improving Quality

Improving Performance

Improving Delivery

Adding Flexibility

Increase innovativeness

JIT is not about automation. JIT eliminates waste by providing the environment to
perfect and simplify the processes. JIT is a collection of techniques used to improve
operations. It can also be a new production system that is used to produce goods or
services.

9.3 JUST IN SEQUENCE (JIS):

JIS is an inventory strategy that matches Just In Time and complete fit in sequence
with variation of assembly line production. Components and parts arrive at a
production line right in time as scheduled before they get assembled. Feedback from
the manufacturing line is used to coordinate transportation to and from the process
area.. JIS is mainly implemented with automobile manufacturing.
JIS is sometimes called In-Line Vehicle Sequencing (ILVS).

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9.4 JUST IN SEQUENCE IS JUST IN TIME

Just in Sequence (JIS) is just one specialized strategy to achieve JIT.
The process concept of JIT sees buffers at the production line as waste in capital
bound. The aim is to eliminate buffers as much as possible at expense of stability
when disturbances arise.

Just in Sequence is one of the most extreme applications of the concept, where
components arrive Just In Time and sequenced for consumption.
The sequencing allows companies to eliminate supply buffers as soon as the quantity
in component part buffers necessary is reduced to a minimum. If not sequencing
according to scheduled variety of production, all required components must be
stocked in buffers.

For flexible production lines, as here in Tata Motors, a modern automotive assembly
line, the variety is an option to produce directly on customer orders. As soon as the
next order arrives at the work centre, the scheduler distributes the supply orders in
line with the production sequence of the final production line.
With JIS the buffer quantities are displaced upward in material flow to the
components suppliers. It is a misinterpretation of JIS to assume that all buffers will be
eliminated. Hence just the cost for buffer inventory becomes re-allocated to the
producers of the supplies. Sequencing eliminates buffers in the final assembly line by
consolidating all similar components into distributed and sequenced buffers, which
partly reside on the paths of transportation to final assembly. This strategy thus
reduces the line-side inventory buffer. However, the effect is worse when the
sequence does not get not correctly scheduled upwards or when the transportation line
gets congested.

9. 5 Elimination of Waste:
JIT usually identifies seven prominent types of waste to be eliminated:
Waste from Overproduction

Waste of waiting/idle time

Transportation Waste

Inventory Waste

Processing Waste

Waste of Motion
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Waste from Product Defects

9.6 BILL OF MATERIAL:

A Complete formally structured list of the components that make up a product or
subassembly

Here the bill of material is a complete, formally structured list of the components that
make up a product or assembly
The list contains the item number of each component, together with the quantity and
unit of measure.

The Internship program was quite beneficial for me. It helped me in improving my
various technical skills and enhanced my knowledge in new areas.

I gained new knowledge in the various issues involved and mechanisms to

tackle them in automobile industries.
By studying and analyzing the contents, I also learnt that how database,
products and operations are all mingled up and how they function in
coordination with each others.
What are the various issues one need to be aware of while looking for Data
Management and Problem tracing for solutions.
Automobile is an ever-green and vast field and through the internship I got
some insight into a how it looks like in world market.
I was working on an analysis topic for the first time and I got introduced to this area and
various methods employed.

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9.7 Work Experience:

My internship was quite satisfactory in terms of work environment.

The team, I worked with, was very friendly and helped me a lot in all my
problems. New experiences include:

Teamwork
In this project I worked with line operators in order to understand the
workin process thus providing enough opportunity for proper teamwork
and coordination. This was a good experience for me as the team was
very cooperative and understanding.

Communication
Working along with the lower level operators and making them
understand the process and also getting the valuable information out of
them in a way that is comfortable to them not making them feel that they
are inferior.

Responsibility and keeping commitments

The importance of honouring commitments and time of others was an
important thing, which I learnt as a Summer Intern. Especially, while
working as a team it is very important to keep these points in mind.

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10) BIBLOGRAPHY

1.
2.
3.
4.
5.
6.
7.

8.

www.google.co.in
www.wikipedia.com
www.tatamotors.com
http://www.acmainfo.com/pdf/Status_Indian_Auto_Industry.pdf
(Graphs 2009, 15, 20).
http://www.imaginmor.com/automobileindustryindia.html (Pi
charts)
http://www.tatamotors.com/know-us/milestone.php
http://www.tata.com/businesses/sectors/index.aspx?sectid=aZ72
PXPwpaI=#Informationsystemsandcommunications
(Tata
Group of Companies)
http://www.exampleessays.com/viewpaper/17379.htm (1800 1st
automobile)

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