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Report on
Material Feeding System
This is to certify that the project titled “Material Feeding System in Assembly
Shop-1C” is a record of the bonafide work done by Mr. Puneet Kakkar submitted
in partial fulfillment of the requirement for the degree of B. Tech (ME) during
academic year 2018-2019. During the industrial training done at TATA
MOTORS Ltd., Pantnagar, this is the original work carried out by the student
under my supervision and this work is found satisfactory.
SIGNATURE SIGNATURE
UDAY PRATAP YADAV BRIJLAL ARORA
(MANAGER), TCF-1C (HR)
TATA MOTORS LIMITED TATA MOTORS LIMITED
PANTNAGAR PANTNAGAR
Acknowledgement
Every project big or small is successful largely due to the effort of a number of
wonderful people who have always given their valuable advice or lent a helping
hand. I sincerely appreciate the inspiration, support and guidance of all those
people who have been instrumental in making this project a success.
Last but not the least, I place a deep sense of gratitude to my fellow trainees
who gave me insights into the working of all the departments in the plant and
therefore helped me better understand the ways of the company.
Contents
Bonafide Certificate
Acknowledgement
History
Pantnagar Plant
Department Profile
Inventory Management
Conclusion
About the Company
Tata Group
Tata Group is an Indian multinational conglomerate holding
company headquartered in Mumbai, Maharashtra, India. Founded in 1868
by Jamshedji Tata, the company gained international recognition after
purchasing several global companies, beginning with Tetley in 2000, recorded
as "the biggest acquisition in Indian corporate history. One of India's largest
conglomerates, Tata Group is owned by Tata Sons, a registered charity.
Each Tata company operates independently under the guidance and supervision
of its own board of directors and shareholders. There are 29 publicly listed Tata
enterprises with a combined market capitalisation of about $151.62 billion as of
March 1, 2018. Significant Tata companies and subsidiaries include Tata
Steel, Tata Motors including Jaguar Land Rover, Tata Consultancy Services, Tata
Power, Tata Chemicals, Tata Global Beverages, Tata Coffee, Tata Swach, Tata
Teleservices, Titan, Tata Communications, and The Indian Hotels Company
Limited (Taj Hotels)
After years of dominating the commercial vehicle market in India, Tata Motors
entered the passenger vehicle market in 1991 by launching the Tata Sierra, a
multi utility vehicle, becoming the first Indian manufacturer to achieve the
capability of developing a competitive indigenous automobile. In 1998, Tata
launched the first fully indigenous Indian passenger car, the Indica, and in 2008
launched the Tata Nano, the world's cheapest car. Tata Motors acquired the
South Korean truck manufacturer Daewoo Commercial Vehicles Company in
2004 and purchased Jaguar Land Rover from Ford in 2008.
The Tata Motors' plant at Pantnagar is the site where the best-selling Tata Ace -
the mini one-tonne truck, and its variants are manufactured. The plant is a
world-class project that is spread across 1,000 acres in Uttarakhand's State
Industrial Development Corporation.
The Pantnagar plant has been built with state-of-the-art facilities and is a key
enabler of Tata Motors' leadership in the mini-truck segment. It also produces a
few SUV models as well as medium and heavy vehicles.
The plant has been designed to enhance speed and efficiency in manufacturing.
It is the company's first plant with an integrated vendor park, which occupies
337 acres of the plant's total area. This helps keep inventory low and ensures
'just-in-time' (JIT) supplies. The 73 vendors based here account for nearly 75
percent of the items supplied to the plant.
2. WELD SHOP –Weld shop is also known as BIW Shop (BODY IN WHITE).Here
different parts are welded together and the whole structure of the car is built including
the chassis frame. This shop plays critical role in maintaining the dimensional accuracy
which would otherwise lead to major assembly-line problems and major downtimes in
their correction. It is divided into 5 sections namely, BIW 1A, 1B, 1C, 1D, 1E.
3. PAINT SHOP – The TAIKISHA paint shop is the beauty parlors of the car plant.
This shop paints the car in various shades. This is the most sophisticated shop of the
plant. It uses world class technology for painting the vehicles. The most interesting
point of this shop is that all vehicles, no matter which type, are all painted under the
same shop together. Thus the paint shop has to work 4 times faster than the TCF, so
that body reaches each of the assembly shops. It takes 18 steps spread over less than 10
hours to accomplish the task. Tata Motors Pantnagar boasts to have the biggest
atomized Paint shop in whole of Asia.
4. POWER TRAIN SHOP – This shop is divided into Gear Train and Engine shop.
This shop takes care of the assembly of the engine and the assembly of the gear box.
The engine and the gear box are assembled separately but are coupled at the end of the
line. Various testing related to engine performance and qualities are checked here. The
final product of this shop is engine and transmission subassembly which is supplied to
the assembly shop.
Product introduced from Pantnagar Plant
TCF SHOP
(Trim Chassis Fitment)
The car delivered by the TCF shop is completely checked with reference to
product’s 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.
TCF -1C
(Simplified Layout of TCF-1C)
Sub- Assembly
Toilet
Rear Axle
Bumper Sub-
Tire
fitment
fitment
cooler -7 Assembly
Front Panel
Assembly
Assembly
assembly
Area
Kitting-4
Assembly
Silencer
Smoke
Wheel
Test
Alignment Roller &
Test Brake test
War
Water
cooler
Rejection area
office
Mechanical
Room
assembly
gear box
Steering
Point
Trolley
parts
Goals
The goal of materials management is to provide an unbroken chain of
components for production to manufacture goods on time for the
customer base.
The materials department is charged with releasing materials to a
supply base, ensuring that the materials are delivered on time to the
company using the correct carrier.
Materials is generally measured by accomplishing on time delivery to
the customer, on time delivery from the supply base, attaining a
freight, budget, inventory shrink management, and inventory
accuracy.
The materials department is also charged with the responsibility of
managing new launches.
Standards
Tata motors limited use ERP systems such as SAP systems to manage
materials control.
TML sees the importance level as managing at the plant level by
hiring an inventory manager or materials manager, and also employ
the concept that the supervisors in the plant are responsible
accompanied by a planners.
2. Purchasing:
Purchasing department is authorized to make buying arrangements on the
basis of requisitions issued by other departments. This department keeps
contracts with suppliers and collects quotations etc. at regular intervals. The
effort by this department is to purchase proper quality goods at reasonable
prices. Purchasing is a managerial activity that goes beyond the simple act of
buying and includes the planning and policy activities covering a wide range
of related and complementary activities.
3. Non-Production Stores:
Non-production materials like office supplies, perishable tools and
maintenance, repair and operating supplies are maintained as per the needs of
the business. These stores may not be required daily but their availability in
stores is essential. The non-availability of such stores may lead to stoppage
of work.
4. Transportation:
The transporting of materials from suppliers is an important function of
materials management. The traffic department is responsible for arranging
transportation service. The vehicles may be purchased for the business or
these may be chartered from outside. It all depends upon the quantity and
frequency of buying materials. The purpose is to arrange cheap and quick
transport facilities for incoming materials.
5. Materials Handling:
It is concerned with the movement of materials within a manufacturing
establishment and the cost of handling materials is kept under control. It is
also seen that there are no wastages or losses of materials during their
movement. Special equipment’s may be acquired for material handling.
6. Receiving:
The receiving department is responsible for the unloading of materials,
counting the units, determining their quality and sending them to stores etc.
The purchasing department is also informed about the receipt of various
materials.
Material Management Workflow
A workflow diagram (also known as a workflow) provides a graphic overview
of the business process. Using standardized symbols and shapes, the workflow
shows step by step how your work is completed from start to finish. It also
shows who is responsible for work at what point in the process. Designing a
workflow involves first conducting a thorough workflow analysis, which can
expose potential weaknesses. A workflow analysis can help you define,
standardize and identify critical areas of your process.
Workflows are also useful to help employees understand their roles and the
order in which work is completed, and to create more unity within different
departments. Originating from the manufacturing industry, workflows are now
used by a variety of industries—from government to finance to commerce—and
are easier than ever to create.
SAP Based Supply Chain Management
1. Material Stock list- This is basically a list of parts required for production of
a vehicle. It includes opening stock of each day, stock available, minimum
stock, maximum stock etc. This list is then sent to the Pre-delivery Inspection
(PDI) Department where they analyse the list and place orders to the vendor.
The management of the inventory in the supply chain involves managing the
physical quantities as well as the costing of the goods as it flows through the
supply chain.
In managing the cost prices of the goods throughout the supply chain, several
costing methods are employed:
1. Retail method
2. Weighted Average Price method
3. FIFO (First In First Out) method
4. LIFO (Last In First Out) method
5. LPP (Last Purchase Price) method
6. BNM (Bottle neck method)
Under the FIFO method, the earliest goods purchased are the first ones
removed from the inventory account. This results in the remaining items in
inventory being accounted for at the most recently incurred costs, so that the
inventory asset recorded on the balance sheet contains costs quite close to
the most recent costs that could be obtained in the marketplace. Conversely,
this method also results in older historical costs being matched against
current revenues and recorded in the cost of goods sold; this means that
the gross margin does not necessarily reflect a proper matching of revenues
and costs.
FIFO at Tata motors, Pantnagar
Material Feeding System
Materials feeding mainly concern what principle to use for feeding the materials
to a workstation or an assembly line. Johansson (1991) describe and analyses
three different principles of feeding materials to an assembly station, namely
continuously, Sequential Supply, and kitting.
Applications:
Forecasting
Resource allocation
Production planning
Flow and process management
Inventory management and control
Customer delivery
After-sales support and service
Aims:
Improve customer service
Reduce inventory
Shorten delivery time
Lower overall handling costs in manufacturing, distribution and
transportation.
In-house Supplier
Sequencing Sequencing
Kitting System
Kitting is the gathering of components and parts needed for the manufacture of
a particular assembly or product. Individual components are gathered together,
as a kit, and issued to the point of use.
The practice of feeding components and subassemblies to the assembly line in
predetermined quantities that are placed together in specific containers is known
as kitting in the industry.
Steps Involved:
The production team, often in conjunction with the manufacturing leads,
define the kit of parts. These are often runner repeater parts that would
currently take up substantial processing time.
Stock will be reviewed and where shortages exist purchase orders
raised.
A method for the issuing of the kit is defined.
In line with the requirement generated by ERP the stores team will pick
parts and load a trolley with the kit of parts and issue for use.
Advantages of Kitting:
Types of Kitting
Stationary Travelling
Kitting Locations
Centralised Decentralised
Picking store Picking store
KITTING PROCESS FLOW CHART
Start
Park completed
trolley in parking
area.
End
IT enabled Kitting (Pick to Light)
Display Screen in the kitting area with Scan-enabled ASN sticker printed
Information about model number, model from kitting machine
name and ASN of the vehicle
Individual items are organized and stored individually in totes, bins or sub-
divided trays and stored within an automated storage and retrieval system.
For maximum picking efficiency, the system’s internal Power Pick Global
inventory management software automatically stores items for the same kit
close together.
When it is time to assemble the items into specific kits, the operator uses the
automated storage and retrieval system as an order picking system, batch
picking multiple kits into totes located on a conveyor or batch station.
After the operator assembles the kits from the selected parts, the completed
kits can be re-stored in the same storage device using a unique part number
or transferred to another zone.
When kits are needed, an operator accesses the storage location and
retrieves the kit(s) and routes them to the next destination (assembly line,
order consolidation, packing, etc.) quickly and easily using AGVs.
Employment of Automated
guided Vehicle (AGV) to
deliver Kit
Fast and efficient system for storage and picking of parts and kits
Eliminates operator travel time
Limited access ensures security of contents
Uses 1/3 the energy of mini-loads and multi-shuttle systems
Kits are delivered in sequence to the assembly area to support just-in-time
manufacturing
Two- Bin System
Two-bin inventory control is an inventory control system used to determine
when items or materials used in production should be replenished. The two-bin
inventory control method is mainly used for small or low-value items. For
example, when items in the first bin (working stock) have been depleted, an
order is placed to refill or replace these items. The second bin is supposed to
have enough items to last until the placed order arrives. The first bin has a
minimum of working stock and the second bin keeps reserve stock or remaining
material. Bin cards and store ledger cards are used to record the inventory.
The two-bin inventory control system is used for quantity control of material to
help minimize costs on the production floor. Small or low-value items are
mainly part of a two-bin inventory control system, as opposed to higher value
items subject to the perpetual inventory system. Depending on historical
patterns of variance in the depletion rate of the working stock (bin no. 1), the
amount ordered for the reserve stock (bin no. 2) can be adjusted. The two-bin
inventory control system is broadly employed across different industries
with manufacturing operations. The system is also effective for hospital
inventory control.
Proposed Improvements:
1. Colour Coding - Use different coloured bins for different areas of your site.
For example, if there are 5 screws that look the same but are very different, put
each type in a different coloured bin for easy identification. Colour code critical
or fast moving parts, yellow for slower and green for slowest.
The main motivation for sequential supply is the fact that if the product is
assembled on a serial line where only a few components are assembled at each
station, kitting is less advantageous since it will require a lot of extra materials
handling to prepare different kits for each station. The sequencing process can
be located within or outside the assembly plant which means that the
materials feeding principle can differ between the assembly station and the
supply chain.
1. The sequencing reduces the inventory levels since only selected articles
sorted by assembly object is displayed hence increasing the control and limiting
the articles exposed to theft, damage etc.
Steps Involved:
Generation of
Assembly Sequence
number (ASN)
Communication of
generated ASN to
kitting area and
Supplier
3.
2.
4.
Sequential Supply
In house sequencing
2. Fuel Tank
3. Brake Booster
4. Radiator 5. Dashboard
Note: Other in-house sequenced parts include- FCM, Door Trim, Head
liner, ORVM, Cross-member
4. Front Panel
Seat
5. Bumper
Seat
It has helped me to remove the gap between the theoretical and practical
knowledge, and to have a better understanding of the stages involved in
assembling processes of an automobile.
Fortunately I was given Basic problem solving project associated with Material
feeding system to assembly along with sequential supply in the vehicle. I’ve
tried my level best to successfully apply my engineering knowledge to suggest
some improvement in this project.
Overall this internship in the Tata Motor has been the most interesting
experience of my life so far.
.