TATA MOTORS LTD.

PROJECTS

1. METHODS FOR ANALYSIS AND EVALUATION OF QUALITY

2. IMPLEMENTATION OF INTEGRATED MANAGEMENT SYSTEM

3. RESEARCH AND STUDY ON WORLD WIDE RECALLS & UPDATION OF THE SAME IN COMPANY’s CHECKSHEET.

4. DETAILED ANALYSIS AND THESIS ON CRANKSHAFT MANUFACTURING PROCESSES

EXECUTIVE SUMMARY

Submitted by-

ANKIT SHAH

MBA (tech) MANUFACTURING

Roll no.-317

Class of 2013

EXECUTIVE SUMMARY

INTRODUCTION

Tata Motors is India’s largest automobile company with consolidated revenues of USD

20 billion in 2009-10. It is the leader in commercial vehicles in each segment, and

among the top three in passenger vehicles with winning products in the compact,

midsize car and utility vehicle segments. The company is the world’s fourth largest truck

manufacturer, and the world’s second largest bus manufacturer.

Established in 1945, Tata Motors' presence indeed cuts across the length and breadth

of India. Close to 4 million Tata vehicles ply on Indian roads, since the first rolled out in

1954. The company's manufacturing base is spread across Jamshedpur, Pune

Lucknow and Ahmedabad, supported by a nation-wide dealership, sales, services and

spare parts network comprising over 1200 touchpoints.

The company's 22,000 employees are guided by the vision to be best in the manner in

which we operate, best in the products we deliver, and best in our value system and

ethics.

At the core of the company’s approach to doing business is the Tata Business Excellence Model. Incorporating sound business principles, like customer satisfaction,quality, attention to detail, conservation of resources and protection of the environment,this model shapes the way Tata Motors designs, manufactures and markets its products.

TATA NANO

Tata motors brought a revolutionary change in an automobile industry by launching the

worlds cheapest car “Tata Nano”. It was a triumph of homegrown engineering; the Nano

encapsulates the dream of millions of Indians groping for a shot at urban prosperity.

Seeing an opportunity in the great number of Indian families with two-wheeled rather

than four-wheeled vehicles, Tata Motors began development of an affordable car in

2003. The purchase price of this no frills auto was brought down by dispensing with

most nonessential features, reducing the amount of steel used in its construction, and

relying on low-cost Indian labor.

After 4 years of research and development Nano was launched at an astonishing price

of just one lakh rupees.

AWARDS

2010 Bloomberg UTV-Autocar car of the year

2010 Business Standard Motoring Indian car of the year

2010 Edison Awards, first place in the transportation category

2010 Good Design Awards, in the category of transportation

PROJECT DETAILS

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PROJECT 1 - METHODS FOR ANALYSIS AND EVALUATION OF QUALITY

Methods for analysis and evaluation of quality includes following tools.

Process flow diagram (PFD) Failure Mode Effect Analysis (FMEA) Control plan Work instruction sheet

These tools are used in the industry for maintain the quality and smooth run of the industry. The objective is to assure quality and minimize the defects so that the production can run smoothly and targets can be achieved with maximum FSO and more production in less period of time with best quality.

These tools ensure the proper flow of work also checks for the failures that may occur or lead to the defect in the car giving the solution to eliminate them and providing in hand guide for the workers working on line. As mentioned below,

A Process Flow Diagram (PFD) is a diagram commonly used in engineering to indicate the general flow of plant processes and equipment. The PFD displays the relationship between major equipment of a plant facility and describes the sequence in which the operations are taking place.

A Failure Modes and Effects Analysis (FMEA) is a procedure in product development and operations management for analysis of potential failure modes. FMEA activity helps a team to identify potential failure modes based on past experience with similar products or processes, enabling the team to design those failures out of the system with the minimum of effort and resource expenditure, thereby reducing development time and costs.

A Process Control Plan (CP) is a summary of defect prevention and reactive detection techniques. The overall intent of the PCP is to control the product characteristics and stability of the product over time. PCP assures a system is in place to control the risks of the same failure modes as identified in the FMEA.

A Work Instruction sheet (WIS) provides a detailed breakdown of instructions required to carry out one or more steps or tasks in a procedure. Work Instructions are usually the accomplishment of best practices by a team and are retained in the department or unit where the work is performed.

PROJECT 2 - IMPLEMENTATION OF INTEGRATED MANAGEMENT SYSTEM

An integrated management system is a management system that integrates all of an organization's systems and processes in to one complete framework, enabling an organization to work as a single unit with unified objectives. With an integrated system, your organization becomes a unified whole, with each function aligned behind a single goal: improving the performance of the entire organization.

From managing employee’s needs, to monitoring competitors' activities, from encouraging best practice to minimizing risks and maximizing resources, an integrated approach can help an organization achieve their objectives.

Tata Motors Ltd Ahmedabad aimed for IMS certification by Bureau Veritas Certification body so that it can can export Nano and grow its business in various other countries. IMS also provide linkages between various systems working in the plant to produce Nano and thus, helps to make the system stronger. After the certification it is equally important to sustain the system through continual improvement program to get maintain the quality of the product. IMS requires documentation of every process and part of the product “Nano” and records of all the changes/improvement done in the product or process. Thus, for the certification we had to integrate all the documents across the plant and make a one system.

Tata Motors Ltd, Ahmedabad has opted for combination of 3 standards which include:-

ISO/TS 16949:2009 - Quality Management System

ISO 140001:2004 - Environment Management System

OHSAS 18001:2007 - Occupational Health & Safety Assessment Series

PROJECT 3 - RESEARCH AND STUDY ON WORLD WIDE RECALLS & UPDATION OF THE SAME IN COMPANY’s CHECKSHEET.

This project was done with the objective of learning from the recalls taken by different automobile companies all over the world.

The vision was to learn from others mistakes and make sure that the required precautions are taken by adding the checkpoint on line so that the same mistakes are not repeated again.

The recall study included the study of leading automobile companies like toyota, nissan, ford, general motors, honda, hyundai, BMW, mercedes, etc

This information was further utilised for making a checksheet which included the similar reasons which the nano could possibly face in future and as a pro active measure these were updated in the companies checksheet.

This would help as a worldwide data source for the awareness of the employees and give them a worldwide view of what is going around and what all problem have already been faced by the other companies and henceforth making it adaptable in the system itself so that same problems do not arise and if they do, atleast they would be prepared in solving the problem. Also the information can be passed on to the suppliers about the faulty components which are being outsourced so that they can be made awared what all problems has been occurred with that part in the past.

PROJECT 4 - DETAILED ANALYSIS AND THESIS ON CRANKSHAFT MANUFACTURING PROCESSES

A detailed thesis was carried out on the manufacturing process of crankshaft. It includes the study of material used in manufacturing,

Crankshaft being the most important part of the engine and also has to go under high tensile stresses, utmost care must be taken of its quality and the material composition that is being used so various tests are done at tata motors to verify its quality i.e. the metallurgical and metrological tests and further the steps of machining done on forged part to get the final product.

A crankshaft is the part of an engine which translates reciprocating linear piston motion into rotation. The shaft is one solid piece made from cast iron or forged steel. Steel is usually used in high loading situations, such as diesel or turbocharged engines. Oil passages are either cast or drilled into the crankshaft to distribute lubricant to the main and rod journals. There are 6 necessary components to a crankshaft: main journals, rod journals, counterweights, snout, flange & harmonic balancer.

This project was carried out in order to keep in hand data of all the procedures that are being carried out at tata motors. This can help to have a handy material for the auditors to check up whether everything is carried out in order or not and also to see if the procedure is updated with the wordwide standards carried out in industries.

In the three months of training at Tata Motors Ltd, Ahmedabad, I have learnt

many lessons about how an industry works, lessons which will be invaluable for me throughout my career and life. Training at Tata Motors has given me a great opportunity to learn not only how an automotive company works, but also the ways and methods of work which is carried out. It gave me the insight to look at many problems in different ways & helped me improve in handling them. After the completion of the training, I felt that it has helped me understand the practicalities an engineer has to face.