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INDUSTRIAL TRAINING WORK REPORT

Submitted in Partial Fulfillment of The Requirement for The award of Degree

Of

Bachelor of Technology

in

MECHANICAL ENGINEERING

Submitted By

PRATEEK KOUL

(University Reg.No: 12-GGCEG-0091)

An ISO 9001:2008 Certified Institution

Approved by AICTE, New Delhi & Affiliated to M.D.University, Rohtak

Mechanical ENGINEERING DEPARTMENT

GURGAON COLLEGE OF ENGINEERING

GURGAON-122413

JUNE 2016

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Mechanical ENGINEERING DEPARTMENT

GURGAON COLLEGE OF ENGINEERING

CANDIDATE‘S DECLARATION

I hereby certify that the work which is being presented in the Project report entitled

Introduction of SIGNA Cabs on PRIMA TRIM LINE in partial fulfillment of the

requirements for the award of Bachelor of Technology in Mechanical Engineering, and

submitted in Mechanical ENGINEERING DEPARTMENT, GURGAON COLLEGE OF

ENGINEERING. Maharishi Dayanand University, Rohtak is an authentic record of Project

of my own work carried out during a period from 30/01/2016 to 07/05/2016 under the

supervision of Mr. ABHISHEK DEEP, Senior Manager, Prima Trim Line (Cab & Cowl

Factory) Tata Motors Jamshedpur Ltd.

The matter presented in this report has not been submitted by me for the award of any

other degree/diploma of this or any other Institute.

(PRATEEK KOUL)

This is to certify that the above statement made by the candidate is correct to the best of

our knowledge.

Signature of Senior Manager Signature of Head, Mech

Engg.

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PROJECT REPORT ON

Introduction of SIGNA Cabins in

Prima Trim Line

Page | 4

AIM OF THE PROJECT

Introduction of SIGNA Cabins in Prima Trim Line

DELIVERABLES:

1. Creation of Process Flow Diagram (PFD)

2. SIGNA Process Mapping with Prima in Prima trim line

3. Line Balancing and identifying bottleneck

Stations / processes

4. Time Study

5. Work Instruction Sheet (WIS)

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INDEX

I. PREFACE 4

II. CERTIFICATION 5

III. ACKNOWLEDGEMENT 6

IV. PROFILE 7-10

V. TATA SIGNA RANGE

VI. DEPARTMENT ASSIGNED 14

VII. DELIVERABLES

Creation of Process Flow Diagram (PFD)

SIGNA Process Mapping with Prima in Prima trim line

Line Balancing and identifying bottleneck

Stations / processes

Time Study

Work Instruction Sheet (WIS)

VIII. CONCLUSION

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PREFACE The Project titled ’Introduction of Signa in the Prima Trim Line’ had been ideated by my project guide, Mr. Hrushikesh Thodge. The project, due to its relevance to the ongoing works of the Prima Trim Line and the overall vision of Tata Motors Ltd. is a motivation in itself. The project involved challenging practical assignments as well as careful thought processes to make it a reality. The project report describes the time study of the operations in the Prima Trim Line, World Truck Factory and finding out the bottlenecks of the Trim Line. As part of introduction of Signa, the project report describes the Operation Mapping of the Prima and Signa cabs, Process Mapping for Prima Cabs as well as Process Mapping for Signa Cabs. The Project Report is intended to acquaint the reader with various operations and processes of the Prima Trim Line as well as the steps that should be necessarily followed for the implementation of a new project on an already existing facility. The project and hence the project report has been an experience in itself.

There is no suggestion as to how the reader should approach this report. The reader is just advised to go through the topics as they appear in the report and have an analytical approach towards the assessment of the same.

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CERTIFICATION This is to certify that Mr. Prateek Koul has successfully completed the project work titled ‘Introduction of Signa in the Prima Trim Line’ in fulfillment of requirement for the award of B. Tech Degree in Mechanical Engineering prescribed by Gurgaon College of Engineering.

The project is the record of authentic work carried out during

the months of January and May, 2016.

Abhishek Deep

Senior MANAGER

PRIMA TRIM LINE, WORLD TRUCK FACTORY

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ACKNOWLEDGEMENT

To start a project from scratch and realize it requires the support and contribution

of many people, without whom the project would be incomplete.

Many people have played a pivotal role in the completion of the project titled

‘Introduction of SIGNA in the Prima Trim Line’.

Firstly, I take this opportunity to express my profound gratitude and deep regards

towards my principal guide, Mr. Hrushikesh M. Thodge, Assistant Manager Mr.

Prochet Sarkar, Assistant Manager, World Truck Trim Line, for his exemplary

guidance, monitoring and constant encouragement in completion of this project

report.

I am equally thankful to Mr. Abhishek Deep, Senior Manager, World Truck Trim

Line and Mr.Rakesh Kumar, Line Head, Prima Trim Line for providing me with

an opportunity to work on this project.

I am also obliged to the staff and members of the Prima Trim Line, World Truck

Factory (Jamshedpur Works, Tata Motors Ltd.) for the valuable information

provided by them in their respective fields. I am grateful for their cooperation

during the period of my assignment.

Lastly, I thank my parents for their encouragement without which this assignment

would not have been possible.

PRATEEK KOUL

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PROFILE

Tata Motors Limited is India's largest automobile company, with revenues of

INR 2,62,796 crores (USD 42.04 billion) in 2014-15. It is the leader in commercial

vehicles in each segment, and the third largest in the passenger vehicles market

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.

The company's 60,000 employees are guided by the vision to be "Most admired

by our customers, employees, business partners & shareholders for the

experience and value they enjoy from being with us."

From Left Jamshedji Nusserwanji Tata, Dorabji Tata, Ratanji Tata(standing back), Naval Tata

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

breadth of India. Tata Motors is a part of the Tata and Sons Group, founded

by Jamshetji Tata and J. Baker. The company was established in 1945 as a

locomotive manufacturing unit and later expanded its operations to commercial

vehicle sector in 1954 after forming a joint venture with Daimler-Benz AG of

Germany. Over 4 million Tata vehicles ply on Indian roads, since the first rolled

out in 1954. The company's manufacturing base in India is spread across

Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh) and

Pantnagar (Uttarakhand).

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Following a strategic alliance with Fiat in 2005, it has set up an industrial joint

venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce

both Fiat and Tata cars and Fiat power trains. The company is establishing two

new plants at Dharwad (Karnataka) and Sanand (Gujarat). The nation-wide

dealership, sales, services and spare parts network comprises over 3500 touch

points; Tata Motors also distributes and markets Fiat branded cars in India.

Tata Motors, the first company from India's engineering sector to be listed in the

New York Stock Exchange (September 2004), has also emerged as an

international automobile company. In 2004, it acquired the Daewoo Commercial

Vehicles Company, South Korea's second largest truck maker. The rechristened

Tata Daewoo Commercial Vehicles Company has launched several new

products in the Korean market, while also exporting these products to several

international markets. Today two-thirds of heavy commercial vehicle exports

out of South Korea are from Tata Daewoo. In 2005, Tata Motors acquired a 21%

stake in Hispano Carrocera, a reputed Spanish bus and coach manufacturer, with

an option to acquire the remaining stake as well. Hispano's presence is being

7expanded in other markets. In 2006, it formed a joint venture with the Brazil-

based Marco polo, a global leader in body-building for buses and coaches to

manufacture fully-built buses and coaches for India and select international

markets. In 2006, Tata Motors entered into joint venture with Thonburi

Automotive Assembly Plant Company of Thailand to manufacture and market

the company's pickup vehicles in Thailand. The new plant of Tata Motors

(Thailand) has begun production of the Xenon pickup, with the Xenon having

been launched in Thailand at the Bangkok Motor Show 2008.

Tata Motors' is also its international footprint, established through exports since

1961. The company's commercial and passenger vehicles are already being

marketed in several countries in Europe, Africa, the Middle East, South East

Asia, South Asia and South America. It has franchisee/joint venture assembly

operations in Malaysia, Kenya, Bangladesh, Ukraine, Russia and Senegal.

The foundation of the company's growth over the last 50 years is a deep

understanding of economic stimuli and customer needs, and the ability to

translate them into customer-desired offerings through leading edge R&D.

With over 1,400 engineers and scientists, the company's Engineering Research

Centre, established in 1966, has enabled pioneering technologies and products.

The company today has R&D centers in Pune, Jamshedpur, Lucknow, in India,

and in South Korea, Spain, and the UK.

It was Tata Motors, which developed the first indigenously developed Light

Commercial Vehicle, India's first Sports Utility Vehicle and, in 1998, the Tata

Indica, India's first fully indigenous passenger car. Within two years of launch,

Tata Indica became India's largest selling car in its segment. In 2005, Tata

Page | 11

Motors created a new segment by launching the Tata Ace, India's first

indigenously developed mini-truck .

In January 2008, Tata Motors unveiled its People's Car, the Tata Nano, which

India and the world have been looking forward to. A development, which

signifies a first for the global automobile industry, the Nano brings the comfort

and safety of a car within the reach of thousands of families. When launched in

India later in 2008, the car will be available in both standard and deluxe

versions. The standard version has been priced at Rs.100, 000 (excluding VAT

and transportation cost).

Designed with a family in mind, it has a roomy passenger compartment with

generous leg space and head room. It can comfortably seat four persons. Its

mono-volume design will set a new benchmark among small cars. Its safety

performance exceeds regulatory requirements in India. Its tailpipe emission

performance too exceeds regulatory requirements. In terms of overall pollutants,

it has a lower pollution level than two-wheelers being manufactured in India

today. The lean design strategy has helped minimize weight, which helps

maximize performance per unit of energy consumed and delivers high fuel

efficiency. The high fuel efficiency also ensures that the car has low carbon

dioxide emissions, thereby providing the twin benefits of an affordable

transportation solution with a low carbon footprint.

In June 2009, the exciting new range of premium luxury vehicles from Jaguar

and Land Rover were introduced for the Indian market. These include the Jaguar

XF, XFR and XKR and Land Rover Discovery 3, Range Rover Sport and Range

Rover.

Tata Motors is equally focused on environment-friendly technologies in

emissions and alternative fuels. . It has developed electric and hybrid vehicles

both for personal and public transportation. It has also been implementing

several environment-friendly technologies in manufacturing processes,

significantly enhancing resource conservation .

The years to come will see the introduction of several other innovative vehicles,

all rooted in emerging customer needs. Besides product development, R&D is

also focusing on environment-friendly technologies in emissions and alternative

fuels.

Through its subsidiaries, the company is engaged in engineering and automotive

solutions, construction equipment manufacturing, automotive vehicle

components manufacturing and supply chain activities, machine tools and

factory automation solutions, high-precision tooling and plastic and electronic

components for automotive and computer applications, and automotive retailing

and service operations.

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TATA MOTORS (JAMSHEDPUR PLANT)

With 603 acres for Tata Motors’ Jamshedpur’s manufacturing, engineering and

support services, Tata Motors has a township made up of 1250 acres, housing a

residential quarters, hospitals and schools. While making technological, product and

service advancements, the plant has been deeply committed to the community within

which it operates. Working closely with various NGOs, it has pioneered initiatives in

Health, Education, Livelihood and Environment. These initiatives have resulted in

significant progress in community and social forestry, sustainable development of

wastelands, road construction, rural health and education, development of rural

industries, water supply and family planning.

The plant manufactures Tata Motors’ entire range of medium and heavy commercial

vehicles (M&HCV), including the Tata Prima, both for civilian and defense

applications.

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With the plant manufacturing over 200 truck variants, ranging from multi-axle trucks,

tractor-trailers, tippers, mixers and special application vehicles, the Jamshedpur

facility has led the company’s evolution into a manufacturer of global repute. Besides

India, these vehicles are sold in South Africa, Russia, Myanmar, the SAARC region

and the Middle East.

The Jamshedpur facility was Tata Motors’ first, set up in 1945, to manufacture steam

locomotives. It led the company’s foray into commercial vehicles in 1954. It has been

modernized through the decades, with a particularly intense scale in the last 10 years.

World-class facility equipped with:

State-of-the-art equipment and assembly lines to produce a truck every five

minutes.

Over 200 models, ranging from multi-axle trucks, tractor-trailers, tippers,

mixers and special application vehicles, catering to civilian and defence

requirements.

3D visualization of new models.

Engine assembly shop, capable of supplying upto 200 engines per day.

Modern testing facilities.

The company has over 130 models of light, medium and heavy commercial

vehicles ranging from two tonnes to forty tonnes, buses ranging from 12-seaters

to 60-seaters, tippers, special purpose vehicles, off-road vehicles and defense

vehicles.

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PRIMA TRIM LINE

Prima Trim Line is the department where all the cabins after getting

welded and painted at Fabrication factory and Central Paint Shop

respectively, is brought for the essential fitments. Fitments like

Dashboard, Windscreen glass, mirror, seats ECU panels, door add-ons

etc. As PRIMA is a very high range truck product, defects in smallest

form will not be accepted in the before delivery inside the company.

The Prima Trim Line has 16 stations which can be expanded into 30

stations for future expansions but currently it meets the needs for the

production requirements. All the outer and inner fitments are carried

out in the first 15 stations where at their respective stations operators

carry out their process. The Cabins are fitted on dies or pegs which are

fixed on the moving conveyors. The parts which have to be fitted under

the cabin are done in another station which is separated from the main

line. This station is called the Under Body Station. Here the die is at

more height than the usual dies or pegs in the main line. This is done so

that the operators have ease in fitting parts under the cabin. The cabin is

lifted from the main line with the help of a machine, cab lifter and then

its dropped at Under Body (UB) station.

Page | 15

There are 4 sub assembly stations where the parts are assembled first

and then fed into the line for its fitment on cabin. Some essential

machines are also used in this line which are the Glass Glazing Robot,

Dashboard manipulator and the seat manipulators. Manipulators are

machines that are used to lift parts and insert them in cabin. Glass

Glazing Robot is an automatic robot made by KUKA Corporation to

add adhesive and seal on the perimeter of Wind Screen Glass.

The fitments of these parts are done at stations where these machines

are located or are closest.

The total manpower in the line including the sub assembly is 120. The

distribution is done using the Process Flow Diagram, Process mapping

and the Load Balancing. The details of all the fitments of PRIMA

cabins with manpower is given below.

Page | 16

Tata SIGNA Range

SIGNA Range Highlights:

Launch of a new SIGNA range of Medium & Heavy Commercial Vehicles,

offering trucking solutions from haulage to construction segments

Aerodynamic front fascia signature design

A large cabin accommodating improved ergonomics, NVH levels for superior

in-cab experience

Large Windscreen for good all-round visibility & road view for more safety

In-built telematics system – Tata FleetMan

Proven and reliable drive

Page | 17

Tata Motors launched its new range of Medium and Heavy Commercial

Vehicles – the new TATA SIGNA, at Auto Expo 2016. With the new Tata

SIGNA range, Tata Motors will bring modern trucking mainstream, addressing

emerging needs for a safe, comfortable and connected commercial vehicle

experience.

With its smartly designed cabin space, improved ergonomics and NVH levels,

the TATA SIGNA range of cabins are built to offer a superior in-cab experience,

enabling drivers to operate fatigue free over long hauls, which in turn offers

significant improvement in productivity. With an inbuilt telematics system, by

TATA FLEETMAN, the new TATA SIGNA empowers fleet operator with a

more connected experience, to better manage their transport business through

optimum driver, vehicle and fuel management.

The new range will continue to retain Tata Motors largest selling, proven and

reliable driveline, which along with Tata Motors service support will offer best

business return to customers.

Ideal for customers who want to upgrade to better in- cab experience, connected

vehicle and proven and reliable aggregates, the SIGNA range will be offered as

Tractor-trailer, Multi-axle truck and Tippers, with the products on display being

the SIGNA 4923.S, SIGNA 3118.T and SIGNA 2518.K .

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Following is a descriptor of the products on display –

The Tata SIGNA 4923.S is a tractor offering from Tata Motors new SIGNA

range of commercial vehicles. With Gross Combination Weight (GCW) of

49000 Kg when coupled with suitable trailers, the Tata SIGNA 4923.S proven

and reliable Cummins ISBe 5.9 Common Rail engine, delivers power of 230 PS

and a torque of 850Nm, with best-in-class Fuel Efficiency and is based on a

proven

power train and aggregates, like the G1150 Gearbox and RA109SRT rear axle.

The Tata SIGNA 4923.S empowers customers with the lowest Total Cost of

Ownership and is offered with multiple fully-built load body options, makes the

vehicle a preferred choice for transporters for various applications.

Page | 19

The Tata SIGNA 3118.T is an MAV truck from Tata Motors new SIGNA

range of commercial vehicles. It is the first MAV Truck in India, with a unique

feature of a Lift Axle, for the flexibility to disengage the vehicles fifth axle in

case of less load, resulting into better fuel efficiency. With a Gross Vehicle

Weight

(GVW) of 31 ton, the Tata SIGNA 3118.T is powered by a world-class Tata

Cummins B5.9 L– 6 cylinder engine, with an optimum combination of 180 PS

and flat torque of 675 Nm at lowest rpm range, delivering best-in-class fuel

efficiency and highest engine life. The lowest Total Cost of Ownership (TCO) of

a commercial vehicle, coupled with a strong and sturdy chassis and vehicle

aggregates make the Tata SIGNA 3118.T, most suitable for all applications.

Page | 20

The Tata SIGNA 2518.K is a Construction and Mining offering from Tata

Motors new SIGNA range of commercial vehicles. With a Gross Vehicle

Weight (GVW) of 25 ton, the Tata SIGNA 2518.K is powered by a world-class

Tata Cummins B5.9 L– 6 cylinder engine, with an optimum combination of

180 PS and flat torque of 675 Nm at lowest rpm range, delivering best-in-class

fuel efficiency and highest engine life. With a reliable and proven power train,

the new Tata SIGNA 2518.K offers its customers better productivity and lowest

cost of operations, for a construction vehicle. Multiple options of aggregates

combinations and load bodies make the Tata SIGNA 2518.K a versatile

workhorse for various applications.

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DEPARTMENT ASSIGNED

PRIMA TRIM LINE, WORLD TRUCK FACTORY, TATA MOTORS LTD. (JAMSHEDPUR WORKS)

Prima Trim Line is involved in the production of prima cabs, for domestic and

international needs. Recently, the Prima Trim Line team has been assigned with

the task of assembling cabs for the Heavy Cab SIGNA.

Variants:

.S (Tractors)

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.K (Tippers)

. T (Trucks)

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Creation of Process Flow Diagram (PFD)

Process Flow Diagram: - A flow diagram in standard symbols showing the

sequence & branches of process.

Operation Description: - Brief description of the operation being performed.

Process Characteristics: - Required man, machine, method & environment

parameters for this operation only.

Product Characteristics: - Desired outcomes from this operation.

Rev. No : 1

Rev. Date : 16.03.16

Transportation Storage Assembly

Operation Operation & InspectionDelay

Opn No.

Work Stn

No /

Machine

No

Main Assly

Flow

Offline

Assly Flow

Plant : Jamshedpur Model : Signa

Tata Motors Cross Functional TeamPart No/s.: NA Part Name/ Process:

CAB TrimVarun Jha

Opn. DescriptionProduct

CharacteristicsProcess Characteristics

PU/ Shop : Prima Trim

LineApproved by : PFC Date(Orig) : 01.04.2014

Module Name : Fitted

Trim CabLegends

/

Abbreva

tions

Critical

Char: <CC>

Team Member : Prateek Koul

Latest Change Letter:NAJA-PL-P17-PFD-TR5-002 Process Flow Diagram ( PFD ) Hrushikesh T

Aggregate No.: NA Aggregate Part Descrptn : Signa CabReviewed by :

Complete Cabin

Cab not per Sequence Cab per Sequence

Door all igned and no

paint rub

400020 0Sub assembly of Rear

Window Mould

400010 0Receive the cab from

CPS in good condition.

Cab Damaged/ Paint

issue

Significant

Char :

<SC>

Operator' s

KnowledgeProper seating of Rear

window with Rubber Operator' s skil l

400040 0Sub Assembly of Side

Window

400030 0 Fitment of Rear window

No gap between

rubber beading & the

Rear Window Beading

Cut

Proper seating of Rear

window beading with Rear Window Glass

Crack

No gap between

rubber beading ends Rear Window

hardness high

Operator' s

KnowledgeProper seating of Rear

window with Rubber Operator' s skil l

400060 0

Sub assembly of

Turning Window

Mould

400050 0Fitment of Side

window

No gap between

rubber beading & the

Proper seating of Side

window beading with

Operator' s

KnowledgeNo gap between

rubber beading ends Operator' s skil l

Condition of Assy

fixture

Operator' s

KnowledgeProper seating of

Turnng window with Operator' s skil l400070 0

Fitment of Turning

window

No gap between

rubber beading & the

Proper seating of

Turning window

Operator' s

KnowledgeNo gap between

rubber beading ends Operator' s skil l

Condition of Assy

fixture

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PROCESS MAPPING

Process mapping can be defined as the process of

comparing operations of production of two different

cabs.

Below the process mapping is done between the PRIMA

Cabs and SIGNA Cabs.

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Station No.Process No. Process Description for Prima Process Description for SIGNA

1 Arrange cab for droppingReceive the cab from CPS(P-III) in good

condition

2 Fitment of Glass & Seal quarter Fitment of Rear window

3 Fitment of glass & Seal rear Fitment of Side window

4 Fitment of Antenna & Grommet Fitment of Turning window

5 Fitment of Antenna Main Wiring Harness Set layout on cab

6 Fitment of Top Marker lamp LH&RH Insulation on bonnet

7 Edge Beading Roof Fitment Cab Dropping on Conveyor

8 Fitment of plug roof hole & Roof Cable Layout

9 Barcode Sticker & Cab no. Plate Tapping of all weld nuts

10 Cab Dropping Dummy cap fitment

1 Gear Shift Lever Unit Pasting of engine hood rubber beading

2 Steering Column Rubber Bellow Fitment of steering ring with bellow

3 Retainer PlateFitment of Wiper Motor Assy on cab with linkage

& wheel box housing

4 Accelerator Pedal Fitment of Front Upper Bracket (For Ac Veh only)

5 Integrated Pedal Unit AC Pipe Routing ( For AC Vehicle only)

6Blower unit/ ac unit with front tube

support bracketFitment of HVAC Unit (For Ac Veh only)

7Steering column mounting bracket

& magnetic valveFitment of Top & Bottom Duct mtg bkt on cab.

8 Assembled steering column Fitment of top marker lamp

9 Blower duct

10 Tipper Valve Bracket

11 Center Carpet

12 Floor Console Harness

13 Pneumatic pipes for HYVA bracket

1 Rear Vent Fitment of dovetail

2 Snorkel Mounting Bracket Fitment of clutch pedal into the cab

0

1

2

Page | 26

Line Balancing

Line balancing is the process of assigning tasks to workstations,

so that workstations have approximately equal time

requirements. We use line balancing to

- minimize idle time

- balance bottlenecks

Rules for Line Balancing: - Identify the cycle time and minimum number of work stations.

Make assignments to work stations in order, beginning with

Station 1. Tasks are assigned to work stations moving left to right

through the precedence diagram.

Before each assignment, use the following criteria to determine

which tasks are eligible to be assigned to a workstation:

All proceeding tasks in the sequence have been assigned.

the task time does not exceed the time remaining at the workstation

If no tasks are eligible, move to the next workstation.

After each task assignment, determine the time remaining at the

current workstation by subtracting the sum of task times already

assigned to it from the cycle time.

Break ties that occur using rules:

Assign the task with the longest task time.

Page | 27

Assign the task with the greatest number of followers.

If there is still a tie, choose one task arbitrarily.

Continue until all tasks have been assigned to work stations.

Compute appropriate measures (percent idle time and efficiency)

for the set of assignments.

SIGNA LOAD CHART1.xlsx

Line Balancing Formulas:

Minimum Cycle Time = longest single task time

Maximum Cycle Time = sum of all task times

N min = theoretical minimum number of stations

OT = operating time/day

CT = cycle time

D = desired output rate

N min = 3t CT = OT Output Capacity = OT

CT D CT

PRECEDENCE DIAGRAM

A (.1min)

B (1.0 min )

D (.5 min)

C (.7min )E (.2 min )

Page | 28

BOTTLENECKS

What is a bottleneck? Literally what is it?

In product layouts, when we want to improve productivity,

we need to find and improve critical operations, known as

bottlenecks. Productivity improvements to any non

bottleneck operation will NOT improve productivity of the

system.

Basically bottlenecks are defined as the time consuming

processes in the production as per the operation cycle.

The steps suggested avoiding or preventing shifting

bottlenecks are:

Step 1) Re-evaluate the maximum load of every machine,

process or work center when accepting a new order.

Step 2) Find the bottleneck in the system and identify its surplus

capacity.

Step 3) Fill the bottlenecks surplus capacity.

Step 4) Find out the release time of the material as a result of the

new bottlenecks scheduling.

Page | 29

As per the Load Chart the bottlenecks are present in the

following Stations: -

Station No.- 1 ( Steering Sub Assembly )

Station No.- 11 ( Dashboard Cover )

Page | 30

TIME STUDY

The Time Study is the process of identifying the actual time

taken to complete an operation in the production line.

Page | 31

400010 RECIEVE THE CAB FROM CPS IN GOOD CONDITION

400020 FITMENT OF REAR WINDOW

400030 FITMENT OF SIDE WINDOW

400040 FITMENT OF TURNING WINDOW

400050 MAIN WIRING HARNESS SET FUSE BOX ASSEMBLY

400060 MAIN WIRING HARNESS SET LAYOUT

400070 INSULATION ON BONNET

400080 CAB DROPPING ON CONVEYOR

401010 ROOF CABLE LAYOUT

401020 TAPPING OF ALL WELD NUTS

401030 DUMMY CAP FITMENT

401040 PASTING OF ENGINE HOOD RUBBER BEADING

401050 FITMENT OF STEERING RING WITH BELLOW

401060 FITMENT OF STEERING SUB ASSY ON CAB

401070 FITMENT OF WIPER SUB ASSY

402010 FITMENT OF LINKAGE

402020 FITMENT OF FRONT UPPER BRACKET (FOR AC VEH ONLY)

402030 AC PIPE ROUTING (FOR AC VEH ONLY)

402040 FITMENT OF HVAC UNIT (FOR AC VEH ONLY)

402050 FITMENT OF TOP & BOTTOM DUCT MTG BKT. ON CAB

402060 FITMENT OF TOP MARKER LAMP

402070 FITMENT OF DOVETAIL

402080 FITMENT OF CLUTCH PEDAL INTO THE CAB

402090 ACCELERATOR PEDAL FITMENT

403010 FITMENT OF ACCELERATOR CABLE

403020 AIR DUCT FITMENT ON CAB

403030 DOOR CHECK STRAP FITMENT

403040 DC-DC CONVERTER FITMENT

403050 FITMENT OF DT VALVE ON COWL/CAB

404010 FITMENT OF AUTO DRAIN

404020 ECU FITMENT ON CAB

404030 FITMENT OF PRE-FILTER/SNORKEL

404040 FITMENT OF WASHING UNIT BOTTLE & PIPES

405010 FITMENT OF CLUTCH FLUID BOTTLE MOUNTING BKT FITMENT

405020 FITMENT OF CLUTCH FLUID BOTTLE SUB ASSY INTO THE CAB

405030 FITMENT OF AIR FILTER BKT

405040 SLD FITMENT

405050 FITMENT OF REAR VENTILATION GRILL

405060 CENTER PANEL STAY ROD FITMENT

406010 FITMENT OF ROOF TRIM

406020 FITMENT OF REAR WALL TRIM

0.7 min

2.1 min

5.1 min

4.3 min

1.2 min

3.10 min

5 min

2.40 min

1.0 min

0.5 min

5.2 min

4.7 min

9.5 min

8.4 min

2.5 min

6.1 min

2.4 min

0.50 min

0.60 min

11 min

2 min

1.5 min

5 min

3 min

6 min

5.49 min

4.3 min

3.2 mins

3 min

2 min

2 min

6 min

8 min

9 min

1 min

1.62 min

10 min

TRIM LINE STATION WISE PROCESS SEQUENCE & ITS TIMING (Time Study)Process PROCESS DESCRIPTION Time

2 min

1.50 mins

1.45 mins

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WORK INSTRUCTION SHEET (WIS)

In Work Instruction Sheet (WIS), we have to create sheet with: -

Job Sequence

Symbols and

Responsibility

Operation Sequence (What is to be done and how it is to be done)

Check Method (Measure, Visual, Touch, Feel, Count, Listen)

Operation (Time in Seconds)

Quality Standards, Risks Involved, Mitigation (safety)

Quality (Effect on down Stream process, End user)

Process Steps/ Sketch / Photographs

Part details including health safety tools.

Here is the excel sheet of SIGNA CAB: -

Work Instruction Sheet Signa.xlsx

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DROPPING OF SIGNA CAB IN THE PRIMA TRIM LINE

The SIGNA Cab is in the working stage. All the steps

necessary to ensure the dropping of the SIGNA Cab are

presently running smooth. Since the SIGNA Cab is almost

similar to the Heavy Cab in terms of the fitment of parts,

the operators are trained by expert operators from HCFL

Line on a Cab placed beside the Prima Trim Line.

Height of the pegs is adjusted for dropping of the cabs,

from the initial height of 1150 cm. As of now, the SIGNA

Cab is dropping properly as per schedule. The peg-heights

are adjusted to suit the requirements.

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FINAL OUTCOME OF SIGNA CABS

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CONCLUSION

The project ‘Introduction of SIGNA in Prima Trim Line’ required the

detailed knowledge of the different processes and operations of the

Prima Trim Line. This required rigorous fact-finding, observation,

knowledge of the inventory and continuous dialogue and discussion

with the people involved in these processes. Observation of the WIS of

different processes, verifying the part numbers of the materials to be

used in the cab, tools required to do these operations and finally

preparing the WIS brought about the thorough understanding of the

work at hand. Bottlenecks for the line were necessary to be identified

and suggestions for removing these bottlenecks were to be provided.

The suggestions include the proper arrangement of bins as per the

stations, increased use of the kitting trolleys, and educating the

operators about the exact part numbers of the materials to be used as

mentioned in the Work Instruction Sheets (WIS): all of these would

ensure that lesser time would be required to complete the operations.

For ensuring the introduction of SIGNA, processes of the HCFL line

needed to be studied and observed. Load Charts for the Prima Trim

Line, showing all the operators for the operations involved, needed to

be prepared. Operation mapping for the Prima Cab and the SIGNA Cab

had to be done. Finally, Load Balancing had to be suggested for the

Signa cab, based on the usage of parts and materials in the complete

assembly of a big cab. The problems were faced during the production

of Signa, which was causing delay in the production of Signa but with

the help of the employees the error has been sorted out.

Now the SIGNA Cab is running properly in the Prima Trim Line.

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REFERENCES

Process Mapping

FP&M World Class Journey

Chris Ahoy,

Facilities Planning & Management

Iowa State University

Process Flow Diagram

Learn about Quality

ASQ Org

Line Balancing

Principles of Management &

Production

Dr. Allison W. Pearson

MISSISSIPI University

Tata Motors Ltd. Work guide

Wikipedia

Thanks