Self Certification Implimentation

8/17/2019 Self Certification Implimentation

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Mechanical Department Sri Indu Institute of Engineering and TechnologyEn1

1. INTRODUCTION

The Mahindra Group is an Indian multinational conglomerate headquartered atMahindra Towers in Mumbai, India, with operations in over 100 countries across theglobe. The group has a presence in aerospace, agribusiness, aftermarket, automotive,components, construction equipment, defence, energy, farm equipment, finance andinsurance, industrial equipment, information technology, leisure and hospitality,logistics, real estate, retail, and two wheelers. It is considered to be one of the mostreputable Indian industrial houses with market leadership in utility vehicles as well astractors in India.

1.1. BRIEF HISTORY:

Mahindra & Mahindra was originally incorporated in 1945 by the brothers J.C.Mahindra and K.C. Mahindra and Malik Ghulam Muhammad in Ludhiana, Punjab totrade steel. Following the Partition of India in 1947, Malik Ghulam Muhammad leftthe company and emigrated to Pakistan where he became the first finance minister ofthe new state (and later the third Governor General in 1951). In 1948, K.C. Mahindrachanged the company's name to Mahindra & Mahindra.

Building on their expertise in the steel industry, the Mahindra brothers begantrading steel with UK suppliers. They also won a contract to manufacture Willys Jeepsin India and began producing them in 1947. By 1956, the company was listed on theBombay Stock Exchange, and by 1969 the company had entered the world market asan exporter of utility vehicles and spare parts. Like many Indian companies, Mahindraresponded to the restrictions of the Licence Raj by expanding into other industries.Mahindra & Mahindra created a tractor division in 1982 and a tech division (nowTech Mahindra) in 1986. It has continued to diversify its operations ever since throughboth joint ventures and Greenfield investments.

By 1994, the Group had become so diverse that it undertook a fundamentalreorganization, dividing into six Strategic Business Units: Automotive; FarmEquipment; Infrastructure; Trade and Financial Services; Information Technology; andAutomotive Components (known internally as Systech). The new Managing Director,Anand Mahindra, followed this reorganization with a new logo in 2000 and thesuccessful launch of the Mahindra Scorpio (a wholly indigenously designed vehicle) in2002. Together with an overhaul in production and manufacturing methods, thesechanges helped make the company more competitive, and since then the Group'sreputation and revenues have risen noticeably. Currently, Mahindra & Mahindra isone of the 20 largest companies in India in 2009, Forbes ranked Mahindra among thetop 200 most reputable companies in the world.


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Mechanical Department Sri Indu Institute of Engineering and Technology 2

In January 2011, the Mahindra Group launched a new corporate brand,Mahindra Rise, to unify Mahindra's image across industries and geographies. Thebrand positions Mahindra products and services as aspirational, supporting customers'ambitions to 'Rise'.

In April 2012, the Mahindra Group showed interest in purchasing the bankruptautomobile company Saab, and actually placed several bids for Saab, though wasoutbid by Saab's new owner National Electric Vehicle Sweden.

1.2. MAJOR BUSINESS VENTURES:

Aerospace: Mahindra Aerospace

GippsAero Aerostaff Australia

Automotive: Mahindra & Mahindra (Automobile Manufacturer) Mahindra Truck & Bus Mahindra Reva SsangYong Motors Mahindra Two Wheeler

Fig 1.1 – Mahindra Business Ventures


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Components: Engines Engineering Mahindra Castings Mahindra Composites Mahindra Engineering Mahindra Gears and Transmissions Mahindra Forgings Mahindra Hinoday Ltd Mahindra Intertrade Mahindra Sona Ltd. Mahindra Steel Service Centre Mahindra Systech

Mahindra Ugine Steel Metalcastello S.P.A

Consulting: Mahindra Consulting Engineers Mahindra Logisoft Mahindra Special Services Group

Defence:

Mahindra & Mahindra - Millatary Defence Division Defence Land Systems

Education: Mahindra United World College of India Mahindra École Centrale

Energy:

Mahindra & Mahindra - Energy Division Mahindra Solar One Mahindra EPC Services Pvt. Ltd.

Hospitality: Club Mahindra Mahindra Holidays and Resorts


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Information Technology:

Tech Mahindra Mahindra Satyam Mahindra Comviva Bristlecone CanvasM

Farm Equipment:

Mahindra & Mahindra - Farm Equipment Division Mahindra (China) Tractor Co Mahindra USA Inc Mahindra Yueda (Yancheng) Tractor Co Mahindra Tractors Mahindra Gujarat Jiangling Tractors

Financial Services:

Mahindra & Mahindra Financial Services Limited Mahindra Insurance Brokers Mahindra Rural Housing Finance

Logistics:

Mahindra Logistics

Real Estate:

Mahindra Lifespaces Mahindra World City

Retail:

Mahindra Retail

Sports:

Mahindra Racing Mahindra-NBA Partnership Mahindra-Celtic Football Club Partnership

Defunct:

Mahindra Renault Mahindra United FC


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1.3. COMMUNITY INITIATIVES:

The Mahindra Group is extensively involved in philanthropy and volunteering.It is considered an active participant in the Indian Corporate Social Responsibility field

and received the Pegasus Award for CSR in 2007. Mahindra engages in philanthropyprimarily through the KC Mahindra Trust, which serves as the CSR arm of the group(although many subsidiaries have their own CSR initiatives, notably Tech Mahindraand Mahindra Satyam). Founded in 1953 by K.C Mahindra, the trust focuses primarilyon fostering literacy in India and promoting higher learning through grants andscholarships. Mahindra operates several vocational schools as well as the MahindraUnited World College. The KC Mahindra Trust’s primary project however is ProjectNanhi Kali, which targets the education of young Indian girls. The foundationcurrently supports the education of approximately 51000 underprivileged girls. Other

initiatives include Mahindra Hariyali (a 1 million tree planting campaign) as well assponsorship of the Lifeline Express, a mobile hospital train. Mahindra employees alsoplan and lead their own service projects through Mahindra’s Employee Social OptionsPlans. In 2009, more than 35,000 employees participated.

The Mahindra Group was responsible for the creation of Mahindra United World College, a UWC campus located in Pune.

Mahindra also supports the Mahindra Excellence in Theatre Awards torecognize Indian theater talent, the Mahindra Indo-American Film Festival, and theMahindra Lucknow Festival. In 2011, it held the first annual Mahindra Blues Festivalwith guests like Buddy Guy, Johnny Lang, and Shemekia Copeland at the MehboobStudios in Mumbai. Mahindra also partners with the NBA and Celtic Football Club tobring grassroots basketball and soccer to India.


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1.4. MAHINDRA GROUP DETAILS:

TYPE Privately held company (BSE : 500520)

INDUSTRY Conglomerate

FOUNDED 2 OCTOBER, 1945

HEAD QUARTERS Mumbai, Maharashtra ,India

AREA SERVED Worldwide

KEY PEOPLE Anand Mahindra (Chairman & ManagingDirector)Keshub Mahindra(Chairman Emeritus)

PRODUCTS Aerospace, aftermarket, agribusiness,automotive, components, constructionequipment, consulting services, defence,energy, farm equipment, financialservices, industrial equipment,information technology, hospitality,logistics, retail, real estate

REVENUE Rs.41,226.49 Cr (Mar’ 14)

PROFIT Rs.3,758.79 Cr (Mar’14 )

SUBSIDIARIES Mahindra & Mahindra, MahindraAerospace, Mahindra EngineeringServices, Mahindra & Mahindra FinancialServices Limited, Mahindra Sys tech, TechMahindra, Mahindra Satyam, MahindraLife space Developers, Mahindra SteelCompany

EMPLOYEES 180,000 (2013)

WEBSITE www.mahindra .com

Table 1.1 – Mahindra Group Details

http://en.wikipedia.org/wiki/Mahindra_%26_Mahindrahttp://en.wikipedia.org/wiki/Mahindra_Aerospacehttp://en.wikipedia.org/wiki/Mahindra_Aerospacehttp://en.wikipedia.org/w/index.php?title=Mahindra_Engineering_Services&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Mahindra_Engineering_Services&action=edit&redlink=1http://en.wikipedia.org/wiki/Mahindra_%26_Mahindra_Financial_Services_Limitedhttp://en.wikipedia.org/wiki/Mahindra_%26_Mahindra_Financial_Services_Limitedhttp://en.wikipedia.org/w/index.php?title=Mahindra_Systech&action=edit&redlink=1http://en.wikipedia.org/wiki/Tech_Mahindrahttp://en.wikipedia.org/wiki/Tech_Mahindrahttp://en.wikipedia.org/wiki/Mahindra_Satyamhttp://en.wikipedia.org/w/index.php?title=Mahindra_Lifespace_Developers&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Mahindra_Lifespace_Developers&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Mahindra_Ugine_Steel_Company&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Mahindra_Ugine_Steel_Company&action=edit&redlink=1http://www.mahindra/http://www.mahindra/http://en.wikipedia.org/w/index.php?title=Mahindra_Ugine_Steel_Company&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Mahindra_Ugine_Steel_Company&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Mahindra_Lifespace_Developers&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Mahindra_Lifespace_Developers&action=edit&redlink=1http://en.wikipedia.org/wiki/Mahindra_Satyamhttp://en.wikipedia.org/wiki/Tech_Mahindrahttp://en.wikipedia.org/wiki/Tech_Mahindrahttp://en.wikipedia.org/w/index.php?title=Mahindra_Systech&action=edit&redlink=1http://en.wikipedia.org/wiki/Mahindra_%26_Mahindra_Financial_Services_Limitedhttp://en.wikipedia.org/wiki/Mahindra_%26_Mahindra_Financial_Services_Limitedhttp://en.wikipedia.org/w/index.php?title=Mahindra_Engineering_Services&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Mahindra_Engineering_Services&action=edit&redlink=1http://en.wikipedia.org/wiki/Mahindra_Aerospacehttp://en.wikipedia.org/wiki/Mahindra_Aerospacehttp://en.wikipedia.org/wiki/Mahindra_%26_Mahindra


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2. MAHINDRA & MAHINDRA (AUTOMOTIVE SECTOR)

A 2 WHEELER TO 20 WHEELER MANUFACTURING COMPANY

2.1. INTRODUCTION:

Mahindra & Mahindra Limited (M&M) is an Indian multinational automobilemanufacturing corporation headquartered in Mumbai. It is one of the largest vehiclemanufacturers by production in India and the largest seller of tractors across theworld. It is a part of Mahindra Group, an Indian conglomerate.

It was ranked as the 10th most trusted brand in India, by The Brand Trust Report,India Study 2014. It was ranked 21st in the list of top companies of India in FortuneIndia 500 in 2011.

Its major competitors in the Indian market include Maruti Suzuki, Tata Motors, AshokLeyland, Toyota, Hyundai, Mercedes-Benz (Merc) and others.

Military Defense:

The company has built and assembled military vehicles, commencing in 1947 with theimportation of the Willys Jeep that had v been widely used in World War II. Its lineof military vehicles include the Axe. It also maintains a joint venture with BAESystems, Defence Land Systems India.

Employees:

As on 31 March 2013, the company had 34,612 employees, out of which 699 werewomen (2%). It also had around 16,000 temporary employees on the same date.

Fig 2.1 –


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Energy:

Mahindra & Mahindra entered the energy sector in 2002, in response to growingdemands for increased electric power in India.

Since then, more than 150,000 Mahindra Powerol engines and diesel generator sets(gensets) have been installed in India, offering standard proper quality power, as domost larger companies, in areas with arguably less reliable grid electricity. Theinverters, batteries, and gensets are manufactured at three facilities in Pune(Maharastra), Chennai (Tamil Nadu), and Delhi; and 160 service points across Indiaoffer 24-7 support to most key markets. Powerol is present in countries across LatinAmerica, Africa, the Middle East, and Southeast Asia — and expanding into the UnitedArab Emirates, Bangladesh, and Nepal. Mahindra Powerol's energy services consistmostly of power leasing and telecom infrastructure management. In 2006, it became

a major market leader in the telecom segment (and in 2011, its market share passed45%). In 2007, it won the Frost and Sullivan "Voice of the Customer" award for bestpractices in telecom.

Mahindra Cleantech Ltd focuses in eco-friendly, or 'green' power. In response togrowing acceptance of Solar Power, it formed a subsidiary, Mahindra Solar, in 2010to offer a range of solar solutions, both off grid and on grid, alongside Engineering,Procurement, and Construction (EPC).

Farm Equipment:

Mahindra began manufacturing tractors for the Indian market during the early '60s. Itis the top tractor company in the world (by volume) with annual sales totaling morethan 200,000 tractors. Since its inception, the company has sold over 2.1 milliontractors. Mahindra & Mahindra’s farm equipment division (Mahindra Tractors) hasover 1,000 dealers servicing approx. 1.45 million customers.

Awards and recognitions:

Bombay Chamber Good Corporate Citizen Award for 2006-07. Businessworld FICCI-SEDF Corporate Social Responsibility Award 2007. The Brand Trust Report ranked M&M as India's 10th Most Trusted Brand in its

India Study 2014 survey. Its Farm Equipment division received the Japan Quality Medal in 2007. The US based Reputation Institute ranked M&M amongst the top Ten Indian

companies in its 'Global 200: The World's Best Corporate Reputations' list for2008.

Bluebytes News rated M&M as India's second Most Reputed Car Companyconducted for the Auto (Cars) Sector in 2012.


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Automobile Assembly Plants & Products:

LOCATION CLASS PRODUCT/VEHICLE

Zaheerabad, Telangana LCV, SUV,3Wheeler,Pick-Up,Tractors

Load King, Bolero, Alfa,

Maxi Truck, Arjun, Bhumiputra

Pithampur, MadyaPradesh 2-Wheeler Rodeo, Duro, Flyte

Haridwar, Uttarakhand LCV,SUV,3Wheeler

Bolero, Alfa

Nashik, Maharashtra UV,SUV Thar, Xylo, Quanto, Bolero,Scorpio, Verito, XUV500

Kandivali, Mumbai, MH Passenger,Tractors

Arjun, Camper, Thar

Nagpur, Maharashtra Tractors Arjun, Sarpanch

Jaipur, Rajasthan SUV, Tractors Bolero, Arjun

Chakan, Maharashtra SUV XUV500

Bangalore, Karnataka Passenger Mahindra REVA Electric Vehicles

2.2. Milestones:

• 1945 : 2nd October, Mahindra & Mohammed established.

• 1948 : The Company was renamed Mahindra & Mahindra Limited (M&M).Steeltrading business commenced, in association with suppliers in UK.

• 1965 : Manufacture of light commercial vehicles commenced. Vickers Sperry of IndiaLimited established – a joint venture with Sperry Rand Corporation, USA.

• 1969 : The Company entered the world market with export of utility vehicles andspare parts.

• 1975 : Mahindra Engines developed an indigenous diesel engine for its vehicles tobeat the fuel crisis.

• 1982 : Mahindra brand of tractors launched.

• 1983 : Mahindra & Mahindra became market leader in the Indian tractor market, aposition it has retained till date.

Table 2.1 - Automobile Assembly Plants


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• 1991: Introduction of Commander Range of vehicles. Mahindra Financial ServicesLimited established as a wholesale fund provider.

• 1994 : Re-organization of the Group creating six Strategic Business Units:Automotive, Farm Equipment, Infrastructure, Trade & Financial Services, InformationTechnology (Telecom and Software) and Systech (MSAT).

• Mahindra Consulting (now Bristlecone) established.

• 1999 : Launch of Bijlee, a battery – operated, environmental – friendly 3 – wheeler.

• Mahindra Logisoft Business Solutions Limited established.

• 2000 : A new age tractor, Mahindra Arjun 605 DI (60 HP), launched.

• 2001 : Champion, a 3 – wheeler diesel vehicle, launched.

• Mahindra MaXX launched, a multi – utility vehicle positioned with the caption'Maximum Space, Maximum Comfort'.

• 2002 : Scorpio launched, a new generation, world – class sports utility vehicle thatredefined the SUV market and lived up toit’s positioning: 'Nothing else will do'.

• 2003 : Invader launched – a sporty open top vehicle.

• MaXX Pick Up launched.

•Indi a's first Turbo tractor launched – Mahindra Sarpanch 595 DI Super Turbo.

• Mahindra & Mahindra ventured into Industrial engine business.

• Mahindra Engineering Services established.

• 2004 : Mahindra World Tractor (75 HP) launched in the International market.

• Mahindra & Mahindra became the first Indian company to achieve sales of onemillion tractors.

• 2005 : Acquired 51% stake in SAR Transmission Private Limited, a company engaged

in manufacture of gears and transmission shafts.• Mahindra & Mahindra became the first Indian auto manufacturer to launch theCommon Rail Diesel Engine (CRDe), offering it in the Scorpio.

• 2007 : On Nov. 1, a wholly owned affiliate of Navistar International Corporation(Other OTC: NAVZ), signed a joint venture agreement with Mahindra & Mahindrato produce diesel engines for medium and heavy commercial trucks and buses inIndia.

• Logan was the highest selling sedan and Scorpio the highest selling UV in July 2007.

• Mahindra launched the Mahindra Pik – Up (double cab) in Chile in July 2007.


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• 2008 : Mahindra introduces FuelSmart system in Bolero and Scorpio SUVs.

• Anand Mahindra receives Harvard Business School Alumni Achievement Award.

• Mahindra to enter the two – wheeler industry.

• Mahindra Tractors launch India’s first bio – diesel tractor.

• 2009 : Mahindra launches the Xylo in January 13.

• Mahindra launches the New, Mighty Muscular Scorpio – March 6.

• 2010 : India’s iconic SUV, the Mahindra Scorpio, took another step to stardom withthe unveiling of a premium, special edition `Scorpio Coffee Table Book’.

• 2011 : In 2011, January 17th Mahindra rise was ignited by Mr. Anand Mahindrawhich explains about a movement of determined people who are working towardsgoals of all sizes, every day. Rise is all about accepting No Limits, Thinkingalternatively and Driving Positive Change.

• 2012 : On 1stFebruary Mahindra & Mahindra Ltd. (M&M Ltd.), India’s leading SUVmanufacturer, today announced a 22% rise in its auto sales numbers, which stood at44717 units during January 2012 as against 36718 units during January 2011.

• 2013 : Mahindra Tractors creates history by rolling out 2 millionth tractor on 01 Mar.

• Mahindra Pick up range crosses 1 lakh mark in domestic sales in FY-2013 on 17 Apr.

• Mahindra launches H-Series Xylo with the advanced technology mHawk engine.

2.3. VISION & MISSION:

M&M as defined its vision statement during the year 2001 as – “Be a globallyrecognized player in M UVs and LCVs by the year 2006”

The long term aspiration is ‘Achieving 1 million vehicles by 2015’ medium and short

term goals. The short term (2013) and Long term (2015) goals are being reworked outand will be declared at the earliest.

It promotes a culture of performance excellence with people focus. It encouragestransparency, freedom of speech, manifestation of unique abilities and talent forgenerating creativity and innovation.


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CORE PURPOSE:

We will challenge conventional thinking and innovatively use all our resources todrive the positive change in the lives of our stake holders and communities across the

world to enhance them to rise.

CORE VALUES:

Our Core Values are influenced by our past, tempered by our present, and willshape our future. They are an amalgam of what we have been, what we are andwhat we want to be. Our core values are as follows

Good Corporate Citizenship

Professionalism Customer First Quality Focus Dignity of the Individual


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3. ZAHEERABAD PLANT

3.1. INTRODUCTION:

The Zaheerabad unit is a certified with ISO / TS 16949 – 2002, ISO 14001:2004 &OHSAS 18001:2007. The plant was started in the year 1985 in the name of AllwynNissan Ltd. and merged with Mahindra & Mahindra Ltd. in the year 1994. Zaheerabadunit is the first LCV manufacturer to provide CRDE Technology in engine complyingBS III standards. The unit has bagged the “State Level Energy Conservation Awardfrom “Andhra Pradesh Productivity Council” for year 2007 and was a runner -up inthe “National Energy Conservation Award - 2006” & got first prize in 2007conductedby the Bureau of Energy Efficiency. The unit’s mantra for success is the customersatisfaction & continuous improvement, which has placed it in the 3rd position for CSIin JD power study conducted during 2005-2006.

The unit has entered in to various export markets of Asian and African countries.In this global competitive market Mahindra has sustained because of more customerfocus and energy management.

M/S Mahindra & Mahindra Ltd is one of the leading automotive industry in Indiahaving manufacturing operation located at Mumbai, Nashik, lgatpuri and Zaheerabad.The Zaheerabad plant is one of the progressive units of the Mahindra group withannual turnover of 250 crores. This plant has uniqueness of having very wide range.

For reducing the operational & energy cost. Various small group activities likeIngenious drive teams, Jishu Hozen Circles, kobetsu Kaizen Teams etc. have beenformed with senior executives as facilitators/mentors to identity & implement theEnergy conservation projects.

The Mahindra & Mahindra Ltd. Zaheerabad unit is basically a vehicle assemblyunit producing about 48 various models of LCV, buses, multi-utility vehicles & 3wheelers. 90% of the manufacturing cost is vehicle assembly parts cost itself and the

energy cost is in the order of 1.06% of manufacturing cost. This unit is totallydepending upon the bore well water and there is no pipeline waste supply from themunicipal administration. The plant is taking stringent measures to become self-sustainable by conserving water through rainwater harvesting, ETP- Waste watertreatment, Bio filter treatment plant, Green belt Development, environmental aspectslike Clean Development Mechanism (CDM) etc.


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Location:

The Mahindra & Mahindra Ltd. Is located 108 KM from Hyderabad on Hyderabad -Mumbai High-way NH-9.

Mahindra & Mahindra Ltd,

Zaheerabad Unit,

Medak District,

Telangana .

Plant Details:

Area:

Total Area : 343 AcresPlant Land area : 271 AcresBuilt up area : 16.6 Acres

Plant capacity:

92,000 vehicles / year

Major Facilities:

Engine Assembly & Testing Transmission Assembly & Testing Axle Assembly Body Shop Paint shop Vehicle Assembly Lines Testing tracks Self-sufficient R&D center

SERVICE Training Center

Fig 3.1.1 – Entrance of Plant, Zaheerabad

Fig 3.1.2 – Top View of Plant, Zaheerabad


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Management Systems in Mahindra, Zaheerabad:

TS(Technical Specification) 16949:2002

Integrated ISO EMS(Environmental Management System) 14001:2004 &

OHSAS 18001:2007

ISO 27001:2002 ISMS (Information Security Management Systems)

TPM (Total Productive Maintenance)

MQS – Mahindra Quality System

MAPS – Mahindra Advanced Production System

SAP (System Applications & Processing in Data Software)

Corporate Sustainability Report

5 S systems

ESOPs (Employee social options)

CSR (Corporate Social Responsibility ) Activities

Mahindra rise drive with workmen & Executive


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MANUFACTURING VEHICLES IN MAHINDRA, ZAHEERABAD:

UTILITY VEHICLES

3-WHEELERs

LIGHT COMMERCIAL VEHICLES

FIG 3.1.3 - BOLERO DI Fig 3.1.4 - CAMPER Fig 3.1.5 - MAXI TRUCK

Fig 3.1.6 - ALFA LOAD Fig 3.1.7 - ALFA

Fig 3.1.8 - TOURISTER - 25

Fig 3.1.10 - LOAD KING Fig 3.1.11 - LOAD KING

Fig 3.1.9 - TOURISTER COSMO


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3.2. PRODUCTION PROCESS:

Zaheerabad unit's production process flow is given below. Production process flowsare similar for three part families viz. 3-wheeler, LCV and U.V to meet the production

planning.

PROCESS FLOW CHART

Functional Areas in the Plant:

a) Body shopb) Paint shopc) Engine shop (or) Transmission shopd) Axle shope) Assembly line

1) Trim line2) Mechanical line

Fig 3.2.1 – Process Flow Chart – Production Process


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A) Body shop:

The pressed panels from vendors are fed to body shop and kept in the trolleys. Thesepanels assembled together by co2 and spot welding. Welding fixtures are used to holdthese panels during welding process. Body manufacturing process is divided intostages where different parts are assembled in sequence to form the complete assemblyto body.

FLOW PROCESS IN BODY SHOP

The following processes are used in the body shop in the assembling any body:

1. Spot welding2. MIG welding3. Brazing4. Nut welding5. Grinding6. Buffing

7. Sandering

Fig 3.2.2 – Flow Process in Body Shop


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1. Spot welding:

Spot welding is the main operation which is used in the joining parts that are madeof sheet metal in the body shop. It is used as it has lot of advantages over otherwelding processes:

It is best process for joining of sheet metal.

Its strength is very high may cause damage to workers and it is also gives betterworking place for operators.

It doesn’t release any inert gas which may cause problem to the operator if hebreathes.

Spot welding is done by welding guns which are of many types and are designed

such that welding can be done at all inaccessible parts in the body. Each of thewelding guns has water, air and current supply. Water is used for cooling theelectrodes after spot welding is done and compressed air is used to move the pistonsuch that movable electrode applies force to the weld. The weld cycle constitutes ofthe following 4 times which can be changed when ever required by adjusting thetimer circuit.

The weld cycle consist of 4 parts they are:

Squeeze time:

During this time the current doesn’t flow but the movable electrode moves f romits initial position to the position where it touches the plate to be welded. So thistime is adjusted based on the type of weld gun used in the process. For guns whichhave large arms the squeeze time is more.

Weld time:

In this period current passes and due to the resistance large amount of heat isproduced and both sheets melt and weld is formed. This time is adjusted on thebasis of thickness of sheets to be welded and metal to be welded. As in this plantonly 0.8mm thick sheet is used and cast steel sheet is used so it is almost constantfor all the guns.

Hold time:

During this period current doesn’t pass and the electrode still holds on to sheets inorder that the weld is to be cooled naturally.

Off time:

During this period welding process is done and electrode returns back to its initialposition.


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2. MIG Welding:

MIG welding is done to join the parts and joints that can’t be joined by spotwelding. This process uses CO2 as inert gas and cast steel wire coated with copperis used as fillet material. This has lower strength than spot welding but it has to bedone as the parts can’t be joined by spot welding.

3. Brazing:

Brazing is done to join the outer parts as its finish is smoother than that of MIGwelding. In this brass is used as filler material.

4. Nut Welding:

Nut welding is the process of joining nuts to sheet metal by projection welding

machine. By doing this process the bolts can be easily fitted with the help of the airgun available. This is done only in parts which are not accessible to hold the nutswhile fixing the bolts.

5. Grinding:

After the body is joined it is sent to metal finish line where its surface is madesmooth and fine. The first process in this line is grinding which is done to removeand dents or convexes or burrs due to spot welding and projections that haveoccurred during MIG welding or brazing. This doesn’t give a high surface finish butit makes surface clear of burrs etc.

6. Sandering:

Sandering is done in the areas which are inaccessible to grinding wheel or anyother process. It consists of a belt called sandering belt which moves like aconveyer with the help of compressed air. By this process surface finish obtained ishigher than that of grinding.

7. Buffing:

Buffing is done after grinding to make the surface finish better even after grinding.so this consist if a rotor which rotates with help of compressed air to which acircular buff paper is attached and used to do the buffing operation.

After this process the body is sent to paint shop. This is called as a body in white.


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B) Paint shop:

Paint shop essentially consists of pre-treatment line, electro deposition, and paintline. The pre-treatment stage is divided into 10 stages. The pre-treatment zone cleansand phosphates the metal to prepare the surface for ED-coating. Cleaning andphosphate are essential to achieve the performance requirements desired by today’send user of the product. A high quality zinc phosphate system using the immersionmethod is primarily used where steel and iron parts are to be coated.

ED-coating is a method of painting which uses electrical current to deposit thepaint. The process works on the principle of “opposite attract”. The electro coat bathand ancillary equipment zone is where the coating is applied and the process controlequipment operations. The ED-coat bath consists of 80-90% de ionized water and 10-20% paint solids. The de-ionized water acts as the carrier for the paint solids which

are under constant agitation. The solids consist of resin and pigment. Resin is thebackbone of the final paint film and provides corrosion protection, durability andtoughness. Pigments are used to provide colour and gloss.

The back oven receives the parts after they exit the post rinses. The back ovencross links and cures the paint film to assure maximum performance properties. Theminimum back schedule is 20minutes with the part temperature at 375 F for most ED-coat technologies.

Over view of paint shop:

Pre-treatment PT unloading CED loading (cathode electro-deposition) Sealant & under coat Wet sanding Primer Top coat QC inspection Touch up

Pre-treatment: Hot water spray. Knock off degreasing (spray type). Dip degreasing (dip type). Rinse1 (dip type), Rinse2 (spray type). Surface activation stage(dip type), Phosphating (dip type). Rinse3 (dip type). Rinse4 (spray type).

Re-circulated DI water (dip type). DI water spray.


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Cathode Electro deposition line:

CED loading area Cathode Electro-deposition bath (dip type). UF1. UF 2. UF 3 CED offloading. Oven.

Step in the production process. Body shells are painted in a semi-cleanenvironment using solvent based. Shells are dipped in chemical tanks to cleanse themof any oils picked up on the panels during their manufacture in Body Shop. Oncebodies have been dipped and cleansed, they are then immersed in an anti-corrosionpaint dip called ED (Electro coat Dip).

This 'dip' coats the entire body, both inside and outside, and is the first paintcoating it will receive. Once the 'dipped' body has been stoved in the ED oven, thebody progresses to the 'Sealing' Booth. In this booth, the body has its interior panel

joints, floor, tailgate, hood and door edges sealed with PVC based sealant, to preventwater ingress and corrosion as the vehicle is driven on the road. Also within this zone,sound pads are added to the floor and boot to reduce road noise (standard practicein the motor industry).

The next booth it enters is the 'Underbody' Booth. In this booth, similar to'Sealing' Booth, the body's wheel arches are sealed using the same PVC based sealant.Then apply the under seal to the under floor and wheel arches. And they apply theSGC (Stone Guard Coat) layer to the sills: this coating is designed for abrasionresistance, i.e. preventing stone chips, scuffs, etc. From here, the body proceeds intothe Undercoat Oven.

The next zone is 'ED Sanding' booth where the body is inspected for any minorimperfections received in the ED Coat. The next zone is the 'Surfacer' Booth, wherethe body receives its second coat of paint, this being the Surfacer Coat, then into theSurfacer Oven. Next is 'Surfacer Sanding' Booth: the same as ED Sanding, this zoneinspects the body for any imperfections picked up within the Surfacer coating.

Next comes the 'Topcoat' Booth, where the body receives its final coats ofpaint, these being Topcoat and Clear coat layers. After being stoved in the Topcoatoven, the body then enters the 'Touch-up' Booth where the body has its finalinspection for any imperfections picked up in the Topcoat process. Once the bodyleaves here, it then moves on to the PBS (Painted Body Store) above Trim and Chassisto await the next.


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C) Transmission shop:

In this shop the transmission – axle assembly is done for Alfa and load king.After the assembly, the docking of Transaxle with the engine is done. The test for thegear ratios is done by a rotating machine which is given as input to the gear box andoutput speed is noted and calibrated in terms of gear ratio which is shown by themachine as output. So the gear ratio for all the gears is tested, checked and then theengine is sent to the mechanical line where it is assembled with the chassis.

D) Axle shop:

In this shop, the brake drums, hubs and spindles are assembled for the front and rearaxles. The rare axle comes with the differential for load king and Alfa differential iswithin the transmission. Assembled axles are sent to vehicle assembly line where it isassembled to the chassis.

E) Assembly line:

1) Trim line:

In this line the body comes from the paint shop, the body is assembled with manyparts such as brake booster, accelerator pads, window glass, wiring, all the meterswhich indicates speed and fuel in the cabin. In this line, the body is moved on atrolley. The trimmed body is sent to the mechanical line where it is fixed to thechassis.

2) Mechanical line:

In this line, first the front and rear axles from the axles shop are brought andfitted to the leaf springs and chassis which comes from the vendors is placed on themand fitted. Then it is placed on a conveyor which moves very slowly such that allother parts are assembled. In these lines after placing the engine and suspensionsystem, that body from the trim line is brought by hoists and raised and fitted. Afterall the parts are fitted, wheel alignment testing is done such that both the pair ofwheels aligns correctly. After this, the vehicle assembled is sent to pre delivery

inspection (PDI) where it is checked for any missing parts or loose fitments.In all these lines, bodies are transferred by hoists which are operated by motors andcan be used to move the bodies easily. Torque wrenches are used at all places todeliver required amount of torque in fixing a nut. All the guns are run by compressedair which is supplied by two compressors separately to the whole plant. The pressureof compressed air is maintained at 6 bars.


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FAI:

There are three buy-off stages and one final buy-off (FAI) in Alfa assembly line.

At each buy-off‘s, they will do vehicle overall inspection and calculate FRC (first run

capability),FBO (first time buy-off),DPV (defect per vehicle).* FRC:- (Total number of vehicles manufactured without any defect/total

vehicles audited)*100 * FBO:-(Total number of vehicles manufactured without any quality defects+

TACT/total number of vehicles audited)*100

TACT: Time assigned to complete task* DPV:-(Total number of defect per vehicle/total no of vehicles inspected)*1000

Here they will calculate defect per vehicle (DPV) in all the Buy-off’s.

In the final buy-off, inspection will do on overall vehicle, if any defects found, theywill rework the defect there itself.

If the defect is big they will put the vehicle in hold and clear the defect in that dayonly.

Vehicle will be tagged withFAI Ok sticker when the vehicle is defect less. Then thevehicle will move to PDI (pre delivery inspection).

PDI:

At PDI the vehicles that are Ok at FAI are inspected further.

Two inspection are carried out at PDI that is

1. Dynamic test &2. Static test

Dynamic test:

After static test has done, the vehicle is driven 5 rounds around PDI. During the ridethe vehicle is inspected for noise, defects and rework the defect there itself.

In dynamic test also includes

1. shower test2. road test3. smoke test4. roll on test(testing of engine and transaxle oil leaks)

Static test is done while the vehicle is stationary. In static test overall vehicleinspection and under body inspection is done.


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After rework and the vehicle without any defect is tagged with PDI ok tag and thevehicle is moved to RFI yard.

RFI:

Ready for inspection means the vehicle having Ok tag in PDI10% of vehicles are takento inspection.

The inspection of RFI carried to check the warranty concerns & field concerns whichwere received from field by driving the vehicle few more kilometers.

At that time, if any quality concern is observed, they will audit the remaining90% ofvehicle’s in yard and rectify all the problems (if found) with the help of productionmanpower.

After the RFI inspection vehicle will send to RFD yard for dispatching.And here there is another inspection called nova-c (new overall vehicle audit).

The audit will be based on the customer point of view.

The selected vehicle will run on road by creating an atmosphere of physicalconditions by putting a load on the auto in the road.

If any concern is found they will give the feedback to concern department in chargefor ICA (immediate corrective action) &

PCA (permanent corrective action) for concern closing


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3.3. INTRODUCTION - UV ASSEMBLY LINE:

An assembly line is a manufacturing process sometimes called progressiveassembly) in which parts (fuel tank, engine, gearbox, muffler, propeller shafts etc) areadded to a product (Chassis) and body is mounted onto the chassis in a sequentialmanner using optimally planned logistics to create a finished product (UV vehicles).Assembly lines are designed for a sequential organization of workers, tools ormachines, and parts. The motion of workers is minimized to the extent possible. Allparts or assemblies are handled either by conveyors or motorized vehicles such asforklifts, or gravity, with no manual trucking. Heavy lifting is done by machines suchas overhead cranesor forklifts. Each worker typically performs one simple operation.

Principles of assembly are shown below:

Place the tools and the men of the operation so that each component partshall travel the least possible distance while in the process of finishing.

Use work slides or some other form of carrier so that when a workmancompletes his operation, he drops the part always in the same place--which

place must always be the most convenient place to his hand--and if possiblehave gravity carry the part to the next workman for his operation.

Use sliding assembling lines by which the parts to be assembled aredelivered at convenient distances.

http://en.wikipedia.org/wiki/Overhead_cranehttp://en.wikipedia.org/wiki/Overhead_crane


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LAYOUT OF UV - ASSEMBLY LINE

Fig 3.3 – Lay Out of UV Assembly Line


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FLOW PROCESS IN UV - TRIM LINE

Fig 3.4 – Flow Process in UV Trim Line


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3.4. OPERATIONS OF UV - TRIM LINE:

ROOF REXENE LINING:

The roof mats made up of Rexene material are fitted in this stage.

BRAKE & CLUTCH FITMENT:

The brake and clutch pedals are fitted in this stage.

REAR DOOR & A/C BLOWER:

The rear door and A/C blower is fitted in this stage.

INSTRUMENT PANEL SUB ASSEMBLY & FITMENT:

Instrument panel is a panel consisting of glove box and switches. The instrument panel is fitted onto to the inner dash board.

DOORS TRIMMING:

The trimming of doors is the stage where the doors and its accessory fitmentsare trimmed in various shapes and sizes according to the requirements.

DOORS FINISHING: After the trimming of doors, finishing is given in order to yield a good door

fitment. A good finishing will yield a good door fitment.

DOOR GLASSES SUB ASSEMBLY:

The door glasses sub assembly is a stage where the glasses of respective sides

are assembled and fitted. SUNVISOR FITMENT:

Sun visor is a part used to protect the driver and co-driver from the sun.

The fitment of sun visor is done in this stage. SEAT MOUNTING:

The seats are mounted at this stage. All the seats in all floors are mounted and fitted in this stage.


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WIND SHIELD GLASS SUB ASSEMBLY FITMENT:

A windshield glass is glass that protects the vehicle's occupants from wind andflying debris such as dust, insects, and rocks.

Windshields are generally made of laminated safety glass, a type of treatedglass, which consists of two (typically) curved sheets of glass with a plastic layerlaminated between them for safety, and are glued into the window frame.

The wind shield glass fitment is done in this stage.

BUY OFF:

A buy off is an inspection stage where all the fitment of parts is done perfectly

without mistakes. The mistakes in various UV assemblies trim line sections areinspected and rectified.


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FLOW PROCESS IN UV - MECHANICAL LINE

Fig 3.5 – Flow Process in UV Mechanical Line


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3.5. OPERATIONS OF UV - MECHANICAL LINE:

CHASSIS INTAKE:

In the case of vehicles, the term chassis means the frame running gear like engine,transmission, driveshaft, differential, and suspension...

For commercial vehicles chassis consists of an assembly of all the essential partsof a truck (without the body) to be ready for operation on the road.

A chassis serves as basis for platforms on tanks, armored personnel carriers,combat engineering vehicles, etc.

FRONT AXLE FITMENT:

Mounting of front suspensions onto the front axle. Docking of front axle assembly onto the chassis.

REAR AXLE DOCKING:

Mounting of rear suspensions onto the front axle. Docking of rear axle assembly onto the chassis.

FRAME TURNING:

After mounting of axles, the chassis is tilted upside down. The tilting is done so that the correct order of the chassis is followed.

BRAKE PIPES AND STEERING GEAR FITMENT:

The fitment of brake pipes both front & rear is done in this stage. The steering gear is fitted after the brake pipes fitment.

ENGINE DROP AND MUFFLER FITMENT:

The engine is dropped onto the chassis and the accessories are fitted. A muffler or silencer is a device for reducing the amount of noise emitted by

the exhaust of an internal combustion engine. The muffler is fitted in this stage.


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NUMBER PUNCHING:

The chassis number is punched in this stage. The numbers are punched using a punching machine.

CHASSIS BUY OFF:

A buy off is an inspection stage where all the fitment of parts is done perfectlywithout mistakes.

The mistakes in various chassis assembly sections are inspected and rectified.

BODY DROP AND FOOT STEP FITMENT:

The body is dropped onto the chassis. The foot step along with its accessories is fitted.

BOOT COVER FITMENT:

A boot cover is a part used to cover the gear box. This boot cover is fitted in this stage.

BRAKE BLEEDING: Filling of brake fluids or brake oil. The lubrication process of brakes is done in this stage.

CARROUSEL FITMENT:

The carrousel accessories such as fenders, air deflector’s, radiator guards and

front fascia are fitted in this stage.

TYRE FITMENT:

The tires made up of rubber material are fitted in this stage. The tires along with the wheels are also fitted in this stage


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BODY DROP BUYOFF:

The body drop buy off is a stage where the process of body dropping isinspected.

A buy off is an inspection stage used for checking the mistakes and sendingback to the rework stage if any mistakes are found out.

A buy off is also called as a certification, inspection, rectification. Stage. The purpose of the Buy-off is to ensure that products which leave an inspection

stage at the end of a pre-determined group of operations must meet therequirements of the next customer.

There must be no defects so that the customer is satisfied. The Buy-off procedure, when correctly implemented ensures a defect free

product to the final customer.

ROLL DOWN:

After all the assembly process taking place in various stages, the final vehicle isready to roll down.

After rolling down of the vehicles, they are sent to a section where thealignment of wheels, head light inclination is done.


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4. PROJECT

SELFCERTIFIACATION

IMPLEMENTATION&

ELIMINATION OF

HUMAN ERRORS


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4.1. OBJECTIVE: To implement self-certification method inUV TRIM LINE. To eliminate the manual errors due to model mix up through self-inspection in

UV Trim line.

4.2. PURPOSE:

In UV Trim line the body comes from the paint shop, the body is assembledwith many parts such as brake booster, accelerator pads, window glass, wiring, all themeters which indicates speed and fuel in the cabin.

There are different models rolling in trim line. They are

1. Bolero maxi truck flat belt2. Bolero maxi truck regular3. Bolero longer4. Bolero di5. Bolero camper6. Bolero camper gold7. Bolero camper gold life style

8. Bolero pick up9. Bolero gold vx

Even there several variants present in each model

MODEL VARIANTS:

1. 2 wheel drive2. 4 wheel drive3. BSII4. BSIII5. AC6. NON AC


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Trim line is a line in which the whole cab interior parts are fitted. Trim lineconsists of following stages:

1. Tapping

2. Stickering3. Dummy plugs

4. Carrousel removal

5. Harness fitment

6. Roof rexene fitment

7. Dunlap application

8. Wiper motor fitment9. Roof rexene sticking

10. Rexene cutting

11. Brake and clutch pedal fitment

12. Back door assembly / Cargo Trimming

13. Seat belt fitment

14. A/C fitment15. Instrument panel fitment

16. Steering column sub-assembly

17. Doors trimming - 1

18. Door trimming – 2

19. Door glass sub-assembly

20. Trim pad Fitment

21. Steering column fitment

22. Seats fitment

23. Wind shield glass fitment

24. Sun visors fitment

25. Trim Buy-off


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There are eight major stages in utility vehicle trim line in which similar parts areassembled to different types of utility vehicles.

1. Brake & Clutch fitment2. Harness fitment3. Steering column fitment4. Door trimming – 25. Trim pad fitment6. Seats fitment7. Wind shield glass fitment8. Sun visor fitment

4.3. Stages and Using Similar parts:

Stage 1 - Brake & Clutch fitment:1. Brake pedal2. Battery tray3. Brake booster

Stage 2 - Harness fitment:1. I/P2. Hazard switch3. EGR controller

Stage 3 - Steering column fitment:1. Steering rod2. Clutch pipe3. Steering cover4. Kit lock5. Combination switch

Stage 4 - Door trimming - 2:

1. Regulator assembly window2. Glass run channel3. Bottom channel for glass4. Strip glass bottom channel

Stage 5 - Trim pad fitment:

1. Trim pad rear door2. Trim pad front door


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3. Door handle4. Handle window5. Bezel door inner escort

Stage 6 - Seats fitment:1. Driver seat2. Co – Driver / Side seat3. Middle seat

Stage 7 - Wind shield glass fitment:

1. Wind shield glass2. Rear view mirror

3. BP lamp4. Side mirrors

Stage 8 – Sun visor fitment:

1. Sun visor

These are the stages, models, variants and circles of utility vehicles line as mentionedabove .by observing these stages we found many similar parts which are shown in theform of circles. Different models of vehicles are assembled at assembly line and they

have different variants by this different models and variants the workers are confusingwhile assemble the parts. There may be a chance of keeping one model part toanother model. By this problem re work time will increase, effects the quality ofvehicle we can’t deliver defect free product to the customer. To reduce this problemwith the help of self-inspection method, for improving the quality of vehicle, reducere work time and deliver defect free vehicle to the customer.

‘THE OPERATOR MAY CONFUSE IN SELECTING A CORRECT PART FOR ACORRECT MODEL’


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4.4. SELF CERTIFICATION:

Self-Certification is a process in which an operation is certified by the operator by self-inspecting the task done by him.

This approach of inspection helps to control the quality of products by helping to fixthe source of defects immediately after they are detected and it is useful for anyfactory that want to improve productivity, reduce defect rates, and reduce reworkand waste.

Self-Inspection Methods:

1) TRAVEL CARD (CHECK SHEET): A check sheet is a structured, preparedform for collecting and analyzing data.

2) ARROW MARK: In arrow mark method, an arrow mark is placed on parts tonotify that the part is to be placed in a specific direction.

3) IDENTIFING MARK: In identification mark method, some identificationstickers are pasted on parts. For example, LH sticker is pasted for partsassembling in left side of vehicle.

From the above methods we are choosing check sheet method.


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4.5. CHECK SHEET

A check sheet is a structured, prepared form for collecting and analyzing data.

In the business world, knowledge really is power and that knowledge requires datacollection.

Check sheets are often the starting point for collecting valuable data that in turn leadsto better information, a better understanding of operations and better decisionmaking – all of which are foundational to continual improvement. Business thatunderstand the importance of improvement are business that stay competitive andcan satisfy customers.

Check sheet simplicity is an advantage:

The great thing aboutcheck sheets is how easy they are to create and use, as well ascustomize, change and to improve overtime. The most important thing is to startedand create a cultural of data collection.

The is no reason to delay implementing a check sheet, as you and add to it ,achecksheet evolves over time to meet real world data needs.

Inspection in manufacturing:

Inspection in manufacturing is conducting inspection during production process. Thisapproach of inspection helps to control the quality of products by helping to fix thesource of defects immediately after they are detected and it is useful for any factorythat want to improve productivity, reduce defect rates, and reduce rework and waste.

Positive impact:

Reduce end line defects Saves time and efforts of final inspection Helps to fix the problems at the outset, and prevents common mistakes being

made repeatedly Helps to ensure quality of products of a production line


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Steps in implementation:

The purpose of in-line inspection is to identify problems with the system thatneed correction and also to identify earlier in the production process

In line inspection can be implemented by line workers under the supervisionof quality control staff

Setup pre-determined in-line inspection points to help the workers toimplement the in-line inspection

Develop and use an in-line inspection check sheet or report to record thefrequency of each type of mistake

Conduct training for line workers on how to conduct in-line inspection and usethe in-line inspection points

The worker should perform their own in-line inspection before they start theirnormal task

If there are any significant mistakes in line, use devices such as light marks orflags to high light the problems in the line for a quick response

Quality control staff should be provided with sample defects and in-lineinspectioncheck list to record the defects

Data on the defects detected during in-line inspection should be stored andused for statistical quality control by the quality control division

4.6. CONCLUSION:By using the check sheet process, we can eliminate the manual errors in

Utility vehicle assembly line.

As a result of self-certification process, we can overcome the hidden errors whileassembling the vehicle, which cannot be inspected further.


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5. PREPARED CHECK SHEET

(i) FRONT PAGE

Mahindra & Mahindra Ltd.AUTOMOTIVE SECTOR , MAHINDRA NAGAR,

ZAHEERABAD – 502 220. MEDAK DIST. (T.S.)

MODEL :- CAMPER REFRESH 4WDBODY SHELL NO :- CARGO NO:-

KEY NO :-

Sr. OPERATION NAME SIGN Sr. OPERATION NAME SIGN1 STICKING STAGE 19 STEERING SUB ASSY

CARGO RED STICKER PASTING 2 ADDITIONAL PLAIN WASHERS BELOW

TYRE PRESSEURE STICKER COMBI SWITCH (DOWN SIDE)2 CARROUSAL REMOVAL SPACER ASSY AND CHECK NUT HAND TIGHT

IDENTIFICATION STICKER EVAPORATOR DRAIN PIPE ROOTING/NO KINK

3 DUMMY FITMENT 20 DOOR ASSY - FRONT (RH)

HAND BRAKE CABLE GROMMET INSPECTING LOCK FUNCTION WITH KEY

ADHESSIVE APPLICATION NO PULL HANDLE PLAY

NAMADA PIECES FITMENT LOCK CYLINDER CLIP INSERTION

4 HARNESS FITMENT 21 DOOR ASSY - MIDDLE (RH)

ROOF HARNESS FITMENT INSPECTING LOCK FUNCTION WITH KEY

DOOR SWITCH FITMENT - RH NO PULL HANDLE PLAY

5 ROOF REXENE FITMENT 22 DOOR ASSY - FRONT (LH)

NAMADA PIECES CHECKING INSPECTING LOCK FUNCTION WITH KEYROOF REXINE DAMAGES CHECK NO PULL HANDLE PLAY

ENSURE NO HORNESS STRUCKUP LOCK CYLINDER CLIP NISERTION

ROOF BINDING WIRE TIE UP AND CENTERING 23 DOOR ASSY - MIDDLE (LH)

6 FAVICOL APPLICATION INSPECTING LOCK FUNCTION WITH KEY

NO EXCESS GUM APPLICATION NO PULL HANDLE PLAY

WRINKLE FREE PILLER PIECES PASTE 24 DOOR TRIMMING FRONT (RH)PILLAR REXENE PASTED BELOW THE UPPER NO FORAGINE MATERIAL IN DOORS

EDGE OF WIND SHIELD ON BOTH SIDES 25 DOOR TRIMMING- MIDDLE (RH)

7 4WD LINK ROD ASSEMBLY NO FORAGINE MATERIAL IN DOORS

BUSHES(2) PLACED ON BOTH SI DES 26 DOOR TRIMMING FRONT (RH)

CERCLIP FITMENT NO FORAGINE MATERIAL IN DOORS7 WIPER MOTOR FITMENT 27 DOOR TRIMMING- MIDDLE (LH)

LINKAGES CONNECTION IN SAME DIRECTION NO FORAGINE MATERIAL IN DOORS

8 REXENE STICKING 28 I/P FITMENT -LH

WRINKLE FREE ROOF LINING SCRATCHLESS I/P FITMENT

NO EXCESS CUT INSIDE THE VEHICLE 29 I/P FITMENT -RH

9 REXENE TRIMMING NO 'A' PILLER REXINE DAMAGE BY

NO KNIFE SCRATCHES ON DOOR OPENINGS USING TEMPLATE

10 DUNLOP CLEANING 30 DOOR FINISHING (LH & RH)

EXCESS DUNLOP CLEANING WRINKLE FREE POLYSCREEN COVER PASTING

11 ACC CABLE FITMENT REGULATOR HANDLE POSSITION INSIDE UP 45 ⁰

SPLIT PIN & COTTER PIN FITMENT ENSURE NO TRIMPAD DAMAGES

TRIM IN DATE :- TIME :-

ECN CHANGE if any :- TRAIL CONDUCTED if any :-

TRIM LINE - CRITICAL OPERATIONS


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(ii) LEFT MIDDLE PAGE

Sr. PART NAME PART NUMBER SIGN Sr. PART NAME PART NUMBER SIGN

1 STICKERING - RH 0108EF0040N 5 DOOR OUT HANDLE (L 0114DN0120N

2 STICKERING - LH 0108EF0040N 6 DOOR LOCK (LH) OO87759

3 DOOR STICKER - RH 0108EF0191N 7 CHANNEL REAR BTM OO675164 DOOR STICKER - LH 0108EF0201N 8 REAR DOOR CHANNEL OO67517

5 RADIUM 1701EAA00590N 9 RELEASE DOOR HANDL 0114DN0151N

6 TYRE PRESURE CHART 00010F0030N

7 FELT ROOF 0105CK0170N

8 STICKER ASSEMBLY DO OO39779 1 REGULATOR ASSY WINDO 0111CAN00220N

2 REGULATOR ASSY WINDO 0111CAN00230N

1 MOTOR/HANDLE WIPER LI OO28417 3 GLASS RUN CHANNEL - OO99327

2 WIPER MOTOR FITME OO69259 4 GLASS RUN CHANNEL - OO99326

3 BRACKET 0101CAN01770N 5 REVEAL MOULDING IN 0105FN0043N

4 WIPER LINKAGE OO28417 6 REVEAL MOULDING O 0105FN0053N

1 ASSY ACCELERATION C 1002AA2910N 1 REGULATOR ASSY WINDO 0111CN0031N

2 BALLET CABLE 1002AA2880N 2 REGULATOR ASSY WINDO 0111CN0021N

3 REVEAL MOULDI NG 01 05FN00 12N

1 PEDAL COMPLETE 0802CA1410N 4 BOTTOM CHANNEL FOR GL OO74554

2 TRAY BATTERY 1401BAA02650N 5 BOTTOM CHANNEL FOR GL OO74553

3 KIT WIND SHIELD WAS 0116CN0020N 6 STRIP GLASS BOTTOM CHA OO397424 STICKER HOLD PLUG 0107FK0030N 7 GLASS RUN CHANNEL OO749745 BRAKE BOOSTER 0607AA0551N 8 GLASS REAR DOOR 0111CK0010N

9 GLASS FRONT DOOR -L OO677O8

1 SEAT BELT PAD - LH 0 105EAN011 20N

2 SEAT BELT PAD - RH 0105EAN01130N 1 TRIM PAD - REAR DOO 0105FAK00660N2 TRIM PAD - FRONT DO 0105EAK00360N

1 BLOWER 1202AAA00130N 3 CLIP (DOOR) PAD OO8O559

4 DOOR HANDLE OO8849O

1 I / P 0112AN0040N 5 HANDLE WINDOW 0111CG0650N

2 WIRING HARNESS 1801BAA07920N 6 BEZEL DOOR INNER RELEAS 0114DN0181N

3 EGR CONTROLLER 1805AA02691 7 REAR VIEW MIRROR I 0109AF0011N

4 DOOR BEEDING OO292OO 8 SUN VISOR- LH 0105DF0010N

9 SUN VISOR- RH 0105CN0100A

1 STEERING ROD OO28214 ## BANRAT LOAD 01102AA0970N2 CLUTCH PIPE 0802CA1210N

3 STEERING COVER OO9934O 1 FRONT OO6772O

4 KIT LOCK WITH COLU 01030K0100N

5 COMBINATION SWITC 1105AA0021N 1 DRIVER SEAT 0110BF0010A

6 STEERING CLAMP OO98535 2 MIDDLE SEAT 0110CF0061A

3 CO-DRIVER SEAT 0110BF0020A

1 GLASS RUN CHANNEL R 0105FK0260N 4 WIND SHIELD BACK G 0111EF0050N

2 QUATER GLASS SUB ASSY ST OO99315 5 WIND SHIELD FRONT OO28414

3 FRONT DOOR CHANNE OO6751O 6 REAR VIEW MIRROR - OO8863O

4 MIDDLE DOOR CHANN OO67518 7 REAR VIEW MIRROR - OO88631

DOOR TRIMMING - 2

STEERING COLUMN

CABLE FITMENT

AC FITMENT

HARNRSS

DOOR BEEDING

FRONT DOOR

DOOR TRIMMING -2

WIPER MOTOR FITMENT

BRAKE&CLUTCH FITMENT

SEAT BELT FITMENT

TRIM PAD FITMENT

DRIVER SEAT FITMENT

REAR DOOR


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(iii) RIGHT MIDDLE PAGE

FRONT VIEW REAR VIEW

TOP VIEW

LEFT SIDE VIEW

RIGHT SIDE VIEW

CARGO REAR VIEW CARGO TOP VIEW

PAINT AND BODY DEFECTS


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(iv) BACK PAGE

SIGN

SIGN

REMARKS

OPERATOR NAME

CHECK MAN

REPAIR MAN

TRIM - FINAL BUY OFF

REPAIR MAN

REMARKS

TRIM - MIDDLE BUY OFF

OPERATOR NAME

CHECK MAN

STAMP

STAMP

Self Certification Implimentation

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