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Training report lakshay tvs 2015

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TRAINING REPORT
OF
TRAINING AT
TVS MOTOR COMPANY LTD.
NALAGARH
H.P.
1 Project Training Report
DECLARATION
I hereby declare that the project work entitled in H.P.
Plant is an authentic record of my own work carried ou...
ACKNOWLEDGEMENT
The concept of industrial training, being a part of
the Engineering studies is of great use to the me. I
g...
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Training report lakshay tvs 2015

  1. 1. TRAINING REPORT OF TRAINING AT TVS MOTOR COMPANY LTD. NALAGARH H.P. 1 Project Training Report
  2. 2. DECLARATION I hereby declare that the project work entitled in H.P. Plant is an authentic record of my own work carried out at TVS Motor Company Limited, Nalagarh, Himachal Pradesh as Required for Four weeks Industrial Training and my University (Maharishi Markandeshwar University Mullana) as a part of my degree in B.Tech. Mechanical Engineering. The projects undertaken by me were under the guidance of Mr. Rohit Dhiman. Mr. Rohit Dhiman Mr.Virendar Chadda (Team Leader) (Unit Manager) (MSIE) (Engineering & QAD) Lakshay Sharma (Project Trainee PT 216) Roll No.11135293 2 Project Training Report
  3. 3. ACKNOWLEDGEMENT The concept of industrial training, being a part of the Engineering studies is of great use to the me. I got an opportunity to work in a motor company and gain a much needed practical experience and exposure while working with the experts in their fields of specialization. I consider myself extremely fortunate that I got the opportunity to gain this valuable practical knowledge during the course of my Four weeks training at TVS Motor Company, Nalagarh. I express my sincere gratitude to Mr. Rohit Dhiman, TVS Motor Company, Nalagarh for guiding me through the training and making my industrial training a meaningful experience. I would also like to thank Mr.Parveen Kaundal for guiding me throught the training period and to all the staff and the workers who helped mein gaining some some knowledge about the company and its culture. 3 Project Training Report
  4. 4. CONTENTS T VS MOTOR COMPANY LIMITED: 01. INTRODUCTION TO COMPANY 5 02. TVS MOTOR COMPANY 10 03. MEANING G OF TVS 18 04. VISION STATEMENT 19 05. KEY MILESTONES FOR TVS MOTORS 21 06. LOCATION OF TVS MANUFACTURING PLANTS 22 07. NALAGARH PLANT 23 08. TVS MOTOR, NALAGARH CORPORATE SOCIAL RESPONSIBILITY 24 09. ORGANIZATIONAL CHART 25 10. PLANT LAYOUT 26 11. PRODUCT SPECIFACTAION 27 12. DEPARTMENTS IN H.P. PLANT 28 13. LEARNING ABOUT THE FACTORY 32 MAUFACTURING PROCESS 33 4 Project Training Report
  5. 5. THE ASSEMBLY LINE 34 THE ACED LINE 39 THE METAL LINE 40 THE PLASTIC LINE 41 ASSEMBLY LINE SPECIFICATIONS 42 14. PROJECT-1 45 TITLE 46 PLANNING DONE FOR PROJECT 47 PARTS LIST 48 WORK DONEBY: FIRST WORKER 51 SECOND WORKER 52 THIRD WORKER 53 LAYOUT 54 PROJECT VALIDATION 55 ACTIVITY CHART 56 15. PROJECT-2 57 TITLE 58 PROCESS 59 PLANNING 60 ACED LOADING 61 PLASTIC LOADING 62 JUPITER SUB ASSY 63 ACTIVITY CHART 64 16. BIBLIOGRAPHY 65 5 Project Training Report
  6. 6. 1. INTRODUCTION TO COMPANY TVS GROUP The TVS group has always been inspired by a century long mission and vision of its own destiny. it is not just a business but a way of doing business, which sets TVS apart from others. 6 Project Training Report
  7. 7. Back in 1911, to the founder of the company, the ordinary ambitions of a bus fleet operator or a vehicle servicing business would not suffice. Rather, he wanted to create an enduring business led by a family of like minded workers and managers united by a set of shared high principles. Driven by this inspiration, the TVS group has today emerged as India's leading supplier of automotive components. Today the TVS Group is the largest automotive component manufacturer in India, with annual turnover of more than USD 4 billion. The group has over 30 companies employing a work- force of 40,000 people. Underlying the success of the group is its philosophy of commitment to the cherished values of promoting trust, value and customer service. This was the personal philosophy of the Group's Founder Shri T V Sundaram lyengar, and it remains the overarching code by which the Group functions. Market leadership and rewards of business have followed naturally. Although the letters TVS represent the initials of our founder, T V Sundaram lyengar, to us within TVS they have 7 Project Training Report
  8. 8. always stood for Trust, Value and Service. The founder of the company embodied these values and set an example for all employees to emulate. TVS believes that the success of any enterprise is built on the solid foundation of customer satisfaction. Continuous innovation and close customer interaction have enabled TVS companies to stay ahead of competition. 8 Project Training Report
  9. 9. Quality at TVS determines not only the end product but the systems, processes and operations at all levels. The first four companies in India, which have won the coveted Deming Prize are from the TVS group. The business ranges across automobile component manufacturing, components distribution, manufacturing of powered two-wheelers, computer peripherals, financial services, contract manufacturing services and software development. TVS Motor company Ltd (TVS Motor) - member of the TVS group is the largest company of the group in terms of size and turnover. 9 Project Training Report
  10. 10. 10 Project Training Report
  11. 11. 2. TVS MOTOR COMPANY In 1979, Sundaram Clayton Limited (SCL) started a moped division at Hosur to manufacture TVS-50 mopeds indigenously designed and developed, marking the start of automobile giant TVS Motors Pvt Ltd. TVS motors is the 3rd largest 2- wheeler manufacturer in India with a market share of 18% and one of the top 10 in the whole world with an annual turnover of over USD 650 millions. TVS motor company has manufacturing units at Hosur, Mysore, and Nalagarh. It also has plant at Indonesia. TVS has launched 37 models starting from mopeds XL in 1979 to apache RTR 180 in 2009.With steady growth, expansion and diversification, TVS commands a strong presence in manufacturing of two-wheelers, auto components and computer peripherals. We also have vibrant businesses in the distribution of heavy commercial vehicles passenger cars, finance and insurance. 11 Project Training Report
  12. 12. TV Sundram Iyengar and Sons Limited operate through the three following divisions: TVS Sundaram Motors Madras Auto Service and TVS and Sons distribute Heavy Duty Commercial Vehicles, Jeeps and Cars. It represents premier automotive companies like Ashok Leyland, Mahindra and Mahindra Ltd., Fiat and Honda. It also distributes automotive spare parts for several leading manufacturers. TVS & Sons has grown into a leading logistics solution provider and has set up state-of-the-art warehouses all over the country. It has also diversified into distributing Garage equipment that ranges from paint booths to engine analyzers and industrial equipment products. Lakshmi Auto Components Ltd -OE supplier of 2-wheeler gears and camshafts. Distribution of auto electrical components in all over India. Axles India Limited - A joint venture with Eaton Limited, U.K. Manufactures axle housings and drive heads for heavy and light commercial vehicles. 12 Project Training Report
  13. 13. Brakes India Limited - A joint venture with Lucas Automotive, U.K. Manufactures foundation and hydraulic brakes as well as other products for automotive and non- automotive applications in collaboration with Grammar, world leader in the category. India Motor Parts and Accessories Limited - One of India's largest distributors of spare parts in India. Nippon Electrical Limited: - A joint venture with Kokusan Denki, Japan. Involved in the manufacture of magnetos. Lucas TVS Limited: - A joint venture with Lucas Industries U.K. Manufactures a range of auto electric systems. Also develops and produces vacuum pumps and gear starters with Hitachi Limited, Japan spares. Southern Roadways Limited - Giant in the Indian road transport industry, company operates largest parcel service all over South India. Sundaram Brake Linings Limited: - First Indian companies to manufacture asbestos-free brake linings, 13 Project Training Report
  14. 14. woven clutch facings and disc pads for automotive applications. Sundaram Fasteners Limited: - India's largest manufacturer of tensile fasteners. First company which receive ISO 9002 certification. Also the principal supplier of radiator caps to GM in USA. Sundaram Finance Limited: - Leading consumer finance company in India. Sundaram Industries Limited: - With a reputation built over five decades, comprises several divisions: custom molded rubber products, tyre services and coach building. Also specializes in refrigerated trucks and bunk beds. Sundaram Motors: - Major dealers for Indian and foreign cars in South India. Sundaram Clayton Limited: -Sundaram-Clayton Limited was established in 1962 in collaboration with Clayton Dewandre Holdings Plc. (WABCO Automotive) pioneering the manufacture of air brake systems in India. SCL enjoys a major share of the Indian OEM market as well as the domestic aftermarket, which it caters to through a strong 14 Project Training Report
  15. 15. and well spread-out distribution network SCL-Brakes division is the first company in India and fourth company outside Japan to win the Deming award for achieving distinctive performance improvements through TQM. In 2002, SCL-Brakes division was awarded Japan Quality Medal. It is the first company in India and second outside Japan to win this prestigious award for continual application of TQM for priority issues to achieve business results. The company's Die Casting Division, from being a captive supplier to the Brakes Division, is developing into a full service supplier of aluminum components to a host of Indian and multi-national companies. It has an installed capacity of 18000 MT per annum of gravity, low pressure and high pressure die castings and plans to increase it to 24000 MT in the next two years. Both the divisions are certified for QS 9000 and ISO 14001. Srinivasan Services Trust: - The SST (Srinivasan Services Trust), an organization initiated by Sundaram Clayton Ltd and TVS Motor Company Ltd for charitable purposes, has been promoting community development programs in Tamil Nadu, Gujarat, Maharasht 15 Project Training Report
  16. 16. Karnataka. Complete Range Of TVS Products 16 Project Training Report
  17. 17. In 1979, Sundaram Clayton Limited (SCL) started a moped division at Hosur to manufacture TVS-50 mopeds indigenously designed and developed, marking the start of automobile giant TVS Motors Pvt Ltd. TVS motors is the 3rd largest 2-wheeler manufacturer in India with a market share of 18% and one of the top 10 in the whole world with an annual turnover of over USD 650 millions. 17 Project Training Report
  18. 18. TVS motor company has manufacturing units at:  Hosur,  Mysore,  Nalagarh. 18 Project Training Report
  19. 19. It also has one plant at Indonesia. TVS has launched 36 models starting from mopeds XL in 1979 to Flame-125 in 2008. The first 18 models were launched in the first 18 years and next set of 18 has been launched in next 8 years. Out of our total product range 22% are mopeds, 60% are motorcycles and 18% of scooter. 3. MEANING OF TVS TVS stands for T – TRUST V – VALUE S – SERVICE 19 Project Training Report
  20. 20. MISSION STATEMENT “We are committed to being a highly profitable and socially responsible, leading manufacturer of high value for money, environmentally friendly, lifetime personal transportation products under TVS brand for customers predominantly in Asian markets and to provide fulfillment and prosperity for employees, dealers and suppliers.” Venu Srinivasan (Managing Director) 20 Project Training Report
  21. 21. 4. VISION STATEMENT TVS Company will be • Driven by customer TVS Motor will be responsive to customer requirements consonant with its core competence and profitability. TVS Motor will provide total customer satisfaction by giving the customer the right product, at the right price, at the right time. • Industry leader TVS Motor will be one among the top two two-wheeler manufacturers in India and one among the top five two- wheeler manufacturers in Asia • Global overview TVS Motor will have profitable operations overseas especially in Asian markets, capitalizing on the expertise developed in the areas of manufacturing, technology and marketing. The thrust will be to achieve a significant share for international business in the total turnover. • At the cutting edge of Modern technology TVS Motor will hone and sustain its cutting edge of technology by constant benchmarking against international leaders. • Committed to total quality 21 Project Training Report
  22. 22. TVS Motor is committed to achieving a self-reviewing organization in perpetuity by adopting TQM as a way of life. TVS Motor believes in the importance of the process. People and projects will be evaluated both by their end results and the process adopted. • Employee dependent TVS Motor believes that people make an organization and that its well-being is dependent on the commitment and growth of its people. There will be a sustained effort through systematic training and planning career growth to develop employees’ talents and enhance job satisfaction. TVS Motor will create an enabling ambience where the maximum self-actualization of every employee is achieved. TVS Motor will support and encourage the process of self-renewal in all its employees and nurture their sense of self worth. 22 Project Training Report
  23. 23. LOCATION'S OF TVS MANUFACTURING PLANTS: 1. Hosur Plant , Tamil Nadu 2. Mysore Plant ,Karnataka 3. Nalagarh plant , Himachal Pradesh 4. Indonesia Plant 23 Project Training Report
  24. 24. 5. KEY MILESTONES FOR TVS MOTORS: 24 Project Training Report
  25. 25. 6. LOCATION OF TVS MANUFACTURING PLANTS: TVS Motor Company has 9 manufacturing plants all over the world, which are as follows: Plant 1 - Moped Division, Hosur started in 1979 Plant 2 - Motorcycle Division, Hosur started in 1984 Plant 3 - Engine Component Division, Hosur started in 1988 Plant 4 - Scooter & Motorcycle Division, Mysore started in 1998 Plant 5 - Spares Warehouse Division, Hosur started in 1988 Plant 6 - Engine Component Division, Mysore started in 2003 Plant 7 - Motorcycle Division, Nalagarh started in 2007 Plant 8 - Bebek Motorcycle Division, Jakarta Indonesian started in 2007 Plant 9 - Auto Manufacturing Division, Hosur started in 2007 25 Project Training Report
  26. 26. 7. NALAGARH PLANT: This is the latest manufacturing plant. Nalagarh plant is situated at village Bhattian, 4 Kms away from Nalagarh city on Bharatgarh Road in Himachal Pradesh. First vehicle rolled out at this plant on 29th April 2007, which marked the beginning of new chapter in TVS motors. CLIMATIC CONDITIONS: • Maximum Temperature - 45°C • Minimum Temperature - 3°C • Humidity – 60%(min) to 90 %(max) PRODUCTS: • Star City 110 cvti & ES • Star Sport cvti & ES • Star Basic • Moped 26 Project Training Report
  27. 27. 8. TVS MOTOR, NALAGARH CORPORATE SOCIAL RESPONSIBLITY: • Construction of drainage canal at village Bhattian. • Parapet wall for school entry culvert at village Bhattian • Primary health center at village Bhattian • Participation in sports day function • Painting competition organized of school children in company on Environment Day 27 Project Training Report
  28. 28. 9. ORGANISATIONAL CHART 28 Project Training Report MANAGING DIRECTOR PRESIDENT VICE-PRESIDENT (INDUSTRIAL RELATIONS) VICE-PRESIDENT (OPERATIONS) VICE-PRESIDENT (FINANCE) GENERAL MANAGER (INDUSTRIAL RELATIONS) GENERAL MANAGER (OPERATIONS) GENERAL MANAGER (FINANCE) UNIT MANAGER (PLANT MAINTINANCE DEPT. (PMD)) UNIT MANAGE (PAINT SHOP) UNIT MANAGER (QUALITY & ENGINEERING) UNIT MANAGER (VEHICLE ASSYMBLY) UNIT MANAGER (MATERIAL PROCUERMENT DEPERTMENT) GROUP LEADER (Sr. Engineer) OPERATORS & INSPECTORS OPERATORS & INSPECTORS
  29. 29. 10. PLANT LAYOUT 29 Project Training Report Vehicleassembly Vehicle parts stores SuperMarket Finishe d goods Paintingunitstores/AHUs Paint parts stores Painting - Metal line Painting - Lacquer line Painting - Plastic line Tim e offic e Fabrication ID M Offi ce ReceptionPer- sonnel Medical Center Planning Room &office Metallurgy lab Learning Centre- Workshop Painting Process lab Fabrication parts stores P M D Final inspection & testing Painting - ACED line Frame parts stores
  30. 30. 11. PRODUCTS & SPECIFICATIONS MOTOR CYCLES: 30 Project Training Report A) ENTRY LEVEL: BRAND: TVS Star LAUNCHED: 2004 SOLD: Above 2 mn. B) EXECUTIVE: BRAND: TVS FLAME LAUNCHED: 2008 BRAND: TVS APACHE 160 RTR LAUNCHED: 2005 SOLD: OVER 1 LAKH C) PREMIUM: BRAND: TVS APACHE 180 RTR LAUNCHED: 2009 SOLD: OVER 1 LAKH
  31. 31. BRAND: TVS WEGO LAUNCHED: 2009 31 Project Training Report SCOOTERS: BRAND: TVS SCOOTY, PEP, PEP+ LAUNCHED: 1994, 2003, 2005 SOLD: OVER 1 MN MOPEDS:
  32. 32. 12. DEPARTMENTS IN H.P. PLANT DM Stores: - All the material, which is directly supplied to the customer, is known as Direct Material, the material that is a part of the final product. The DM stores are the department, which takes care of the stock of the direct materials. IDM Stores: - For indirect material e.g. lint free cloth, gloves. QAD Himachal: - (Quality Assurance Department) This department at Himachal is looking after the day-to- day quality issues in the plant. The materials handled by this department are the incoming and outgoing materials. It keeps a check on the material if it is within the specified norms and if not it rejects the material and notifies its supplier. ISD: - (Information System Department) Manages the information system and technology for all the plant. 32 Project Training Report
  33. 33. Paint shop-ACED:- The ACED paint shop paints the finished metal components (only primer coating) and then passes them on to the Lacquering line where the components are then painted with a Topcoat color, which the customer wants. Paint shop-Metal:- At this stage the metal components are painted with a topcoat of the wanted color and then Lacquering is done on them. Paint shop-Plastic:- In this paint shop all the plastic parts of the vehicle are painted and then supplied to the customer, Vehicle assembly . PMD: - (Plant Maintenance Department) PMD looks after the supply of Water, Electricity and Air to each and every spot in the plant. It also has to look after the maintenance of the same. Fabrication: - This Department maintains the stock of fuel tanks wanted by its customers and has to check the quality of the same before supplying it to them. 33 Project Training Report
  34. 34. Vehicle Assembly: - All the departments that manufacture different products stages of the plant have vehicle assembly as their final customer. Here the whole assembly of vehicle is done. 34 Project Training Report
  35. 35. Learning About The Factory 35 Project Training Report
  36. 36. MANUFACTURING PROCESS: The manufacturing process is explained clearly with block diagram below: 36 Project Training Report Vendor Stores Fabrication Machining Engine Assembly Vehicle Assembly Painting Stores Warehouse Dealer Customer
  37. 37. THE ASSEMBLY LINE: Operations done on pre-line: • Frame numbering • Rear fender loose assembly • Swing arm assembly • Shock absorber loose assembly • Drum rear sprocket loose assembly • Rear wheel assembly • Front wheel to frame • After that the vehicle is loaded to main line for another assemblies and operations • In pre-line there are some sub-assemblies. These are: • SAI valve sub assembly • Chain adjuster sub assembly 37 Project Training Report
  38. 38. • Bracket sub assembly • Front fork sub assembly • Front fender to fork sub assembly Operations done on main line left side (ML): • Handle bar • RFR (Rider Foot Rest) • Engine Loading • Engine mounting • Clutch cable • Engine holding • Horn • Battery • Rear TSL (indicators) • Seat lock • Chain play • Flash unit (relay) • Tool holder (battery holder) 38 Project Training Report
  39. 39. • Battery assembly • Chain case tightening • Front brake assembly • Sprocket cover • Cover magneto assembly • Choke • SAI • Zone inspection • Regulator assembly • Tank assembly • Tank tightening • Gear shift lever assembly • Cover frame assembly • Head lamp assembly • Logo pasting • T1 Inspection (Testing) • T2 Inspection (Defect solving) 39 Project Training Report
  40. 40. • T3 Inspection (Road testing) • T4 Inspection (Final inspection) Operations done on the main line right side (MR): • RFR (Rear Foot Rest) • Brake pedal sub assembly • Loose assembly of engine mounting net • Air filter and HT coil • SAI assembly to engine • Mini air filter assembly • Mini air filter tightening • Torque link loose assembly • Throttle assembly 40 Project Training Report
  41. 41. • Rear brake assembly • Muffler (Silencer) • Center axle nut tightening • Clutch paly • Front TSL connections • Zone inspection • Front brake lamp connection • Front bolt tightening • Tail cover tightening • Fork bolt and lock nut torque check • Seat assembly • Cover frame assembly • Head lamp assembly 41 Project Training Report
  42. 42. THE ACED LINE: • Quality check of material • Mounting of parts on the jig • Hot Water Rinse at 70-80 degree Celsius • Pre Degreasing Tank at 50-60 degree Celsius • Dip Degreasing Tank 50-60 degree Celsius • Water Rinse-1 at ambient temperature • Water Rinse-2 at ambient temperature 42 Project Training Report
  43. 43. • Activation at ambient temperature • Phosphating at 40-45 degree Celsius • Water Rinse-3 at ambient temperature • Water Rinse-4 at ambient temperature • PT RCDI Water Rinse at ambient temperature • E-Coat at 26-30 degree Celsius • UF Rinse-1 at <30 degree Celsius • UF Rinse-2 at <30 degree Celsius • ED RCDI Rinse at ambient temperature • Heating in the Oven at 170 degree Celsius for approximately 1 hour. THE METAL LINE: • Getting parts from ACED • sanding part surface to make it rough • mounting it on jigs • cloth cleaning of part to remove dust • air blow cleaning 43 Project Training Report
  44. 44. • Base Coat • Air Time • Top Coat • Heating in Oven • Cooling Time • Stickering • Sanding • Lacquering • Final Inspection • Mount to trolley THE PLASTIC LINE: • Unloading parts from SACL boxes and crates • Pre-check if parts are OK or NOT OK • mounting the part on the jig • Cloth Cleaning 44 Project Training Report
  45. 45. • Air Blow cleaning to remove dust • Base Coat or Primer • Air Time • Top Coat • Oven Time • Unloading • Inspection • Fault removal • Snickering • Mounting on trolley Assembly Line Specifications:  Manufactured By: PAJA MECHANICALS LIMITED.  Type: Slat Conveyer 45 Project Training Report
  46. 46.  Length: 90.2 m  Height: 600 mm at drive end  Speed: 6.032 m/min.  Pitch: 2800 mm Load per pitch: 150 kgs. Slat width: 600 mm Chain: Flanged roller with bearing pin bush type Drive: A.C. Frequency invertor No. of working: 65 Use: Assembly of Moped/Scooter/Motorcycle 46 Project Training Report
  47. 47. PROJECT-1 47 Project Training Report
  48. 48. TITLE "Eliminate Manual Movement Of Zone 2 Kitting Person By Clubbing The Movement With Kitting Person" Planning Done For The Validation Of The Project: 48 Project Training Report
  49. 49. •Firstly the area was identified , actually with which the procedure is being followed up. •After that the movement was identified. •After that counting of the components was done. •Counting was done in such a way that the components counted should not be counted again. •Later the study is done such that the task can be performed by 2workers. Part List Of Feeding Person 2: [ For City+ ] 1. Cover seat tail 49 Project Training Report
  50. 50. 2. Cover frame 3. Housing head lamp [ For Sport ] 1. Cover seat tail 2. Sport cover frame 3. Housing head lamp 4. Outer cover frame Part List Of Feeding Person 3: [ For City +] 1. Head lamp 50 Project Training Report
  51. 51. 2. Rear lamp 3. Visor 4. Tail Centre piece 5. RC lamp bracket 6. Inner 7. Lower cover frame [ For Sport ] 1. Head lamp 51 Project Training Report
  52. 52. 2. Rear Lamp 3. Visor 4. Lower Bracket 5. Tail centre piece 6. RC lamp bracket [ For Moped ] 1. Head lamp Work Implementation By First Worker: 52 Project Training Report
  53. 53. a)Initially the bins are transferred to the trolley from the station ML28 b)The trolley containing the bins is parked in front of the second worker for the kitting . c) The trolleys are taken to the sub assemblies d)The bins are kept on the rolling bars of the vehicle unit sub assembly Work Implementation By Second Worker: 53 Project Training Report
  54. 54. a)When the bins are brought by the first worker he starts collecting the desired parts for kitting. b)He checks the kitting parts for zero defect and on passing it does the kitting of them. c) He also does the feeding of the housing head lamp by bringing the trolleys from the super market and takes it to the sub assembly area. Work Implementation By Third Worker: 54 Project Training Report
  55. 55. a)The bins which are delivered by the jumbo kept on the rolling bars are feeded by him. b)The bins containing the desired parts are kept on the bin stands at the respectful sub assembly station . c) the call is been made by the sub assembly workers whwn the feeding bins get empty. d)He is also employed in bringing the visor trolley from the super market area and feeds it to the head lamp sub assembly. LAYOUT 55 Project Training Report
  56. 56. Project Validation: By studying the work flow process followed by the three workers the process can be thus followed as. 56 Project Training Report
  57. 57. The first worker brings the trolleys from ML 28 places it to the painted plastic parts area . By the time kitting is being done he can wait for a call given by sub assembly workers for the bin parts . He can even check for the trolleys of the visor and the housing head lamp simultaneously. The second worker does the kitting of the parts and will move the trolleys to the sub assembly . The bins are loaded by the second worker on the roller bars of sub assembly. The empty trolley is taken back by the first worker back to ML 28 for getting more empty trolleys and second worker does the feeding work. 57 Project Training Report
  58. 58. 58 Project Training Report
  59. 59. PROJECT-2 TITLE 59 Project Training Report
  60. 60. " To Make The Videos For Time Study Of Manpower In Plastic Loading Unit And ACED Unit'' PROCESS The idea of generaion for the video study is to manage the work force employed on the line so as to calculate 60 Project Training Report
  61. 61. their takt time on each working station such that an efficient working condition can be generated . By the help of video study the division of work and the division of employes is also done such that every employ gets his particular and desired work for a calculated takt time which makes the work division flexible and easy to divide. Thus the process of video study plays an important role in the re destribution of the work when needed and in case of eliminating certain worker from certain area unwanted. Planning done for effective video making: 61 Project Training Report
  62. 62. • First of all I understood the deployment of the workers • After that their process of work was understood. • The video making was carried out in an efficient manner • For effective result more no. of cycle of work was taken i.e 10 cycles per work. • After that analysis or time study was calculated. • Finally takt time was calculated. Takt time = no. to be produced / time available ACED Unit Loading 62 Project Training Report
  63. 63. [ For Motorcycle]:  Stage1: Lock testing and masking fuel tank  Stage2: Fuel tank loading  Stage3: Handle pillion loading [ For Moped ]:  Stage1:Lock testing and masking fuel tank  Stage2: Stay mudguard loading  Stage3: Stabalized tube loading  Stage4: front fender walking time [ For Jupiter ]  Stage1: Front fender loading  Stage2: Handle pillion loading  Stage3: Front fender walking time Plastic Line Loading 63 Project Training Report
  64. 64. [ For Motorcycle ]  Stage1: Housing head lamp (city+ sport)  Stage2: Tail cover L/R (city+ sport)  Stage3: Cover frame L/R (city+ sport)  Stage4: Front fender (city+ sport) [ For Jupiter ]  Stage1: Housing head lamp  Stage2: Front panel top  Stage3: Front panel bottom  Stage4: Tail centre piece top  Stage5: Tail centre piece bottom  Stage6: Side panel L/R 64 Project Training Report
  65. 65. Jupiter Sub Assembly:  Stage1: Fuel tank testing  Stage2: Front fender sub assembly  Stage3: Front leg assembly  Stage4: Jupiter chassis no. marking assy  Stage5: SAI sub assembly 65 Project Training Report
  66. 66. BIBLIOGRAPHY 66 Project Training Report
  67. 67.  TVS company profile (www.tvsm.com)  www.howstuffworks.com  www.wikipedia.org 67 Project Training Report

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