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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 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
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
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
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
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
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
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
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 Project Training Report
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
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
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
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
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
Karnataka.
Complete Range Of TVS Products
16 Project Training Report
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.
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TVS motor company has manufacturing units at:
 Hosur,
 Mysore,
 Nalagarh.
18 Project Training Report
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
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
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
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
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
5. KEY MILESTONES FOR TVS MOTORS:
24 Project Training Report
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
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
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
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
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
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
BRAND: TVS WEGO
LAUNCHED: 2009
31 Project Training Report
SCOOTERS:
BRAND: TVS SCOOTY, PEP,
PEP+
LAUNCHED: 1994, 2003, 2005
SOLD: OVER 1 MN
MOPEDS:
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
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
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
Learning
About The
Factory
35 Project Training Report
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
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
• 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
• 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
• 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
• 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
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
• 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
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• 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
• 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
 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
PROJECT-1
47 Project Training Report
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
•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
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
2. Rear lamp
3. Visor
4. Tail Centre piece
5. RC lamp bracket
6. Inner
7. Lower cover frame
[ For Sport ]
1. Head lamp
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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:
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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
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
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
Project Validation:
By studying the work flow process followed by the three
workers the process can be thus followed as.
56 Project Training Report
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 Project Training Report
PROJECT-2
TITLE
59 Project Training Report
" 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
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
• 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
[ 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
[ 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
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
BIBLIOGRAPHY
66 Project Training Report
 TVS company profile (www.tvsm.com)
 www.howstuffworks.com
 www.wikipedia.org
67 Project Training Report

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Training report lakshay tvs 2015

  • 1. TRAINING REPORT OF TRAINING AT TVS MOTOR COMPANY LTD. NALAGARH H.P. 1 Project Training Report
  • 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. 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. 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. 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. 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. 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. 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. 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
  • 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. 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. 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. 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. 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. Karnataka. Complete Range Of TVS Products 16 Project Training Report
  • 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. TVS motor company has manufacturing units at:  Hosur,  Mysore,  Nalagarh. 18 Project Training Report
  • 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. 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. 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. 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. 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. 5. KEY MILESTONES FOR TVS MOTORS: 24 Project Training Report
  • 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. 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. 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. 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. 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. 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. 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. 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. 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. 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
  • 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. 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. • 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. • 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. • 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. • 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. 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. • 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. • 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. • 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.  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
  • 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. •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. 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. 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. 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. 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. 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. 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. 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. 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
  • 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. 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. • 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. [ 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. [ 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. 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
  • 67.  TVS company profile (www.tvsm.com)  www.howstuffworks.com  www.wikipedia.org 67 Project Training Report