1.
JAMSHEDPUR
SIGNA
Name : SAURABH KUMAR PAL
Institute : JADAVPUR UNIVERSITY, KOLKATA

2.
2 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
This is to certify that SAURABH KUMAR PAL, Pre-Final Year,
PRODUCTION ENGINEERING DEPARTMENT, JADAVPUR
UNIVERSITY, KOLKATA; has completed his training cum project
work successfully and satisfactorily on the topic:
“PRODUCTIONISATION OF SIGNA”
during the period of 4th June to 2nd July 2016 under my
guidance. During his training period in the Tata Motors we found him
hard working, sincere and diligent person and his behaviour and
conduct was good. We wish him all the best for his future endeavours.
PROJECT GUIDE
Mr. Subir Ganguly,
A.G.M.,
Product Planning & Program Management,
TATA Motors Limited,
Jamshedpur.

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3 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
ACKNOWLEDGEMENT
I have taken efforts in this project. However, it would not have been possible
without the kind support and help of many individuals and organizations. I
would like to extend my sincere thanks to all of them.
I am highly indebted to Mr. Subir Ganguly and Mr. Anup Kumar Adak for their
guidance and constant supervision as well as for providing necessary
information regarding the project & also for their support in completing the
project.
I would like to express my gratitude towards my parents for their kind co-
operation and encouragement which help me in completion of this project.
I would like to express my special gratitude and thanks to industry persons in
the shop floor for giving me such attention and time.
My thanks and appreciations also go to my colleague in developing the project
and people who have willingly helped me out with their abilities.

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4 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
CONTENTS
Sl. No. Topic Page No.
1 ACKNOWLEDGEMENT 3
2 INTRODUCTION 5
3
MASS PRODUCTION OF
AUTOMOBILES
8
4
VEHICLES PRODUCED BY TATA
MOTORS LTD.
9
5
TATA MOTORS LTD. JAMSHEDUR :
OVERVIEW
10
6
STATIONWISE OPERATIONS IN LINE 1,
2 & 3
14
7 NEED OF A NEW PRODUCT 20
8 SPECIDICATIONS OF SIGNA 4923.S 21
9
1-5-25 CONCEPT IN
PRODUCTIONISATION
25
10 ISSUES OBSERVED IN SIGNA 26
11 DEFECT ANALYSIS AND SOLUTIONS 28-33
12 CONCLUSION 34

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5 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
INTRODUCTION
Tata Motors Limited (formerly TELCO, short for Tata Engineering and Locomotive Company)
is an Indian multinational automotive manufacturing company headquartered
in Mumbai, Maharashtra, India, and a subsidiary of the Tata Group. Its products include
passenger cars, trucks, vans, coaches, buses, construction equipment and military vehicles. It
is the world's 17th-largest motor vehicle manufacturing
company, fourth-largest truck manufacturer, and second-
largest bus manufacturer by volume.
Tata Motors has auto manufacturing and assembly plants
in Jamshedpur, Pantnagar, Lucknow, Sanand, Dharwad,
and Pune in India, as well as in Argentina, South Africa,
Thailand, and the United Kingdom. It has research and
development centres in Pune, Jamshedpur, Lucknow, and
Dharwad, India and in South Korea, Spain, and the United
Kingdom. Tata Motors' principal subsidiaries purchased the
British premium car makerJaguar Land Rover (the maker of
Jaguar, Land Rover, and Range Rover cars) and the South
Korean commercial vehicle manufacturer Tata Daewoo. Tata
Motors has a bus-manufacturing joint venture
with Marcopolo S.A. (Tata Marcopolo), a construction-
equipment manufacturing joint venture with Hitachi (Tata
Hitachi Construction Machinery), and a joint venture with Fiat
Chrysler which manufactures automotive components and
FiatChrysler and Tata branded vehicles.
Tata Motors is listed on the (BSE) Bombay Stock Exchange,
where it is a constituent of the BSE SENSEX index,
the National Stock Exchange of India, and the New York Stock
Exchange. Tata Motors is ranked 287th in the
2014 Fortune Global 500 ranking of the world's biggest
corporations.

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6 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
Tata Motors Limited, a USD 42 billion organisation, is a leading global automobile
manufacturer with a portfolio that covers a wide range of cars, sports vehicles, buses, trucks
and defence vehicles. Our marque can be found on and off-road in over 175 countries
around the globe.



       

         
VISION, MISSION & VALUES

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7 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
TATA MOTORS LTD. FACILITIES
MANUFACTURING
Our manufacturing facilities have more than just state-of-the-art technology; we have the
best and passionate engineering and quality talent working to produce superior vehicles.
Striving for excellence is an integral part of the Tata Motors culture. Our plants are certified
for world class manufacturing and quality standards. Our focus on automation and
technology has kept us at the forefront of the automobile industry. That is why we are the
leader in India’s commercial vehicle market and among the top vehicle makers in the world.
DESIGN
At Tata Motors, design is vital simply because a vehicle’s colour, shape and features are
crucial to its being bought. Our design unit in Coventry, UK, specialises in clay modelling,
digital modelling and alias modelling, our unit in Turin, Italy, specialises in styling,
architecture, packaging and surfacing; and our Pune unit takes over design execution from
the technical aspect. Our recent offerings, Bolt, Zest and Ultra, reflect global design
dimensions. While designing commercial vehicles, our designers focus on safety,
maintenance and elements such as driver fatigue. Our designers bear in mind that to the man
on the street, the vehicle must convey a trendy, trustworthy message. Tata Motors’ Ultra
trucks offer global styling, enhanced driving comfort and fuel efficiency.
R&D CENTERS
Tata Motors’ mission is to offer the best vehicle experience to its global customers.
Consequently, its R&D centres focus on various issues such as the look and feel of a vehicle,
safety and efficiency and of course, fuel economy. The fruits of its R&D centres can be seen in
its various products such as the Zest and Bolt and in its commercial vehicles such as the Ultra
and Ace. Among our latest R&D centres is the state-of-the-art centre in Pune, one in the UK
and another in South Korea. This international confluence of cultures brings a unique flavour
to the end product, one that is unmatched anywhere in the world.

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8 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
MASS PRODUCTION OF AUTOMOBILES
Mass production or flow production is the production of large amounts
of standardized products, including and especially on assembly lines. Together with job
production and batch production, it is one of the three main production methods.
The term mass production was popularized by a 1926 article in the Encyclopedia
Britannica supplement that was written based on correspondence with Ford Motor
Company. The New York Times used the term in the title of an article that appeared before
publication of the Britannica article.
Mass production was popularized in the late 1910s and 1920s by Henry Ford's Ford Motor
Company, when introduced electric motors to the then-well-known technique of chain or
sequential production.
Henry Ford designed his first moving assembly line in 1913, and revolutionised the
manufacturing processes of his Ford Model T. This assembly line, at the first Ford plant in
Highland Park, Michigan, became the benchmark for mass production methods around the
world.
In 1913, Henry Ford installs the first moving assembly line for the mass production of an
entire automobile. His innovation reduced the time it took to build a car from more than 12
hours to two hours and 30 minutes.
The Model T made its debut in 1908 with a purchase price of $825.00. Over ten thousand
were sold in its first year, establishing a new record. Four years later the price dropped to
$575.00 and sales soared. By 1914, Ford could claim a 48% share of the automobile market.

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9 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
VEHICLES PRODUCED BY TATA MOTORS
Hatchbacks
Sedans
Utility Vehicles
Trucks
Passenger Transportation

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10 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
JAMSHEDPUR
The Jamshedpur facility was Tata Motors’ first, set up in 1945, to manufacture steam
locomotives. It led the company’s foray into commercial vehicles in 1954. It has been
modernized through the decades, with a particularly intense scale in the last 10 years. It is
spread over an area of 822 acres.
VARIOUS DIVISIONS OF TATA MOTORS
● Auto Division ● Forge Division ● Foundry Division ● Excavator Division ●Management
Service Division ● Export and Spare Part Division ● Industrial Engineering Division ●
Administration and Security Division ● Management Training Centre ● Quality Assurance ●
Finance ● Engineering Services Division

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11 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
Salient features of TATA MOTORS JAMSHEDPUR Plant
 Tata Motors Jamshedpur plant rolls-out a truck every five minutes.
 The entire plant is entirely a green zone.
 The in-house test track is the first of its kind in India.
 The Jamshedpur plant rolled out its 2 millionth vehicles in 2013.
 It is the first manufacturer in India to build a race truck and run a
championship.
 The plant has got an off-road test track; the only one of its kind in India.
 It's one of the leading suppliers of defence vehicles to country's security
forces.

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12 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
TATA MOTORS OPERATING DIVISIONS
HRD: Human Resource Development is a major priority at Tata Motors, whether it is at the
workers or engineer levels. Over the years, young men have been trained for skilled jobs to
meet the growing demands of advancing technology. The training activity includes preparing
fresh recruits to meet job challenges as also retraining of all levels of employees to further
meet new requirements.
ERC (Engineering Research Centre): While the main Engineering research centre is located
at Tata Motors Pune plant, the Jamshedpur unit has its own research wing, which regularly
upgrades components and aggregates. A torture track enables rigorous and exhaustive
testing of modifications before they become regular fitments.
PPC (Production, Planning and Control): PCC acts as a navigator to the production. It is
responsible for release of production plan on Annual, Monthly, Weekly and Daily basis. PPC
gets schedule from sales headquarter Mumbai and transfers it into detail manufacturing
plants which is communicated to different divisions of plant.
AUTO MATERIALS: Auto Materials is responsible for procurement of material required for
production. The ADD (Ancillary development department) is responsible for new vendor
development.
TRUCK DIVISION ASSEMBLY LINE: It consists of two Assembly lines. The main Assembly line
(Assembly line-I) measure 180 meters in length, has 20 stations- a vehicle rolls out every 8
minutes. The second Assembly line is totally dedicated to Special Purpose Vehicles.
ENGINE DIVISION ASSEMBLY LINE: It is the vibrant heart of TATA MOTORS. Engine Division is
involved in the manufacturing of engine. Raw materials to this division come in the form of
castings like the cylinder head, block, clutch housing, or forging like crankshaft, Connecting
rods.
CAB AND COWL ASSEMBLY LINE: All sheet metal components requirement as well as all cab
and cowl fabrication is done here.
FOUNDRY DIVISION: Experts today acclaim the foundry as being among the better, cleaner
and more automated foundries in the world. The foundry supplies high grade SG Iron castings
for automobile components and steel castings for excavators. The foundry has the
sophisticated Kunkel Wagner high pressure moulding line. Other facilities include channel
furnaces, computerized testing equipment etc.

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13 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
FORGE DIVISION: This division meets almost the total forging requirements of the
Jamshedpur plant and part requirements of the Pune and Lucknow plant with an annual
output of around 26000 tones. Today the Forge plant with its semi-automated forging line,
with the 40,000 mkg Beche hammer and state of the art presses from Kurimoto of Japan is
one of the most modern forging setups in the country and manufactures most of the critical
forging like crankshafts, front axles beams and steering parts for Jamshedpur plant.
VEHICLE DISPATCH AREA: After manufacturing of vehicle in truck division assembly line, it
comes to vehicle dispatch area. From this area vehicle is dispatch to regional sales office and
dealers.
AREA SALES OFFICE: It is responsible for sales of all commercial vehicles and passenger cars in
the Jharkhand region.

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14 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
STATIONWISE OPERATIONS IN ASSEMBLY LINE 1
Station Number Operations
1. Frame drop/VIN generation
2. Chassis number punching
3. Link rod fitment ( Tilt cab hydraulic pipe assembly)
4. Propeller shaft fitment
5. Lift axle kit fitment
6. Front leaf spring fitment
7. Rear leaf spring fitment, Quality Gate- 1
8. Steering gearbox fitment
9. Rear/ lift axle drop
10. Front axle/ dummy axle drop
11. Rear/ dummy axle tightening
12. front/lift axle tightening
13. Quality gate- 2
14. Chassis inversion
15. Brake/ fuel pipe fitment
16. Front shock absorber & steering fitment
17. Engine drop
18. Drop axle shaft fitment with gear box
19. Radiator drop
20. Fuel tank brkt. Fitment
21. Cab/cowl drop
22. Battery brkt fitment
23. Battery drop & fuel tank fitment
24. Wheel fitment
25. Wheel nut tightening
26. Clutch oil/coolant/ diesel filling
27. Steering oil filling/ engine cranking
28. Spare wheel fitment / air leakage test
29. Quality gate- 3
30. PDI station
31. Side shield, AC corner checker plate
32. Smoke testing
33. Pit inspection

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15 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
STATIONWISE OPERATIONS IN ASSEMBLY LINE 2
Station Number Operations
1.
Frame drop
F/R cable
Air Drier
Purge tank
Cowl Mtg. Bkt.
R/V Bkt.
Relay Valve
Control Valve
2.
Anti-roll bar
Link rod assy
F/R cable & Nylon pipe
Air dryer &P/T pipe
Air tank Bkt
3.
Linkage fitment
Pipe lines bkt.
Rear S/A bkt.
Frame dropping on RGV
4.
Front to rear cable fitment
F/R cowl mtg. Bkt. Fitment
Shock absorber bkt. Fitment
torsion bar fitment
Anti-roll bar bolt tightening
6 dia break pipe fitment
12&15 dia air pipe fitment
Different L&U shaped bkt. Fitment
Air dryer & purge tank
Air dryer & purge tank pipe fit.
Air tank bkt. Fitment
rear axle shock absorber fitment
5.
All pipes clamping
silencer hanger fitment
spring shackle
Rear air tank fitment
6.
Front spring fitment
Rear spring fitment
Grease nipple Nut washer.
Wedge screw attachment
7.
Front axle sub assy. & assy.
Rear axle sub assy. & assy.
Rear axle shock absorber fitment
8.
Steering sub assy.& assy.
P-shaft sub assy.& assy.
Centre bearing bolt tightening

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16 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
Air tank &its pipe fitment
Battery carrier fitment
Sensing tank fitment
9.
Dummy axle sub assembly
Dummy axle assembly
Greasing
silencer intermediate pipe fitment
10. Inversion
11.
Toe pin breather plug
Break pipe fit.
Front brake pipe fit.
Air tank pipe fit
Press Switch, Fuel pipe clamp
Shock Absorber Fit
12.
Tight. Of control Mtg. Pipe line & rectification
Strg. Pipe line fit.
Control Lever Box assy.
Control lever Box fit.
Number punching, E/M pads
Tail lamp Fit
Tail lamp sub-assy
13. Engine dropping
14.
Prop Shaft Fit
Silencer Fit
Fuel line & cab spring
Hydraulic pipe fit
Oil filter neck fit
Service break, accelerator pull rod hyd oil pipe fit
Compressor Pipe Fit
15.
Radiator assembly
Radiator dropping
Hose & aluminum pipe fit in the radiator
Radiator Fit
Cotter pin (rectification)
16.
Strg column assy
Strg spindle Fit
Air pipe assy
Pipe, foot rest fit.
Clutch pipe assy
Horn & combo switch fit
Wheel choke and nut fit
17.
Cowl pushing and cowl dropping
Electrical Fitment
18.
Pedal Fit.
Cowl mtg. Air pipe connection
19.
Hyd connection
Fuel Tank Fit

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17 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
Battery drop and electrical connection
Bkt. Fit
Tyre Sub-assy
20.
Spare wheel
Tyre sub-assy
Tyre inflation
21.
Coolant filling and diesel filling
Wheel nut tightening
Bumper Fitting
22.
Bumper Fitting
Electrical Checking
Air Pipe Checking and rct (LH/RH)
Clutch Fluid Bleeding
Hydr Pil filling and leakage
23. Clutch Bleeding and vehicle strgt rectification
24. Wheel nut checking
25.
Driving
Bottom rectification
Electrical Checking
Pit rectification
Engine hood sub-assy

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18 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
STATIONWISE OPERATIONS IN ASSEMBLY LINE III
Station Number Operations
FA2-01. Frame drop
FA2-02. Trunion drop
FA2-03. Trunion tightening and riveting
FA2-04. Trunion tightening and V rod fitment
FA2-05. Air tank fitment
FA2-06. Nylon Bunch and harness routing
FA2-07. Nylon bunch clamping and dressing
FA2-08. RUPD and rear autoroll bar fitment
1. Wiring harness brkt
2. FUPD brkt
anti roll bar fitment
POKA YOKE number vehicle number
punching
3. Frame drop
4. Steering hydraulic line fitment
5. Rear leaf spring
Quality gate 1
6. Rear axle fitment
7. Propeller shaft mounting
Front axle fitment
8. Rear axle (U bolt tightening)
9. Inter axle shaft
10. Axle alignment
11. Greasing
Quality gate- 2
12. Chassis lifting
POKA YOKE Conveyer
13. Chassis transfer
14. Chassis drop
15. Fuel tank brkt
(Quality)
16. Front Fender assembly
17. Engine dropping
Exhaust pipe fitment
(Quality)
18. Engine fitment
19. Engine Fitment
20. Radiator dropping
21. Cab mounting X- member
Quality Gate- 3
22. Spare wheel carrier fitment

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19 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
23. Cab drop
(Quality)
24. Cab drop
POKA YOKE Air pr. Conveyer
25. Cab fitment
26. Cab tilt
Oil filling
27. Fuel tank
28. Front tire sub assembly
Tail lamp sub assembly
Quality gate- 4
29. Rear tire sub assembly
Battery fitment
30. Rear tire tightening
31. Diesel filling
Tire tightening
32.
Quality gate 5
33. Sub assembly of head lamp and bumper
Bumper fitment
POKA YOKE serial number plate
34. Clutch bleeding
35. Engine cranking
POKA YOKE coolant filling
36. Wheel choke
Quality gate 6
37. RPM settings
38. Air leakage
39. Quality gate
40. Quality gate
41. Quality gate
Pit Inspection
42. Quality gate

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20 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
Why there is a need to introduce a new product when there is
already a similar product in the market from the same firm?
Tata Motors in 2008 launched PRIMA series. Vehicles produced in this category come with
advanced technology previously not introduced in Indian Heavy Commercial Vehicle (HCV)
market. It has features like common rail engine, automatic transmission, , dual clutch, and
world class cabin with HVAC, air suspension driver seats, data logger for performance
tracking, adjustable steering wheel, GPS, air conditioning and 4 way adjustable driver seats.
The PRIMA series was marketed as the ‘Global Truck’ by Tata Motors.
The PRIMA range offers better driver comforts along with advanced vehicle mechanics. But
this comes with a high price tag. So keeping in mind the traditional Indian fleet owners Tata
Motors introduced another range of Medium and Heavy Commercial Vehicle as SIGNA.
SIGNA range highlights:
- Aerodynamic front facia signature design
- Large cabin space with improved ergonomics and NVH levels for superior in- cab
experience
- Large windscreen for good all round visibility and road view for more safety
- In built telematics system Tata Fleetman
The superior in cab experience enables drivers to operate fatigue free over long hauls, which
in turn improves productivity. The built in telematics system helps in vehicle engine and fuel
management.
Roads in India are undergoing a transformation, as reflected in the Golden Quadrilateral
Project and the NS-EW corridors which connect the major cities with world-class highways.
To keep pace with the infrastructure development and changing economic scenario Tata
Motors offered its new SIGNA range to the Indian fleet owners.
Vehicle offerings in SIGNA range and Specifications:
The Tata Signa 4923.S is a tractor offering from Tata Motors new Signa range of commercial
vehicles. With a gross combination weight (GCW) of 49,000kg, when coupled with suitable
trailers, the Tata Signa 4923.S proven and reliable Cummins ISBe 5.9 Common Rail engine,
delivers power of 230PS and a torque of 850Nm, with best-in-class fuel efficiency and is
based on proven power-train and aggregates, like the G1150 gearbox and RA109SRT rear
axle. Empowering customers with the lowest total cost of ownership, the Tata Signa 4923.S is
also offered with multiple fully-built load body options, making the vehicle a preferred choice
for transporters for various applications.
The Tata Signa 3118.T is an MAV truck from Tata Motors new Signa range of commercial
vehicles, with both steerable and lift axle options. with a gross vehicle weight (GVW) of

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21 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
31tonne, the Signa 3118.T is powered by a world-class Tata Cummins B5.9 L– 6 cylinder
engine, with an optimum combination of 180 PS and flat torque of 675 Nm at lowest rpm
range, delivering best-in-class fuel efficiency and highest engine life. Coupled with a strong
and sturdy chassis and vehicle aggregates, the Signa 3118.T is most suitable for all
applications, also providing customers with the lowest total cost of ownership (TCO).
The Tata Signa 2518.K is a construction and mining offering from Tata Motors new Signa
range of commercial vehicles. With a gross vehicle weight (GVW) of 25 tonne, the Tata Signa
2518.K is powered by a world-class Tata Cummins B5.9 L– 6 cylinder engine, with an
optimum combination of 180 PS and flat torque of 675Nm at lowest RPM range, delivering
best-in-class fuel efficiency and highest engine life. With a reliable and proven power train,
the new Tata Signa 2518.K offers its customers better productivity and lowest cost of
operations, for a construction vehicle. Multiple options of aggregate combinations and load
bodies making the Tata Signa 2518.K a versatile workhorse for various applications.
Technical Specification of Signa 4923.S:
Description
Vehicle Application
Designation
Veh_Drive
Fuel
Fuel Tank Shape and Size
Engine
Engine Description
Bore/ Stroke
Engine Type
Compression Ratio
Firing Order
Max Speed
Max Engine Output
Max Torque
Clutch
Outside Dia of Clutch Lining
Engine Clutch Type
Type of Actuation

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22 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
Transmission Specification
Transmission Type
Gearbox Model
Gear Shift
Propeller Shaft
CAB Specification
CAB Description
Mirrors
Body Type
Wind Shield
Seating Arrangement
Seat Upholstry
Net Inside Loading Space
Steering Type
Steering Wheel
Wheels and Tyres
Number of Wheels/ Tyres
Tyre Pressure
Front Tyre
Rear Tyre
Wheel Rim
Frame
Type
Width
Depth

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23 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
Brakes
Type
Brake Drum Dia
F/R Brakes
Service Brakes
Parking Brake
Auxiliary Braking System
Suspension
Type
Anti-Roll Bar
Shock Absorber
Main Chassis Dimensions
VEH_ Overall_ Dimensions
Ground Clearance
Height of CG
Min Turning Circle Dia
Min Turning Clearance Circle Dia
Distance- Front Axle- First Rear Axle

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24 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
Performance
Max Speed
Max. Climbing Ability in First Gear at Rated
GVW
Angle of Departure
Angle of Approach
Weight
Grosss Vehicle Weight
Kerb Weight
Gross Combination Weight (Permissible)
Max. Permissible FAW
Max. Permissible RAW
Concept of Productionisation followed by TATA Motors: 1-5-25
Introduction of new product is taken care by NPI (New Production Introduction) which was
further modified to PPPM (Product Planning and Program Management). Planning of the
product is taken care by the Pune branch while the project management in Jamshedpur plant
by NPI. NPI introduced the concept of 1-5-25 in which only one product is developed in Beta-
Proto Shop and then the defects are analysed. Considering those defects 5 more vehicles are
produced and further improvements are made. 25 more vehicles are produced and defects
are analysed and solved as much as possible to make the process more streamlined, hence
facilitate productionisation.

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25 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
PROJECT TITLE
PRODUCTIONISATION
OF
SIGNA

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26 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
ISSUES OBSERVED IN SIGNA
1
Aero corner holes are not
aligned with those of mating
cab holes
2
Front 6pc bumper assembly
cannot be fitted in line due to
extreme hole outs and flush
in/out near the footrest
3
Bumper mtg. bkt. is being
fitted with 180ᴼ inversion by
operator in line
4
Headlamp glass is fouling
with the bumper which is
prone to break due to
vibration over a long time
5
Single core indicator wire
fouling with mtg. bkt. which
may get cut with usage
6
Clutch pipe falls short to be
mounted in the bkt. along
the long member

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27 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
7
Coolant tank fouling
observed in few signa's with
the radiator which is due to
their relative positions which
have not been standardised
Photo not attached
8
LH cab mtg. part has a hole
out where reaming had to be
done to fit it
Photo not attached
9
Steering middle joint inside
the cab was difficult to lock
due to accessibility issues
Photo not attached
10
Vent tube connecting bkt.
was provided and problem
solved
Photo not attached
11
Bending was corrected
manually and fitted
Photo not attached

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28 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
DEFECT ANALYSIS AND SOLUTIONS
AERO CORNER HOLE OUT
Problem Statement : Aero corner is an aesthetic component of the SIGNA cab's front part
which makes it give a facelift from the existing old cabs. During the production of SIGNA it
has been found that the AERO CORNERS are having a typical issue of hole out in the left hand
side and in the right hand, in the inside part of the aero corner mounting inside the hood.
Inside part holeout Hole doesn't even match LH outer hole out
The original drawing was studied and the corresponding part dimensions were checked and
compared. Careful examination of the process in assembly line unearthed the fact that most
of the hole out's (if present) were in the horizontal direction in the outer side and in the
vertical direction in the inner side mounting of the aero corner.
The mating arrangement provided in the aero corner were not holes but slots which were
horizontal in the outer side and vertical in the inner side.
Horizontal Vertical
Proposed Remedy : As it was observed that the hole out's
were in horizontal direction, therefore we suggest that
the slots in the outer side should be oriented horizontally
and those in the inner sides to be oriented vertically. This
would solve the problem to a great extent if the hole
outs are not a random error in the manufacturers
process.
vertical slots to be oriented
horizontally

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29 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
BUMPER MOUNTING HOLE OUT AND FLUSH IN/OUT ISSUE
Problem Statement : The front bumper assembly has fitment issues along with various hole
outs and uneven gap in the sides near the footrest. Fitment of the bumper parts with the
mounting brackets are a complete mismatch in the left hand side. It is becoming impossible
to rectify it in the assembly line and the vehicle has to be sent to another shop for bumper
fitment at the end of the line, thus adding up to lack of productivity, hampering the overall
productivity of assembly line 3.
6pc. bumper flush in/out center bumper assy. hole out
LH side bumper does not get fit properly and even if it does, it creates an uneven gap near
the footrest. Operators provided a washer in one bolt in its mounting part to align it properly
as a temporary solution. On careful inspection and comparison of the part features with the
actual drawing, everything was found to be in compliance.
washer provided to align
Proposed Remedy : Then the correctness of the two parts was doubted. The bent pipe
mounted on the chassis and its connecting pipe angle was checked for their geometry. It was
observed that the mating plane of the two parts was not flat as directed in the original
drawing provided by ERC in case of the LH side. The two parts were manufactured by a third
party "Japtech" and thus they were told to supply modified parts as the previous ones were
deemed defective.
mating plane 90ᴼ with mounting base as per drawing

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30 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
Also the front bumper is a 6pc assembly which is done in the line which tends to decrease the
productivity by taking more time and it in turn tends to increase the complexity of the
fitment.
We propose that if the fitment of the bumper can be done as a whole unit, it will greatly
increase the productivity. We found out that the upper bumper houses the headlamp and also
provides it support through its mounting bracket. Thus strength is necessary. The
corresponding bracket for fitment of the lower 3 bumpers are just for the bumpers solely and
doesn't provide support for strength purpose.
We propose to change the bumper design and weld the 6 components together making it a
single unit. The support for the bumpers will be provided by the pre-existing upper side
bumper mounting brackets and it will have a projection downwards to accommodate the
lower side bumpers. The side mounting brackets for the lower bumpers can be eliminated,
reducing material costs greatly.
Weld these parts together part can be eliminated

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31 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
BUMPER MOUNTING BRACKET WRONG ASSEMBLY
Problem Statement : The mounting brackets for the center piece front bumper assembly was
often oriented wrongly and it led to late realization and ended up taking a lot of time in
rework affecting the productivity.
mounting brackets
The LH and RH side brackets are different. But each one of them can be fitted wrongly in the
holes provided by getting inverted by 180 degrees. It has been occurring often due to lack of
experience by the operator as SIGNA is a new variant being introduced.
Proposed Remedy : The correct orientation of the brackets can be ensured by providing a
locating pin and hole combination in the bracket and bumper respectively in a suitable
position in each one of them. This will ensure that the brackets do not get fitted in a wrong
orientation and it will not create the confusion and enhance the productivity by eliminating
rework.
add a locating pin here
corresponding locating hole in this part

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32 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
HEADLIGHT GLASS FOULING WITH BUMPER
Problem Statement : The headlight glass is normally provided by clearance with the bumper
to avoid any vibration induced damage. The SIGNA has an issue where the glass did not have
sufficient clearance.
gap not present
The headlamp assembly was inspected and found that :
 One way locking mechanism was not working properly
 The headlamp mountings were a bit outwards thus the glass fouled with bumper.
Proposed Remedy : The problem could be solved temporarily by providing washers to raise the
level of the headlight assembly temporarily. This could have a permanent solution if the
mounting brackets could be welded a little inside by taking this clearance measurement into
consideration.
Also the locking arrangement would come out of its place from the hole as it would not
properly go into the hole. If we control the hole diameter accordingly then the locking
mechanism would not come out and the problem would be resolved.
bracket to be welded
locking mechanism
locking nut hole

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33 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
INDICATOR WIRE FOULING WITH MOUNTING
Problem Statement : Indicator wire in the headlight assembly is a single core wire which has
its connection in the bulb through a horizontal and vertical port. The wire coming out of the
vertical port is fouling with the mounting arrangement which has a sharp edge and it tends to
get cut. With prolonged usage of the vehicle it is bound to get cut.
Wire fouling
Proposed Remedy : The problem can be solved in three ways :-
 To provide corrugation till the full length of the wire. This will provide an external
protection to the wire.
 To shorten the length of the vertical port which is given unnecessarily.
 To increase the hole diameter shown below in which this indicator goes into.
Increase the diameter of this hole

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34 SIGNA | TATA MOTORS LIMITED, JAMSHEDPUR
CONCLUSION
It was a great experience working with TATA MOTORS LTD. where I got the
golden opportunity to actually play a role in the productionisation of its new
signature vehicle, the SIGNA range of trucks.
It was a great learning experience working with the industry persons of various
levels and help know in depth about the work culture of a great automobile
company - TATA MOTORS.
I am highly indebt to my project guide and my collegues for their support
without whom this work of mine would not have been a success.