1. Daimler India Commercial Vehicles Pvt. Ltd.
QM/8-1-2014 1
INDUSTRIAL TRAINING REPORT
(Duration -45 Days at PTI)

2. Daimler India Commercial Vehicles Pvt. Ltd.
QM/8-1-2014
2
Introduction
Focus area in assembly
Quality Feedback loops & Quality Gates
Quality inspection gates
Damage code purpose
Damage code architecture and comparison
Project description and methodology
Acknowledgement
1
3
2
5
4
6
Training period : 5th
Dec’13 To 17th
Jan’14
Trainer : Mr. Muralikrishna.P / Mr. Bhaskar.P
Project : Damage codes
7
8

3. Daimler India Commercial Vehicles Pvt. Ltd.
Introduction
Well over a century ago, when horse-drawn modes of transport were the only known ways of mobility in
the world, Gottlieb Daimler and Carl Benz came up with a revolutionary idea: motorized movement.
By combining an engine with a cab-over-chassis structure, the first truck was invented.
Our rich history of over 125 years of innovation is driven by excellence that continues into the 21st
century. Numerous patents in automotive performance, safety and eco-friendly innovations, some of
which are milestones in the history of the truck, are eloquent testimonies to our commitment to
redefining mobility for the world.
As the inventor of the truck, Daimler assumes responsibility for their future. Our Road to Emission-free
Driving stands for our commitment to securing sustainable mobility.
Our aim is to markedly reduce fuel consumption and emissions already today and to eliminate them
entirely in the long term. To this end, we are developing a broad spectrum of state-of-the-art drive
technologies that meet the specific requirements placed on today’s and tomorrow’s mobility in all
modes of road transportation.
QM/8-1-2014
3

4. Daimler India Commercial Vehicles Pvt. Ltd.
4
Introduction
In DICV PTI shop , engine and transmission are assembled such as 170kw & 205kw HDT Engine
and G131, G85 & MO36 Transmission are assembled .
EURO 3 OM-906 LA G131 G85 MO36
QM/8-1-2014

5. Daimler India Commercial Vehicles Pvt. Ltd.
QM/8-1-2014
5
CRANKSHAFTCAM SHAFT
CYLINDER
HEAD
CONNECTING
ROD
CRANKCASE
ENGINE MAIN
PARTS
Introduction

6. Daimler India Commercial Vehicles Pvt. Ltd.
QM/8-1-2014 6
INPUT SHAFT
COUNTER
SHAFT
MAIN SHAFT
TRANSMISSION MAIN
PARTS
-1st
gear
-2nd
gear
-3rd
gear
-4th
gear
-5th
gear
-6th
gear
-Reverse gear
-Gear hubs
-Tapper roller
Bearing
-Oil seal
-Oil pipe
-Circlip
-Tap roller gear
-1st
gear bracing
-2nd
gear bracing
-3rd
gear bracing
-4th
gear bracing
-5th
gear bracing
-6th
gear bracing
-Twin gear
Introduction

7. Daimler India Commercial Vehicles Pvt. Ltd.
QM/8-1-2014 7
• Washing and cleaning cabinet
•
•Torque analyser
PERFORMANCE
TEST
•SFC , Power and smoke
Test
• Casting and forging material
confirmation
• Tear down audit
•Geometrical parameters and indexing in
gears
Focus area in
engine and
transmission
assembly
PART MATERIAL QUALITY PART CLEANLINESS
TORQUE INTEGRITYPRODUCT AUDIT
PART DIMENSIONAL
QUALITY
Focus area in assembly

8. Daimler India Commercial Vehicles Pvt. Ltd.
DICV Q-CONCEPT
Q means QUALITY
QM/8-1-2014
8
The Q-Concept describes the functions of
the QM and its relations to Production,
Logistics, and Supplier Management. It will
be signed of by all Vice Presidents of DICV.
Main contents are:
Q-Methods, Standards, Product liability
request, Q-Philosophy for Feedback loops,
tasks and responsibilities etc.
Supporting process descriptions are linked
to the operative documents e.g. checklist.
T
Q-Concept
Engine and transmission Q
SETTING UP QUALITY PROCESS
THROUGH
•Manufacturing PPAP
•PFMEA
•Control plan
•Process study capability
•Operator self certification
•100% quality gates inspection
•Section product audit
•Process auditThe realization of this Q-concept is
monitored by QM during the project
phase with a tool called “Q-Plan” and is
the basis of Q-Release for process and
product

9. Daimler India Commercial Vehicles Pvt. Ltd.
Quality feedback loops 0-5
QM/8-1-2014 9

10. Daimler India Commercial Vehicles Pvt. Ltd.
QM/8-1-2014 10
Engine and transmission assembly quality gates

11. Daimler India Commercial Vehicles Pvt. Ltd.
Quality inspection gates in engine assembly
QM/8-1-2014
11

12. Daimler India Commercial Vehicles Pvt. Ltd.
Quality inspection gates in transmission assembly
QM/8-1-2014
12

13. Daimler India Commercial Vehicles Pvt. Ltd.
Damage Code purpose
During the transportation chain when automobiles change possession they must be inspected immediately with any
damage or missing items being noted. The purpose of this manual is to provide a standard up-to date set of codes for
recording vehicle exceptions to all personnel responsible for handling vehicles throughout the transportation chain.
It is important the damage codes be accurately detailed. The codes are recorded manually on delivery receipts or in
portable data terminals for transfer into the manufacturers claims systems. Individual manufacturers may issue
manuals with photographs depicting several of the damage areas and types. Damage are of many types like
Broken , Broken off , Sheared off , Disengaged but continued to run , Engaged and overrun , Cracked , Torn, Torn
off, Burst , Sewing/thread fault etc.
Damage code helps in easy understanding of the damage part in the vehicle . If the customer complained about
any part then the customer care service centers will analyze that part and note down the damage in the vehicle in the
form of damage code and can send that vehicle to the company for damage reference . Every part has some
damage code from washer to crankcase.
QM/8-1-2014
13

14. Daimler India Commercial Vehicles Pvt. Ltd.
Damage code architecture
QM/8-1-2014
14

15. Daimler India Commercial Vehicles Pvt. Ltd.
Damage code concept comparison
QM/8-1-2014
15

16. Daimler India Commercial Vehicles Pvt. Ltd.
Project description
The purpose of this project is to provide a standard up-to date set of Damage codes for recording the defects in
the online concern tracking portal and MES usage .I have compared the Build sheet parts and the damage codes
available on the online portal and compiled the coded which were not available with the classification.
Current status
- Total damage codes available in online portal for engine : 2041
- New damage codes compiled/developed : 645
- Gap between available & required : 645
QM/8-1-2014
16

17. Daimler India Commercial Vehicles Pvt. Ltd.
QM/8-1-2014
17
Damage code developed (SAMPLE)
Failure
T ype area
Digit 1
CONST RUCT ION
GROUP 'DAMAGE
PART
Digit 2-3
LOCAT ION
'DAMAGE PART
Digit 4-6 DAMAGEPARTDESC
DAMAGE
TYPE
Digit 7-8
REPAIR
T YPE
Digit 9
DAMAGE
TYPE
Digit 10-11 DAMAGE T YPE DESCRIPTION
ASSEMBLED
DAMAGE CODE
UPTO 11T H
DIGIT
Q 03 201 Connecting rod 28 X 00 offset Q0320128X00
Q 03 201 Connecting rod IA X 05 Materialfault Q03201IAX05
Q 03 201 Connecting rod 99 X 10 Damaged Q0320199X10
Q 03 201 Connecting rod 42 X 00 Poorfit Q0320142X00
Q 03 201 Connecting rod C8 X 00 Incorrectpart Q03201C8X00
Q 03 301 Piston,Engine 28 X 00 offset Q0330128X00
Q 03 301 Piston,Engine IA X 05 Materialfault Q03301IAX05
Q 03 301 Piston,Engine 99 X 10 Damaged Q0330199X10
Q 03 301 Piston,Engine 42 X 00 Poorfit Q0330142X00
Q 03 301 Piston,Engine C8 X 00 Incorrectpart Q03301C8X00

18. Daimler India Commercial Vehicles Pvt. Ltd.
Methodology followed
QM/8-1-2014 18
 Current data of online damage code available was reviewed
I reviewed the main damage codes list available at DICV and compared it with all the parts used in assembly
line and listed all those parts which were not having damage codes.
 Actual data collected
After listed all the parts which were not having their damage codes , their construction group , location ,
damage type were collected from the DICV damage part codes list.
 Gap analyzed
Total 645 damage codes were not available in the DICV damage codes list .
 Compiling the new damage codes
After collecting all the data ( construction group , location, damage type) then it were compiled in
according to damage code architecture .
 Uploading the new file with developed existing damage code file.
 Result
Total damage codes including new damage codes : 2686

19. Daimler India Commercial Vehicles Pvt. Ltd.
Acknowledgement
I am highly grateful to Daimler India Commercial Vehicles Pvt. Ltd . for allowing me to do this
project work. It is truly a matter of great pleasure me to express my sincere thanks and gratitude to
Daimler India Commercial Vehicles Pvt. Ltd . for his supervision and encouragement throughout this
project.
I am highly obliged to “ Bhaskar.P , Muralikrishna P, Sampath Kumar K ,Baraneedharan S ,
Jayakumar V , Arvind S ” for their guidance kind concern and encouragement throughout this project.
I am immensely indebted to “ Daimler India Commercial Vehicles Pvt. Ltd .” for the invaluable help
that he rendered at every step of this project. It is a wonderful experience to be a part of “Daimler
India Commercial Vehicles Pvt. Ltd . ” Where I work under brilliant minds. I owe my deep regards
for the supporting and kind staff authorities who helped me in my lean patches during these 1.5
months.
The knowledge I gained throughout our studies have the practical implementation during this period.
I am grateful to all the staff of “Daimler India Commercial Vehicles Pvt. Ltd . ”
YOURS OBEDIENTLY
ANUBHAV GOEL
19