1. The document summarizes the summer training report submitted by Jitesh Chauhan to the Department of Mechanical Engineering about his training at Mahindra CIE Automotive Ltd., a manufacturer of speciality steel and automotive parts. 2. Mahindra CIE has four stamping facilities in India and supplies major parts like cross car beams, cab closures, and fuel tanks for vehicles. The report describes the baffle plate, strainer, and other components of the fuel tank and the spot welding and seam welding processes used in its construction. 3. The report also discusses various industrial aspects practiced at the plant like 5S methodology for workplace organization, Kaizen for continuous improvement, P

1. Department of Mechanical Engineering
SUMMER TRAINING REPORT
2014-2015
Submitted to : Submitted by :
Jitesh Chauhan
2064109
Btech. M.E. 7th sem.

2. MAHINDRA CIE AUTOMOTIVE LMT.

3. • Mahindra CIE Automotive Ltd. Formerly known as Mahindra Ugine
Steel Company Ltd.
• It is a manufacturer of speciality steel, stamping, and rings
headquartered in Mumbai, India. It subsidiary of the Mahindra
Group.
• It has four stamping facilities in India: Kanhe, Nashik, Rudrapur,
Pantnagar.
• Pantnagar plant is situated in SIDKUL sector 11 Tata Vendor
Park, Pantnagar ,Uttarakhand.

4. Major Parts Supplying From Mahindra CIE :
1. Cross Car Beam(CCB): CCB is a support that usually holds all
instrumental panel including HVAC system(heating, ventilation, air
conditioning) ,steering column, electrical components, airbag
system. It is located behind the vehicle dashboard.

5. 2. Cab Closure: The main function of cab closure is to connect
chassis and driver cabin.
3. Fuel tank : Fuel tank is a safe container for flammable fluid.

6. FUEL TANK
BAFFLE PLATE
• function of baffle plate is to present a fuel surge caused by an incline
of the vehicle or an abrupt turn of the vehicle.
• In this regard, The fuel can be stably supplied to a fuel pump and a
noise caused by fuel surge can be reduced.
• Holes are formed in plate so as to allow fuel to pass the baffle plate.

7. FUEL TANK
STRAINER
• It is a device through which a liquid is passed for purification
filtering or separation from solid particle.
• It consists of electronic sensors results it indicates the level of fuel in
fuel tank.
DRAIN PLUG
• It is provided at the bottom for periodic removal of the sediments.

8. WELDING
SPOT WELDING
In resistance spot welding, the overlapping metal parts are held
between two bar type metal electrodes which apply pressure,
while an electric current is passed through them.
H = I 2RT

9. SEAM WELDING
Seam welding is continuous spot welding, where the electrodes are in
the form of rotating disc electrodes. The heat generation and current
are localized by the peripheral shapes of electrode wheels.

10. CONSTRUCTION OF FUEL TANK
1. The most important and only raw material used in the
manufacturing of fuel tank (TATA MAGIC) is SHEET METAL of
definite thickness 1mm.
2. The sheet metal is then pressed by using subsequent dies for
making MAGIC FUEL TANK CELL under four steps ( dies of
three 300 and one 250 ton are used).

11. 3. Same kind of sheet metals is then press worked on dies (little lighter than former
ones) to give end cover and center cover (baffle plate) impression.
END COVERS BAFFLE PLATE

12. 4. The cell is then SPOT WELDED and SEAM WELDED.
SPOT WEDED
SEAM WELDED

13. 5. Next step involves the SPOT and SEAM WELDING of the end and
mid covers to the cell of the fuel tank
6. After this, with the help of MIG WELDING the end cover is fitted
with a pipe for the inclusion of fuel in the fuel tank.

14. 7. The fuel tank is then sent to paint shop to get painted and after that
checked for leakage in LTM (Leakage Testing Machine).
8. FINALLY, the fuel tank is fitted with strainer on the hole with larger
diameter and is then ready for dispatch.

15. PILLOW TEST
• Take one square sheet of required thickness (1mm in case of Tata magic fuel tank)
• Make a drill 8-10 mm in the centre of sheet.
• Now use one rod or pipe 8mm diameter and braze it in that hole
• Now take another sheet of same size and thickness and seam both the sides (one in
which we have brazed the pipe) together as shown in figure.
• Now pump a pressure up to 0.5 bars inside the sheet through pipe hole and it will take a
shape of pillow.
• Now do the leakage testing for the above part as shown in figure.

16. SOME NECESSARY INDUSTRIAL ASPECTS
5S’s
Seiri (sorting) :Remove unnecessary items and dispose them properly
Seiton (systematic arrangement) : Arrange all the necessary items so they can
be easily selected for use. Ensure first-come-first-served basis
Seiso (shine) : Clean your workplace completely. Keep workplace safe and
easy to work
Seiketsu (standardize) Everything in its right place.
Every process has a standard.
Shitsuke (self discipline) Discipline and Training is goal oriented process. Its
resulting feedback is necessary monthly.

17. Kaizen
Kaizen is the practice of continues improvement in quality,
technology, processes, company culture, productivity, safety.
• Kaizen is a system that involves every employee – from upper
management to the cleaning crew
• Not only quality improvement and productivity improvement
• But also provide motivation to workers for their skill up

18. Poka yoke
• Poka yoke is a Japanese term that means “mistake-proofing” in all
aspects of manufacturing, customer service, procedure, etc
• Its purpose is to eliminate product defects by preventing, correcting,
or drawing attention to human errors as they occur.

19. WORKPLACE SAFETY RULES
• You are responsible for your own safety and others.
• If you are not trained, don’t do it.
• Use right tools and equipment.
• Never wear loose clothes.
• Practice good housekeeping.
• Always wear personal protective equipments (PPEs).

20. THANK YOU