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INTRODUCTION

A promise is promise and I kept my promise - this is the

historical statement which Mr. RATAN TATA said when he
launched his ambitious TATA NANO; the people’s car in India
on 23 rd march 2009. Tata has always given value products in
the Indian Car Market whether it is path breaking recently
launched TATA NANO or TATA INDICA (which created great
brand into the car industry in the diesel segment).

TATA GROUP OF COMPANIES

The Tata group comprises over 100 operating companies in seven business
sectors: communications and information technology, engineering, materials,
services, energy, consumer products and chemicals. The group has operations in
more than 80 countries across six continents, and its companies export products
and services to 85 countries.

Every Tata company or enterprise operates independently. Each of these

companies has its own board of directors and shareholders, to whom it is
answerable. There are 31 publicly listed Tata enterprises and they have a combined
market capitalization of about $80.61 billion (as on July 12, 2012), and a shareholder
base of 3.6 million. The major Tata companies are Tata Steel, Tata Motors, Tata
Consultancy Services (TCS), Tata Power, Tata Chemicals, Tata Global Beverages, Tata
Teleservices, Titan, Tata Communications and Indian Hotels.

Founded by Jamsetji Tata in 1868, Tata’s early years were

inspired by the spirit of nationalism. Tata Industries was set up by
Tata Sons in 1945 as a managing agency for the businesses it
Page 1
promoted. Following the abolition of the managing agency system,
Tata Industries' mandate was recast, in the early 1980s, to promote
Tata's entry into new and high-tech businesses.

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Tata Industries has initiated and promoted Tata ventures in several sectors,
including control systems, information technology, financial services, auto
components, advanced materials, telecom hardware, airlines and
telecommunication services. In more recent times, its pioneering spirit has been
showcased by companies such as TCS, India’s first software company, and Tata
Motors, which made India’s first indigenously developed car, the Indica, in 1998 and
recently unveiled the world’s lowest-cost car, the Tata Nano.

Areas of business
Tata Industries has two operating divisions which function as independent
profit centers:

 Tata Strategic Management Group: An independent management

consulting division that assists Tata as well as non-Tata companies in
enhancing their competitive edge.
 Tata Interactive Systems: Among the world's leading e-learning
organizations, it offers services such as project management, instructional
design and graphics, and technical know-how.

Tata Motors makes passenger cars, multi-utility vehicles and light, medium and
heavy commercial vehicles.

 Passenger cars: compact Tata Indica in 1998, the sedan Indigo in 2002 and
the station wagon Indigo Marina in 2004. Tata Motors also distributes Fiat’s
cars in India.
 Utility vehicles: The Tata Sumo was launched in 1994 and the Tata Safari in
1998.
 Commercial vehicles: The commercial vehicle range extends from the light
two-tonne truck to heavy dumpers and multi-axled vehicles in the above 40-
tonne segment.
 Passenger buses: The Company also manufactures and sells passenger buses,
12-seaters to 60-seaters, in the light, medium and heavy segments. Page 2

Tata Industries' main activities are:

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 To promote Tata’s entry into new businesses

 To maintain shareholding in promoted companies
 To invest in operating companies to facilitate growth

Board of directors
 Ratan N Tata, Chairman  Ravi Kant
 Farrokh K Kavarana  Cyrus P Mistry
 RK Krishna Kumar  Kishor A Chaukar, managing
 Ishaat Hussain director
 S Ramadorai  KRS Jamwal, executive director
 B Muthuraman  RR Bhinge, executive director
 Prasad R Menon

Tata Group of Companies

Chemicals

 Tata Chemicals  Infiniti Retail

 Rallis India  Tata Tea Limited is the world's
 Tata Pigments Limited second largest manufacturer of
 General Chemical Industrial packaged tea and tea products.
Products  Tetley
 Brunner Mond  Tata Coffee
 Advinus Therapeutics  Tata Industries
 Magadi Soda Company  Titan Industries
 Trent (Westside)
Consumer Products  Cromā
 Tata Sky
 Tata Salt
 TajAir
 I-shakti
 Tata International Ltd.
 Casa Décor
 Tanishq
 Tata Swach
 Tata Refractories Page 3
 Tata Global Beverages
 Westland
 Eight O’clock Coffee
 Tata Ceramics Energy

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 Tata Power is one of the largest
private sector power
companies.
 Tata BP Solar, a joint venture
between Tata Power and BP
Solar
 Hooghly Met Coke and Power
Company
 Jamshedpur Utilities and
Services Company
 North Delhi Power
 Powerlinks Transmission
 Tata Power TradingTata Auto
Comp Systems Limited
 Tata Projects
Engineering
 TAL Manufacturing Solutions
 Tata Auto Comp Systems
Limited (TACO)
 Hispano CarroceraTata Auto
Comp Systems Limited
 Tata Motors, manufacturer of
commercial vehicles (largest in
India) and passenger cars
 Jaguar and Land Rover
 Tata Daewoo Commercial
Vehicle
 Tata Projects
 Tata Consulting Engineers
Limited
 Tata Cummins
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 Telco Construction Equipment
 TRF
 Voltas, consumer electronics
company
 Voltas Global Engineering
Centre
 Tata Advanced Materials
 Tata Advanced Systems
 Tata Motors European Technical
Centre
 Tata Petrodyne
 Tata Precision Industries
Information systems and
Communications
 Computational Research
Laboratories
 INCAT
 Nelco
 Nelito Systems
 Tata Business Support Services
 Tata Consultancy Services Ltd.
(TCS) is Asia's largest software
company.
 Tata Elxsi
 Tata Interactive Systems
 Tata Technologies Limited
 Tata Teleservices
 Virgin Mobile India
 Tata Communications Page 4
 CMC Limited
 VSNL International Canada
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 Tatanet, Managed connectivity
and VSAT service provider
 Tata Teleservices
 Tata Teleservices (Maharashtra)
 Tatanet
Services
 Tata Sons
 The Indian Hotels Company
 Ginger Hotels
 Roots Corporation
 Landmark
 Tata Housing Development
Company Ltd. (THDC)
 Tata Limited
 TATA AIG General Insurance
 TATA AIG Life Insurance
 Tata AG
 Tata Asset Management
 Tata Financial Services
 Tata Capital
 Tata International AG
 Tata Investment Corporation
 Tata Advanced Systems Limited
 Drive India Enterprise Solutions
 Mjunction services
 Tata Quality Management
Services
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 Tata Realty and Infrastructure
Limited
 Tata Interactive Systems
 Tata Africa Holdings
 Tata Auto Comp Systems
 Tata Industrial Services
 Tata NYK
 Tata Services
 Tata Strategic Management
Group
 Telco Construction Equipment
Steel
 Tata Steel
 Tata Steel Europe
 Tata Steel KZN
 Tata Steel Processing and
Distribution
 JAMIPOL
 NatSteel Holdings
 Tata BlueScope Steel
 Tata Metaliks
 Tata Sponge Iron
 Tayo Rolls
 The Tinplate Company of India
 TM International Logistics
Page 5
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TATA MOTORS

Tata Motors Limited is India's largest automobile company, with consolidated

revenues of INR 1, 65,654 crores (USD 32.5 billion) in 2011-12. It is the leader in
commercial vehicles in each segment, and among the top three in passenger
vehicles with winning products in the compact, midsize car and utility vehicle
segments. It is the world's fourth largest truck and bus manufacturer.

The Tata Motors Group’s over 55,000 employees are guided by the vision to be
''best in the manner in which we operate, best in the products we deliver, and best
in our value system and ethics.''

Established in 1945, Tata Motors' presence indeed cuts across the length and
breadth of India. Over 6.5 million Tata vehicles ply on Indian roads, since the first
rolled out in 1954. The company's manufacturing base in India is spread across
Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar
(Uttarakhand), Sanand (Gujarat) and Dharwad (Karnataka). Following a strategic
alliance with Fiat in 2005, it has set up an industrial joint venture with Fiat Group
Automobiles at Ranjangaon (Maharashtra) to produce both Fiat and Tata cars and
Fiat powertrains. The company's dealership, sales, services and spare parts network
comprises over 3,500 touch points.
Page 6
Tata Motors, the first company from India's engineering sector to be listed in the
New York Stock Exchange (September 2004), has also emerged as an international
automobile company. Through subsidiaries and associate companies, Tata Motors

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has operations in the UK, South Korea, Thailand, Spain and South Africa. Among
them is Jaguar Land Rover, a business comprising the two iconic British brands that
was acquired in 2008. JLR supports two state of the art engineering and design
facilities and three manufacturing plants (Solihull, Castle Bromwich & Halewood) in
the UK.

Tata Motors is also expanding its international footprint, established through

exports since 1961. The company's commercial and passenger vehicles are already
being marketed in several countries in Europe, Africa, the Middle East, South East
Asia, South Asia, CIS, Russia and South America. It has franchisee/joint venture
assembly operations in Bangladesh, Ukraine, and Senegal.

The foundation of the company's growth over the last 66 years is a deep
understanding of economic stimuli and customer needs, and the ability to translate
them into customer-desired offerings through leading edge R&D. With over 4,500
engineers and scientists, the company's Engineering Research Centre, established in
1966, has enabled pioneering technologies and products. The company today has
R&D centers in Pune, Jamshedpur, Lucknow, Dharwad in India, and in South Korea,
Spain, and the UK. It was Tata Motors, which developed the first indigenously
developed Light Commercial Vehicle, India's first Sports Utility Vehicle and, in 1998,
the Tata Indica, India's first fully indigenous passenger car. Within two years of
launch, Tata Indica became India's largest selling car in its segment. In 2005, Tata
Motors created a new segment by launching the Tata Ace, India's first indigenously
developed mini-truck.

Tata Motors is equally focused on environment-friendly technologies in emissions

and alternative fuels. It has developed electric and hybrid vehicles both for personal
and public transportation. It has also been implementing several environment-
friendly technologies in manufacturing processes, significantly enhancing resource
conservation.
Page 7
With the foundation of its rich heritage, Tata Motors today is etching a refulgent
future.

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PLANT LAYOUT

Overhead conveyer Overhead conveyer

BODY IN WHITE PAINT-SHOP
(Welding)
1A,1B,1C & 1D

TRIM CHASIS FITMENT

ENGINE & GEAR-BOX (ASSEMBLY)
ASSEMBLY 1A, 1B, 1C & 1D

DISPATCH YARD
Page 8

Location

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Tata Motors' plants are located at
 Jamshedpur (eastern India),
 Pune and Sanand (western India),
 Lucknow and Pantnagar (northern India).
 Tata Motors and Fiat have a common manufacturing facility at Ranjangaon,
near Pune.

TATA MOTORS (Small Car Division) Pantnagar

The Company has set up a plant for its mini-truck Ace and the passenger carrier
Magic (based on the Ace platform) & Venture at Pantnagar in Uttarakhand. The
plant began commercial production in August 2007. This is the company's fourth
plant, after Jamshedpur (commercial vehicles), Pune (commercial vehicles and
passenger vehicles) and Lucknow (commercial vehicles). The plant is spread over
953 acres, of which 337 acres is occupied by the vendor park.

State-of-the-art facilities include weld shops, paint shops, engine and gear box
shops and assembly lines. The Company has invested over Rs.1000 crores in the
plant. Vendors for the vehicle have made additional investments to set up their
plants in the vendor park adjoining the plant. The operation has generated about
7500 direct and indirect jobs in the plant, among vendors and service providers in
the area.

DESCRIPTION OF SHOPS

 ASSEMBLY SHOP –

o Also known as TCF Shop (TRIM CHASSIS FITTING). In this shop all the
assembly works like Engine,
o Suspension, Tyres, Lights, Dashboard etc. fitment is carried out.
Page 9

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PRODUCTION SYSTEM

MANUFACTURING PRODUCTION PLANNING

 BIW(Body in white)  MES(Manufacturing

execution system)
 PAINT
 SAP
 TCF(Trim chassis fitment)
 PDI (Pre-Delivery Inspection)
 POWERTRAIN
 MATERIAL SUPPLY
(JIT,KAIZEN,JIS)

 WELD SHOP –
o Also known as BIW Shop (BODY IN WHITE).
o Here the different parts are welded together and the whole structure of
the car is built.
o This shop plays very important role in framing the body shell. The press
panels are transported from Bhuj and Pune plant.
o It has three main assemblies, which includes-UB(under body), ML(Main
line or main frame) and MF(metal finish) where different welding
processes of
 Projection welding  CO2 welding
 Stud welding  MIG welding
 Spot welding

Are done and after that the parts are attached to the main assemblies.
Page 10

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SUB ASSEMBLIES

MAIN METAL
UNDER BODY
FRAME FINISH LINE PAINT SHOP
LINE
LINE

SUB ASSEMBLIES

 POWER TRAIN SHOP –

o This shop is divided into Power Train and Engine shop. Here various
operations related to Engine, Gear Trains etc. are performed.
o It consists of
 Engine Assembly Shop
 Transaxle Assembly Shop
 Engine Dressing Line
In Engine assembly the various components of the Engine are
assembled into a single unit and sent for the various tests.

 PAINT SHOP –

o The TAIKISHA paint shop is the beauty parlors of the car plant. This
shop paints the car in various shades. It takes 18 steps spread over less
than 10 hours to accomplish the task.
o Here in Paint shop:
 Colour and appearance
 Covering of gaps between the weld joints
 Corrosion resistance
 Smothering of sharp corners
Page 11

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Shop layout

WELD BODY PRETREATMENT ELECTRODEPOSITION ED OVEN

UNDERCOAT UNDER COAT SOL SEALING

COOLING
OVEN (UB) SEALANT

INTERMEDIATE I/C OVEN COOLING

DRY SANDING COAT (I/C)

TOUCH UP AND T/C TOP COAT

TCF INSPECTION OVEN (T/C) DRY SANDING

Page 12

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TCF SHOP
Here the painted chassis delivered from the Paint shop is accessorized from scratch
to a finish car ready for dispatch and also tested.

The car delivered by the TCF shop is completely checked with reference to product’s
utility quality and manufacturing quality. After several inspections made by line
operators for operational conformance and ethical looks the Car is permitted to be
dispatch from TCF shop by the assurance of Line supervisors and operators.

The cart dispatched from the TCF shop is delivered, through drive test to the PDI
(Pre-Delivery Inspection) shop where final touching to looks is given and the
conformance of working of all the accessories is done.

SHOP LAYOUT

TRIM LINE UNDER BODY LINE

MECHANICAL LINE
(TR1, TR2) (UB1, UB2, UB3, UB4)

CANOPY TEST ROLL AND BRAKE TEST WHEEL ALIGNMENT

NOK OK

REWORK PRE DISPATCH To

INSPECTION (PDI) PAD costumer

 PDI SHOP –

o PDI is the final quality check, in this the overall checking of the vehicle takes
place, in this the fitment is not done, only the outward checking is completed. Page 13
The final QA OK of the vehicle is done here and after this the vehicle is sent for
dispatch.

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o Parts which are checked are mentioned below:

1. Brake, Brake oil. 21. Inner handle.

2. Carpet fitment. 22. Instrument cluster.
3. Central lock 23. Keys.
4. Coolant filling 24. RH front door.
5. Dents 25. Roof lamp.
6. Door pad 26. Roof lining.
7. Drive shaft 27. Rear bumper.
8. Engine oil. 28. Rear door LH, RH.
9. Engine wiring harness. 29. Rear door lock LH
10. Front bumper. 30. Rear door lock RH.
11. Front door LH 31. Rear seat
12. Front door lock LH 32. Seat. Belt
13. Front door lock RH 33. Spare wheels
14. Front seat 34. Scratches on whole body
15. Fuel. 35. Steering wheels.
16. Gear shifter. 36. Tail lamp.
17. Head lamp. 37. Washer jet.
18. Hood LH. 38. Window glass.
19. Hood RH 39. Wind shield washer.
20. Horn 40. Wiper.

Page 14

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TATA MOTORS
SUMMER INTERNSHIP PROJECT
ELIMINATION OF ENGINE MOUNT NOISE IN
ACE ZIP & MAGIC IRIS

What is Engine Mount?

Engine mounts hold a vehicles engine in place on the frame. An engine mount is just
that it mounts the engine to a vehicle. It keeps the engine from moving or shifting
out of place while the vehicle is operating. If a mount becomes worn out or broken it
can allow the engine to move excessively providing a rougher ride. If allowed to
persist extra strain will be put on the other mounts increasing their chance of failure,
allowing the engine to come free in the vehicle causing very costly repairs.

Structure
An engine mount consists of two attached metal parts with rubber in Page 15
between. One side of the mount is bolted to the engine while the other
is attached to the frame. The rubber in the center absorbs vibrations
while allowing a small amount of movement.

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Function
The engine mount keeps the engine secured, prevents it from vibrating
excessively and ensures that it stays properly connected. It also keeps
vibrations from traveling through the frame and other parts of the
vehicle.

Malfunction

Engine mounts may malfunction due to the bolts or rubber on the

mount being cracked and worn. The symptoms of a faulty mount
include excessive shaking or vibration from the engine and thumping
noises from under the hood. If symptoms indicate the engine mount is
not secure, it should be replaced right away to avoid damage to the
engine.

The Engine Mount acts as a transition between the motor and the surrounding
components, and allows installers to secure the motor within the device. The right
motor mount can extend the life of the device while the wrong mount may result in
excess vibration and a shortened lifespan for the engine. When choosing motor
mounts, take the time to match the type of mount with the application in order to
maximize its performance.

Types of Engine Mounts:-

Rigid Mounts
In a rigid mount, the motor mount is attached to the frame of the
device with fasteners or bolts. Some rigid mounts may even be built
into the vehicle or equipment or permanently welded in place.
According to "Electrical Construction and Maintenance" magazine, rigid
mounts are most often used with small motors rather than large ones. Page 16
Rigid mounts provide the most accurate alignment between the motor
and the surrounding mechanisms, but may be damaged by vibration
under heavy-duty operation.

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Resilient Mounts
Resilient motor mounts feature a layer of rubber or insulation between
the mount and the motor. This material helps to reduce noise and
vibration, which may extend the life of the motor and related parts.
Resilient motor mounts also allow for some flexibility and movement
without compromising the performance of the motor. According to
"Electrical Construction and Maintenance" magazine, these mounts are
often found in larger motors or in applications where excess noise or
vibration could be problematic. These mounts also help to reduce the
impact as the motor starts and stops, which minimize shock to the
surrounding system.

Hydraulic Mounts
Hydraulic, or hydro motor, mounts contain some form of gel or liquid
to help absorb impact and vibration during operation. This may include
glycol or hydraulic fluid, or any other types of fluid substance. This type
of mount is often used in four-cylinder motors, which produce large
amounts of vibration or noise. They may also be used with other types
of motors when noise levels must be kept to a minimum.

Face Mounts
In a motor designed for face mounting, or NEMA "C" mounting, the
motor attaches directly to the surrounding components without the
use of a standard mount. Often, installers will use a NEMA "C" face
mount adapter in order to adapt a face-mounted motor to a vehicle
designed for another type of motor mount. In this type of mount, the
bolts on the motor pass right through pre-drilled holes in the motor
casing and into the surrounding components or devices.
Page 17

Mechanical problems caused by bad Engine Mount:

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Excessive Engine Vibration

Motor mounts help to keep a vehicle's engine anchored securely inside the
engine compartment. Bad motor mounts, especially broken motor mounts,
frequently allow a vehicle's engine to move or shake excessively; causing
excessive engine vibration, which often gets transmitted into the passenger
compartment of the vehicle.

Abnormal Engine Position

An engine that appears lopsided or out of alignment relative to its normal

position is normally an engine, with broken or severely damaged motor
mounts. In addition to securing an engine within the vehicle hood
compartment and stabilizing its movements, motor mounts serve to keep an
engine aligned and positioned properly to allow for adequate engine
operation, and adequate operation of all of the supporting mechanical
devices underneath a car's hood. Bad motor mounts can allow an engine to
sag or tilt, a situation that is easily spotted by a diligent individual.

Engine Damage
In extreme cases, bad motor mounts can totally lose their structural integrity
and allow a vehicle's engine to shift excessively to one side, especially during
rapid engine acceleration or at high rates of speed, which can allow various
mechanical engine parts, including pumps, pulleys, and diaphragms to
contact the vehicle frame and break.

Broken Belts/Hoses
In addition to broken engine parts, bad motor mounts can cause damage to
an engine's belts and hoses. If bad motor mounts allow excessive engine
movement or tilting, various engine fan belts and/or radiator hoses can be Page 18

damaged or broken, especially under heavy engine acceleration when engine

movement is most pronounced.

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So, what is Engine Mount Noise?
Many times bad or broken engine motor mounts will cause loud or excessive
engine noise, usually knocking or clanking types of noises. These types of engine
noises are usually the result of the engine block pounding or bumping against the
broken or damaged motor mounts that have lost their snug fit against the engine.

The engine of Magic Iris and Ace Zip is rear drive type. The engine is
mounted/ supported on four mounts, namely – A, B, C and D.

Fig: A mount Fig: B mount

Fig: C mount Fig: D mount

When the engine is started, it produces torque. Due to the torque produced Page 19
by the engine, it vibrates. If the mounts on which the engine is mounted are loose,
broken or not fixed in correct position, it produces unwanted noise. This outcome
comes in the form of metal-metal clanking noise. Usually, this mount noise are

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found and solved in the UNDER PIT section of the TCF shop. Then the vehicle goes
for road test. After road test, any further mount noise which was not found in the
U/P section is found and repaired.

Specification of mounts

A mount B mount C mount D mount

Bracket Centre Bracket Centre Bracket Centre Bracket Centre

bolt bolt bolt bolt bolt bolt bolt bolt

No. of 2 1 4 1 3 1 4 1
bolts

Torque 4.5 8 2.3 7.7 2.3 4.5 2.3 4.5

used
(KgM)

Potential causes at each mount which leads to mount noise are as

follows:
1) A mount
a) Gap between engine mount and engine bracket is less.
b) Bracket bolt is loose or free.
c) Centre bolt is loose or broken.
d) A-mount arm bolt is free or loose. (will cause mount noise if 2 or more bolts
are loose).

2) B mount Page 20

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a) Centre bolt loose or free.
b) Bracket of B-mount bend due to
over-tightening.
c) Bracket bolt missing or free.

Due to over tightening

the
B mount and engine
bracket
clash with each other
3) C mount
a) Bracket bolt loose or free.
b) Bracket of C-mount bend due to over-tightening.
c) Centre bolt loose or free.

4) D mount
a) Bracket bolt loose or free.
b) Bracket of D-mount bend due to over-tightening.
c) Gap between engine bracket and engine mount more than required limit.

Due to loose fitment of

bracket bolt of C mount the
engine bracket and BIW part
clash with each other.

Page 21

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Engine Mount Noise Monitoring Sheet
Under Pit Section

SL. Fouling `No. of Vehicles Cause

No. Location

5th July 6th July 7th July 9th July

1. A- mount |||| |||| | |||| |||| ||||  Bracket bolt is loose

|||  Amount arm bolt is free
 Arm bracket is not proper

=4 =6 =9
=8
2. B- mount | |||| || |  Bracket bolt loose or free
 Centre bolt is loose
 Bracket bend

=1 =5 =2 =1

3. C- mount | ||| ||| ||  Bracket bolt is loose

 Centre bolt loose or free

=1 =3 =3 =2

4. D- mount | | |  Bracket bolt is loose or free

 Centre bolt is loose or free
NIL

=1 =1 =1

Page 22

Engine Mount Noise Monitoring Sheet

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Road Test Section

SL. Fouling `No. of Vehicles Cause

No. Location

5th July 6th July 7th July 9th July

1. A- mount NIL NIL NIL NIL NIL

2. B- mount | |||| |||| || |||| ||  B MOUNT over-tight or loose

=1 =5 =7 =7

3. C- mount | ||| |||| ||||  Bracket bolt is loose

 Centre bolt loose or free

=1 =3 =5 =5

4. D- mount NIL NIL NIL |||  Bracket bolt is loose or free

 Centre bolt is loose or free

=3

Page 23

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25 120

80-20 point
100
20
No. of Vehicles with mount noise

80
15

60 Volume
Cum.
10
40

5
20

0 0
B mount C mount D mount A mount

Figure: Pareto Chart for Mount Noise Monitored

Analysis:
Potential Mount Noise Area

A mount
B mount
C mount
D mount

Page 24
After taking readings from the monitoring sheet, it is found that maximum mount
noise is coming from B and C mount.

Proposed Solution:
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Here at TCF-1D, I was trained by the Line-supervisor to identify the root cause of
mount which can be reduced by proper functioning during fitment process.

During fitment due to human error or by some other way in Under Body section,
mount noise can occur. So proper care need to be to eliminate it.

For resolving the problem mentioned above a standard procedure is followed

during the fitment of mount at trim line.

The procedure is in the form of Work Sheet. It is as follows:

WORK SHEET
Subject: Fitment of B-mount
Model: All ACE ZIP & MAGIC IRIS
Sl. No. OPERATION SEQUENCE
Pick B mount and hand tighten it in the BIW (Body in White) with 4 Nos.
Step1.
of MBX22 Hex. Flange screws.
Tack these bolts and torque tighten these bolts with torque ranch at 2.3
Step2.
KgM.
Pick up the central bolt and fit it into the hole of B mount and engine
Step3.
bracket and hand tighten it.

Step4. At the quality gate check whether the screws are there & are tight or not.

Torque tighten the central bolt of B mount with torque ranch at 7.7 KgM.
Step5.
Avoid over tightening or applying torque more than required.

Page 25

WORK SHEET

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Subject: Fitment of C-mount

Model: All ACE ZIP & MAGIC IRIS
Sl. No. OPERATION SEQUENCE
Pick C mount and hand tighten it in the BIW (Body in White) with 3 Nos.
Step1.
of MBX22 Hex. Flange screws.
Tack these bolts and torque tighten these bolts with torque ranch at 2.3
Step2.
KgM.
Pick up the central bolt and fit it into the hole of B mount and engine
Step3.
bracket and hand tighten it.

Step4. At the quality gate check whether the screws are there & are tight or not.

Torque tighten the central bolt of B mount with torque ranch at 4.5 KgM.
Step5.
Avoid over tightening or applying torque more than required.

Page 26

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After following the above mentioned procedure 20 vehicles were monitored, which
are as follows:

SL. No. Vehicle No. U/P(Under Pit) R/T(Road Test)

1) MAT491005CJG26351
2) MAT491005CJG26352
3) MAT491005CJG26353
4) MAT491005CJG26354
5) MAT491005CJG26355
6) MAT491005CJG26356
7) MAT491005CJG26357
8) MAT491005CJG26358
9) MAT491005CJG26359
10) MAT491005CJG26360
11) MAT491005CJG26361
12) MAT491005CJG26362
13) MAT491005CJG26363
14) MAT491005CJG26364
15) MAT491005CJG26365
16) MAT491005CJG26366
17) MAT491005CJG26367
18) MAT491005CJG26368
19) MAT491005CJG26369
20) MAT491005CJG26370
 
 
 
We see that after following
 
the procedure, the no. of
 
vehicles with mount noise
 
has reduced.
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Major reasons which caused are:

 The body parts which are sent from BIW are not properly fabricated. Page 27
 The line man of TCF-1D are not using proper means like torque wrench for
the fitment of Under Body. So, over tightening case become prominent.

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Hence I observed that:

 Testing and inspection should be carried out at every quality gate.

 Tightening of nut and bolt should be proper.

 By using automation and precise machinery.

 The assembly parts should be manufactured by advanced manufacturing

processes in Vendor Company.

 The training and motivating policy should be applied to workers.

 Kaizen should be applied.

 Job rotation policy should be applied.

Possible further aspects in the project:

͞WHAT CAN GO WRONG ANALYSIS͟: By doing this one can also find the root cause
of the untraceable line problems and take suitable steps towards its elimination and
thus TML TCF-1D shop can assure nearly perfect fitment for the car .

CONCLUSIONS
Page 28

After analyzing the problem, in the Under Body section (Magic iris and Ace Zip) the
mount noise was eliminated with positive results.

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