A

Training Report

Submitted

In fulfillment

For the award of the degree of

Bachelor of Technology in Mechanical Engineering

2018-2019

Submitted to: Submitted by:

Mr. I.B Shekhawat Nitesh Yadav

====================================================================================================

DEPARTMENT OF MECHANICAL ENGINEERING

VIVEKANANDA INSTITUTE OF TECHNOLOGY
SISYAWAS, SECTOR-36, NRI ROAD, JAGATPURA, JAIPUR, RAJASTHAN
==================================================================================================
 AN
INDUSTRIAL TRAINING REPORT

Submitted on fulfillment of the

SUMMER TRAINING at the Esteemed organisation

Tata Motors Limited

For the degree of

MECHANICAL ENGINEERING
BY
Name: NITESH YADAV
Roll No. 15EVJME044

Under the guidance of

MR.MANOJ KUMAR(HEAD)
MR.SURAJ KHADE(ASST.)
 VIVEKANANDA INSTITUTE OF
TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This to certify that this report on practical training taken at “TATA

Motors ” is submitted by Nitesh Yadav, 15EVJME044 to the
Department of Mechanical engineering, VIT, Jaipur, for the award of the
degree in B.TECH Mechanical Engineering is bonafide record of work
carried out by him. The contents of this industrial training report, in full
or in parts have not been submitted to any other Institute or University
for the award of any degree or diploma.

Mr. I. B. Singh Mrs.Nisha Payal

Incharge (Practical Training Seminar) HOD, MECH
 ACKNOWLEDGEMENT

It is matter of great pleasure and privilege for me to present this report

on the basis of practical knowledge gained by me during practical
training at TATA Motors INDIA after completion of my 6 th semester. I
am also grateful to MR.MANOJ KUMAR & MR. SURAJ to support
me at each and every step of my training schedule. I attribute heartiest
thanks to Mechanical department, Engineers and Federal Mogul
Production head for their Ample Guidance during my training period in
TATA MOTORS .

I wish to extend my sincere gratitude to respective Practical Training

Coordinator Mr. I. B. Singh for his valuable guidance and regular
encouragement which has been absolutely helpful in successful
completion of this training report. I am indebted to Mrs. Nisha Payal
(HOD, Department of Mechanical Engineering) for her valuable
support. I am also thankful to all the ME faculty members for their keen
interest and at last my coordinal thanks to my batch mates and friends
for their cooperation.

Nitesh Yadav
15EVJME044
CONTENTS

CHAPTER 1

1. Introduction…………………………………………………….…6
2. History…………………………………………………………….6
3. Products ….……………………………………………………….7
4. General layout……………………..……………………………...7

CHAPTER 2

1. Paint shop...................................................................................8
2. Main line assembly.....................................................................10
3. PDI..............................................................................................12
4. Welding equipment......................................................................14

CHAPTER 3

1. Frame shop...................................................................................16
2. Main line assembly.....................................................................18
3. PDI..............................................................................................20
4. Welding equipment......................................................................22

CHAPTER 4

1. BIW
shop…………………………………………………………………………………………..
……23
2. Process flow
digram…………………………………………………………………………..……25
3. Main supply line
…………………………………………………………………………….…………26

CHAPTER 5
 1.Transale
shop……………………………………………………………………………………………….
….27
2.Main supply line
…………………………………………………………………………………………….…28
3.Engine dressing line
……………………………………………………………………………………………30

CHAPTER 6

1. TRIM CHASSIS FINAL (TCF) SHOP...........................................................32

2.Summary…………………………………………………………………………………………
……..34
3.Trim line
assembly………………………………………………………………………………….37
4.
Torque……………………………………………………………………………………………
…….. 38
5 Electric
system…………………………………………………………………………………………41
CHAPTER 1

INTRODUCTION

TATA Group
The Tata group’s core purpose is to improve the quality of life of the communities it serves
globally, through long-term stakeholder value creation based on leadership with trust

Brief Synopsis
Type Private Industry Global Diversified Enterprise
Founded 1868
Founder Jamsetji Tata
Headquarters Mumbai, Maharashtra, India
Area served Worldwide
Key people Cyrus P Mistry
Products Airline, Automotive, steel, IT, Electricity generation, Chemicals, Beverages, Telecom,
Hospitality, Retail, Consumer goods, Engineering, Construction, Financial services

The major facilities at the plant comprises of:

o Vehicle Factory - Assembly Plant for Trucks and Bus Chassis

o Integral Bus Factory - Assembly Plant for Module Buses catering to the needs of Tata
Marcopolo Motors Limited and FBV operations

o Transmission Factory - Gear Parts, Crown wheel & Pinion and Heat Treatment facility

o Production Engineering Shop catering to the tool design and manufacturing needs

o A well established Training Centre through which around 500 apprentices are trained in
various trades.

o Engineering Research Centre with specific focus on buses, including a Digital prototyping lab,
use of PLM software etc.

o Service Training Centre providing training to drivers and technicians of the STU's.

o RECON Factory (for Reconditioning Business)

o The satellite plant of TMML which caters to the Hi-end buses for the Northern Market.

Tata Motors Limited

Tata Motors Limited is an Indian multinational automotive manufacturing company 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.

Brief Synopsis
Type Private Industry Automotive Founded 1945
Founder Jamsetji
Tata Headquarters Mumbai, Maharashtra, India
Area served Worldwide
Key people Cyrus P Mistry
Products Automobiles, Commercial Vehicles, Coaches, Buses, Construction equipment,
Military vehicles, Automotive parts Services Automotive design, engineering and outsourcing
services

Karnataka Plant

Tata Motors Karnataka (TML) was established in 1992 to meet the growing demand for
Commercial Vehicles in the Indian market.

This plant rolls out commercial vehicles & is specialized in the designing & manufacturing of
a range of modern buses which includes Low-floor, Semi Low-floor, and High Deck & CNG
Buses.

Plant has recently commissioned JV Company, Tata Marcopolo Motors Ltd. in the premises.

CHAPTER 2

FRAME SHOP
 Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear nose Protection
o Wear hearing Protection

Main Line Assembly

Station No Station Name Process Pokayoke Equipment

Used
FRM-10 Spot W/F Stage 1 Geometric Assembly Spot counter C-Gun
Respot for assy of frame-1 Part identification Elbow Lift
frame complete Spot Welding LH & RH
Assy of long member
LH & RH
Assy of rear
suspension C/M
FRM-20 Spot W/F Stage 1 Spot Welding Spot counter C-Gun
Respot for assy Assembly of parking Parking tube outer X-Gun
frame complete tube outer bracket bracket part miss Elbow Lift
Number Plate is fixed
to frame
Assy of H C/M
FRM-30 Geo for assy frame Spot Welding Spot counter C-Gun
complete Assy of outer LH & Steering bracket X-Gun
RH steering brackets part shift Elbow Lift
Assy of Front steering
bracket
Assy of cover plate
Assy of Arm
mounting
Assy of D-Mount

FRM-40 Spot W/F Stage 2 Spot Welding Spot counter C-Gun

Respot for assy Assembly of Tie Hook Tie Hook part X-Gun
frame complete and washers identification Elbow Lift
Sealant application

FRM-50 Spot Welding fixture Spot Welding Spot counter C-Gun

for frame assy Assembly of Long Fuel tank bracket X-Gun
complete member reinforced and rear end panel Elbow Lift
LH & RH and rear part shift
end panel
Assy of bracket fuel
tank
Reinf long front
suspesnion

FRM-60 Spot W/F Stage 4 Spot Welding Spot counter C-Gun

Geo for assy frame Assembly of wheel X-Gun
complete arch cover Elbow Lift
Assy of Front reinf
long member
FRM-70 Spot W/F Stage 4 Spot Welding Spot counter C-Gun
Respot for assy Assembly of spare Spare wheel X-Gun
frame complete wheel mounting mounting bracket Elbow Lift
bracket BSIV part identification
Sealant Terakol-57 is
applied
FRM-80 Spot W/F Stage 5 for Spot Welding Spot counter C-Gun
assy frame complete Assembly of long Long member X-Gun
member cover and reinforced part Elbow Lift
seat c/m identification

FRM-90 Spot W/F Stage 6 Spot Welding Spot counter C-Gun

Geo for assy frame Sealant application Rear seat part X-Gun
complete Rear seat c/m identification Elbow Lift
No loss tank mounting

FRM-100 Spot W/F Stage 6 Spot Welding Spot counter C-Gun

Respot for assy X-Gun
frame complete Elbow Lift

FRM-110 MIG Weld assy MIG Welding MIG weld counter MIG Welding
frame complete GC Assembly of horn Horn mounting gun
mounting, cradle reinf bracket miss Elbow Lift
brackets

FRM-120 MIG Weld assy MIG Welding Spot counter MIG Welding
frame complete GC Stud Welding MIG weld counter gun
Bin fix is bolted to Elbow Lift
front suspension
Assembly of Fuel
filter bracket
mounting

FRM-130 Inspection and MIG Welding MIG weld counter MIG Welding
Rework Assembly of Fuel Fuel filter bracket gun
filter bracket mounting part miss Elbow Lift
mounting

Pre Delivery Inspection (PDI):

Check for
o Spot Weld (Spot burr, Deep spot, Spot dent, Improper pitch)
o Spot miss
o CO2 weld bead (Blow holes, Heavy weld, MIG weld wire)
o Weld nut overlap
o Weld nut breakdown
Welding Equipment:
MIG Welding:

Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding. MIG welding is a
commonly used high deposition rate welding process.
MIG welding is an arc welding process in which a continuous solid wire electrode is fed through
a welding gun and into the weld pool, joining the two base materials together.
A shielding gas is also sent through the welding gun and protects the weld pool from
contamination
Spot Welding:
Spot welding is one form of resistance welding, which is a method of welding two or more metal
sheets together without using any filler material by applying pressure and heat to the area to be
welded.
The process is used for joining sheet materials and uses shaped copper alloy electrodes to apply
pressure and convey the electrical current through the workpieces.
To create heat, copper electrodes pass an electric current through the workpieces.
The heat generated depends on the electrical resistance and thermal conductivity of the metal,
and the time that the current is applied.
Types of welding guns used:
C-Gun:
X- Gun:
CHAPTER 3

PAINT SHOP

Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear nose Protection
o Wear hearing Protection

Conveyor speed : 1.3 mtr/min

TACT : 4 min
Weight of body with skid : 350 kg
Type of painting : Autophoretic ( Powder coating)
Station No Station Name

P-01 Jig fitment

Tackle loading

P-02 ACC paint processing stage

P-03 EMS paint processing stage

P-04 ACC painted body baking stage

P-09 Under body sealant application

Tag-o-rag application area

P-10 Manual and auto powder coating area

P-11 Powder coated body baking stage

P-12 Sanding/ Polishing stage

Run down
Cutting/ Touch up

P-13 Cavity waxing

Sealant Line

Station No Station Name

SL-01 Outer body masking

Melt sheet application area

SL-02 Body sanding

SL-03 Roof sanding

Tag-o-rag
Roof bead application

SL-04 Load body sealant application

SL-05 Cabin inside sealant application

SL-06 Front panel, door, Load body sealant application and tail
gate wiping

SL-07 PCC door jig fitment

Sealant wiping

SL-08 Scissor lift conveyor

Sealant Used:
o Terotex 3010 – 100 PC AAIN TEROSON (UB)
o Terotex 3010 – 100 PC AAIN TEROSON (SS)
Autophoretic coating:
Autophoretic, also known as auto deposition or A-coat, is a waterborne process which depends
on chemical reactions to achieve deposition.
The mildly acid bath liberates a small amount of iron from the steel parts being immersed,
causing an immediate surface reaction that releases iron ions. These ions interact with the latex
in solution causing coating deposition on the surface of the steel parts.
The newly deposited organic film is adherent yet quite porous. This allows the chemical
activators to diffuse rapidly in the film and etch the surface of the metal. The continuous
formation of coating provides a film with a high degree of surface protection and corrosion
resistance.
The coating thickness of the auto deposited film is time and temperature related.
A unique feature of the Autophoretic® process is the formation of a very uniform film over the
entire surface of the workpiece, even in difficult-to-reach areas.
Pre Delivery Inspection (PDI):
Check for
o Aquence coating
o ACC rough surface
o ACC oil patch
o ACC scratch
o Sealant bead
o Dry spray
o Oil spot
o Touch mark
o Sealant lump
o Paint missing
o Thin paint
o Run down

CHAPTER 4

BIW SHOP
Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear nose Protection
o Wear hearing Protection

Process flow diagram for BIW Shop

Despatch to paint shop

 PDI ATS CONVEYOR
MFL-100 MF-290 UBL-
240
MF-310 UBL-220
MFL-90 MF-360 UBL-
190
MF-380 UBL-180
MFL-70 MF-390 UBL-
170
MF-400 UBL-160
MFL-60 MF-410 UBL-
150
MF-420 UBL-140
MFL-50 MF-430 UBL-
130
MF-450 UBL-120
MFL-30 MF-460 UBL-
110
MF-470 UBL-100
MFL-20 MF-490 UBL-
70
MF-500 UBL-
60
MFL-10 MF-510 UBL-40
ATS PARI
Metal finish line Main framing line Under Body Line

Entrance to BIW

Under Body Line

Station No Process Pokayoke

UB-40 Frame unloading Model identification

Sealant application (Mastic sealant) Sealant guide

UB-60 Wheel arch assembly front LH & RH To check LH & RH wheel

Spot welding arch part
Load body floor assembly Spot Counter
UB-70 Spot welding Spot Counter
Strut plate assembly Tip dress alarm

UB-100 Spot welding Spot Counter

CPL loading To check front floor postion
Front floor assembly To check model
Sealant application
UB-110 Spot welding Spot Counter
Sealant application Sealant run miss

UB-120 Spot welding Spot Counter

Sealant application Sealant run miss

UB-130 Spot welding Spot Counter

UB-140 Robot Spot welding Spot Counter

Front wall assembly To check model
Sealant application To check robot front wall
gripper
UB-150 Spot welding Spot Counter
Sealant application Sealant run miss

UB-160 Spot welding Spot Counter

Side skirt assembly To check A pillar LH & RH
A pillar assembly position

UB-170 Spot welding Spot Counter

UB-180 Spot welding Spot Counter

UB-190 Spot welding Spot Counter

UB-200 MIG welding Co2 run miss

UB-210 Sealant application Sealant run miss

UB-220 Toy tabbing of body side outer To check chassis

To check model
To check frame LH & RH

UB-240 Robot Spot welding Spot Counter

To check chassis
To check model

UB-260 Spot welding Spot Counter

Main Framing Line

Station No Process Pokayoke

MF-290 Initial release Spot Counter

Respot

MF-310 Spot welding Spot Counter

Bumper bracket mounting fitment

MF-360 Spot welding Spot Counter

MF-380 Spot welding Spot Counter

Closing plate assembly

MF-390 Sealant application Sealant run miss

MF-400 Robot Spot welding Spot Counter
Roof loading To check chassis
To check model

MF-410 Robot Spot welding Spot Counter

Rear wall Assembly To check chassis
Sealant application To check model

MF-420 Robot Spot welding Spot Counter

MF-430 Spot welding Spot Counter

Sealant application Sealant run miss

MF-450 Spot welding Spot Counter

Load body side wall assembly To check chassis
Rear cross outer wall assembly To check model

MF-460 Spot welding Spot Counter

MF-470 Robot Spot welding Spot Counter

To check chassis
To check model

MF-490 Spot welding Spot Counter

Spot guide sensor

MF-500 MIG welding Spot Counter

Co2 run miss

MF-510 Earthing bolt fitment Earthing bolt weld nut miss

Bumper bracket fitment
B mount bolt fitment

CHAPTER 4
TRANSAXLE SHOP
Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear nose Protection
o Wear hearing Protection

Main Line Assembly

Station No
Station Name Process Pokayoke

Dropping of front half and rear To measure presence of

MA-01 FH Dropping half on the mainline pallet all parts in front and rear
Oil collector fitment half

MA-02 Scanning bar code sticker and To ensure calculated

Shim selection shim selection shim is taken from
Differential assembly dropping in machine
FH housing To check all parts present
in differential assembly
MA-03 Inner gut dropping on front half To ensure correct
Inner gut dropping B-Mount bracket fitment on FH algnmnet of shifter forks
housing into shifter sleeves

MA-04 RI shaft, spacer and idler gear To ensure orientation of

Rev gear & bracket assembly RI gear
assembly Reverse bracket assembly fitment

MA-05 Rear Housing dropping RH dropping and RI bolt torquing To ensure gap for sealant
Oil channel fitment & sealant dispense

MA-06 EWH bracket insertion on FH To ensure presence of all

RH bolt insertion Insertion of 14 bolts 14 bolts

MA-07 Tightening of 14 housing bolts To meaure pressure of all

Tightening bolts

MA-08 Snap ring fitment Shifter cap fitment To ensure the presence of
Snap ring fitment two snap rings

Dummy plug fitment Dummy plug fitment To ensure no gap in

MA-09 Sealant dispensing and rear cover sealant dispense
assy

Rear Cover assembly Tightening of 6 rearcover fitment To ensure presence of all

MA-10 bolts bolts
 Filler plug fitment & TA position changing from To ensure the presence of
MA-11 RI switch assy horizontal to vertical copper washer in filler
Filler plug fitment plug

Speed sensor fitment To ensure the presence

MA-12 Speed sensor 2 no’s Housing bolt fitment of

Two interlock piece fitment To ensure the presence

MA-13 Top cover asembly Sealant dispensing & fitment of of top cover on RH
top cover housing

Tightening of 4 top cover fitment To ensure the presence

MA-14 TC tightening bolts of all bolts

Cable anchoring bracket fitment To ensure the free ration

MA-15 Cable bracket fitment of all gears

Fitment of air leak TA bar code scanning To check leak test for TA
MA-18 adaptor Leak test for transaxle & accepatable leak rate
15cc/min @ 0.3 bar

TA unloading from coveyor To check the presence of

MA-19 TA unloading breather tube and cap

End of line testing Testing of transaxle for NVH, To check speed sensor
MA-20 Speed sensor and RI switch and switch working
working

Engine Dressing Line

Station No Process Pokayoke

ED-01 Assembly of Hose & intermediate pipe, Upper To ensure miss match of ASN
cooling line fitment sticker on BS IV engine

ED-02 To ensure proper fitment of

Fitment of solid dowel (1 Nos) solid dowel
Tightening of studs M8 x 25 (6 Nos) To ensure proper torquing of
studs to the engine cover

ED-03 To ensure proper presence of

Adaptor plate assembly earth cable
Earth cable fitment To ensure proper torquing of
Earth cable bolt

ED-04 Assembly of hose and intermediate pipe, upper To ensure proper alignmnent of
cooling line fitment intermediate pipe with 2 hoses

ED-05 Assembly of D-Mount and Exhaust mount To ensure proper fitment of

OMS bracket mounting fitment D-Mount and Exhaust mount

ED-06 Assembly of hose and intermediate pipe, upper To ensure proper alignmnent of
cooling line fitment studs with starter plate

ED-07 To ensure proper clutch cable

Alternator mounting routing bracket weld nut should
be away from alternator side

ED-08 Clutch cover assembly and screw tightening To ensure splines of clutch plate
C Mount fitment should be gear box side
To ensure torquing operation of C
Mount bolt
TA Mounting To check proper alignment of
ED-09 Bolt alignment to the Engine Transaxle to the engine

Tightening of TA to Engine adaptor plate bolts To ensure torquing operation of

ED-10 M10 x 35 bolts

Catcon bracket assembly To ensure torquing operation of

ED-11 Engine mount assembly catcon bracket
Fitment of benjo bolts To ensure torquing operation of
Engine mount bolt
 Alternator assembly To check reading of belt tension
ED-12 Belt tensioning
Battery positive assembly

To ensure proper routing and

ED-13 Wire harness and routing fitment damaged parts
To ensure locking of all
connectors wire harness
Wire harness and routing fitment To ensure torquing operation of
ED-14 Heat shield fitment Heat shield

Oil filling To ensure the oil filling quantity

ED-15 Radiator lower hose fitment is 1.3 lts

Power train unloading

ED-16 Engine pallet removing To check all the fitments

Engine Supplier : Greaves Cotton Ltd, Aurangabad

Engine oil filled : 1.3 lts
Engine oil grade : M/GRD Engine Oil (C14 15W40)
Types of gears:
Spur gear:

A parallel and co-planer shaft is connected by the spur gear. With straight teething parallelism to
the axis on the wheel, they form spur gearing. The type of gear is suitable for slow speed. Teeth
shapes should be determined by their cost effectiveness and purpose. However, they apply to any
speed as long as noise is not a problem.
Helical gears:
Their teeth are inclined to the shafts’ axis, assuming the shape like a helix. The name helical is
derived from their nature. Helical gear functions with high speed and hence, can handle a heavy
load. No noise or sound from their motion. When using a helical gear, one needs to put thrust
bearings. It is due to their management on the radical and thrust loads.
Spiral gear:

The umbrella name that is given to this gear is bevel. Both forms are cone-shaped applied in
shafts, which are intersecting. Spiral gear gets its name from their nature: they have spirally
shaped tooth trace. The other form has straight shaped tooth trace hence, named straight bevel
gear.

Herringbone

This gear is like a helical gear, position side by side. Mostly, people refer to them as double
helical. This arrangement the thrusts are balanced, and the bearings do not experience thrust
loading.

Hypoid
This gear is mainly found on the rear axle in vehicles. This gear is arranged to form forms a 90
degrees translation. Due to how they revolve on the same contact line, the gear is not
interchangeable. They are made from frusta hyperboloids. The centre lines on the shaft do not
come together, which makes the only difference between hypoid and spiral bevel gear.

Rack and pinion

This category is from the spur gear. Rack and pinion appears in a linear shaped variation. Their
variation is concerning the spur. Any rack gear is a bar that is toothed. It has a large curvature
radius, and it may be perceived as sector gear. A rack is meshed with a pinion to form a linear
force. As the pinion turns, the rack is in a straight line. This formation is mainly used in
automobiles.

Gear Nomenclature:
Pitch surface: The surface of the imaginary rolling cylinder that the toothed gear may be
consideredto replace

Pitch circle: Circle centered on and perpendicular to the axis, and passing through the pitch
point. A predefined diametral position on the gear where the circular tooth thickness, pressure
angle and helix angles are defined.

Addendum: Radial distance from the pitch surface to the outermost point of the tooth.

Dedendum: Radial distance from the depth of the tooth trough to the pitch surface.
Clearance: Distance between the root circle of a gear and the addendum circle of its mate.
Working depth: Depth of engagement of two gears, that is, the sum of their operating
addendums.
Backlash = Space width – tooth thickness
Circular pitch: Distance from one face of a tooth to the corresponding face of an adjacent tooth
on the same gear, measured along the pitch circle.
Axis: Axis of revolution of the gear; center line of the shaft.
Pitch point: Point where the line of action crosses a line joining the two gear axes.

Gear Box:
Gear box is device connected to engine which transmits the power from engine to drive shaft at
different required speed and torque.

Types of gear box:

Sliding mesh gear box:

This is one of the oldest type. It this, gears on the main shaft are moved right or left for
meshing them with appropriate gears on the counter shaft for obtaining different speed. This
type of gear box derives its name from the fact that the gears are meshed by sliding. One
disadvantage of it is that, special skill is required to operate this gear box.
Constant mesh gear box:

In this gearbox, all the gears are in constant mesh with each other all the time. The gears on the
main shaft rotates freely without rotating the main shaft. Constant mesh gear box consists two
dog clutches. These clutches are provided on the main shaft, one between the clutch gear and the
second gear and the other between the first gear and reverse gear.

Synchromesh gear box:

This gear box is same as the constant mesh gear box except dog clutch is replaced by
synchromesh devices. Synchromesh gear devices works on the principle that two gears to be
engaged are first brought into frictional contact which equalizes their speed after which they
are engaged readily and smoothly. The synchromesh looks like as the cone clutch where the
outer surface of cone consist the frictional surface. This type of gear box is widely used in
automobile.

Pre Delivery Inspection (PDI):

Check for
o Wire harness
o Oil leakages
CHAPTER 6

TRIM CHASSIS FINAL (TCF) SHOP:

Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear hearing Protection

TCF Shop Summary:

o Total number of stations : 73 (Trim Line – 38, Uder body – 22,
Mechanical line – 13)

o Total number of parts in kitting : 367

 o Total number of cells : 6 (Trimline – 4, Under Body -2 )

Trim Line Assembly

Station No Station Name Pokayoke

Body loading, Fitment of LH & RH rubber stopper

TR-03 B, C & D mounts assembly
A Mount arm assembly

TR -05 Fitment of cabin grommets & GRM Fitment RH

TR -06 Number punching, Fitment of floor adapotor, No IPMS interfaced plate

loss tank punching
Assy of manufacturing plates & RH door foam B pillar punching
pressure interlock
Torque wrench pokayoke
TR -07 Fitment of ventillation duct assy, accelerator
stopper bracket and LH secondary seal

TR -08 Fitment of main wiring harness fuse box

Cabin earthing
Rear tail lamp

Fitment of head liner

TR -09 Assy of sunvisor, IRVM, reverse lamp, flasher,
Hook plug, antena and cable

Wiper motor, washer tank, accelerator peal brakcet, Torque wrench pokayoke
TR -10 relay bracket

Fitment of A pillar trim Strut side confirmation

TR -11 Assy of strut loose
Door beeding

Primer application
TR -12 Fitment of head lamp, bezel and secondary seal RH
 Fitment of seat belt LH RH DC nut runner
TR -13 Seat belt adaptor LH RH
Door latch outer handle

TR -14 Cable routings & FCM loose assembly

Torque wrench pokayoke

TR -15 Fitment of door lock, FCM & sturt torque

Fitment of accelerator stopper bracket, parking

TR -18 lever & window winding mechanism LH

Fitment of gear shifting mechanism & brake bundy Torque wrench pokayoke
TR -19 & cable routing

Fitment of rear glass, steering column, floor bellow Torque wrench pokayoke
TR -20 window winding mechanism RH

Fitment of LH RH door glass, waist seal assy, pop

TR-21 up knob, ORVM, coner cover menbrane assy

Fitment of steering column, I shaft, combi switch &

TR -22 membrane braking

Fitment of dashboard & scanning Torque wrench pokayoke

TR -23 Fitment of grab handle, coupler connection, ignition
torque

Fitment of LH RH door sticker, door pad, door pull Cluster missmatch

TR -24 handle, rear wall screw torque, RH earthing toque interlock

Fitment of windshield glass, CA & speed limit Guide for windshield

TR -29 sticker & wiper blade loose assy insertion
 Driver & Co driver seats, fuel neck cap, floor upper Torque wrench pokayoke
TR -30 LH & RH
Fitment of knob with TP sticker pasting, steering
wheel
Process completion
TR -33 Electrical e checking & wiper blade torquing interlock

Under Body Line-1

Station No Process Pokayoke

UB-01 Fitment of T-joint, brake bundy connection &

torquing, A/F body connection

UB-02 Routing of main wiring harness, Torque wrench pokayoke

Fitment of LH RH wishbone & stub axle

UB-03 Routing of clutch cable with help of multi clamp

& Fitment of FCU

UB-04 Fitment of fuel tank, torquing of A mount arm Torque wrench pokayoke

UB-06 Process completion interlock

Engine stuffing

UB-07 Fitment of STA LH RH with frame bracket Torque wrench pokayoke

Fitment of coil spring and shock absorber

UB-08
Engine loading

Under Body Line-2

 Station No Process Pokayoke

UB-11 Routing & setting of clutch cable, torquing of C Torque wrench pokayoke
& D shock absorbers, fuel filter, RH wheel
guard, Hub cap & stay rod

UB-12 Catcon fitment rack and pinion Torque wrench pokayoke

I shaft
Horn fitment

UB-13 Battery tray DC nut runner

Rear suspension torquing Torque wrench pokayoke

UB-14 Battery fitment

UB-15 Front suspension torquing Front DC nut runner

UB-16 TA oil filling TA oil grade confirmation

Bumper fitment TA oil filling process completion
interlock

UB-17 Shut off

Accelerator
Fuel excess cable fitment

UB-18 Wheel mounting

ECU & spare wheel fitment

UB-19 Wheel torquing Wheel DC nut runner

Mechanical Line
 Station No Process Pokayoke

ME-03 Impact beam fitment, Engine earthing Torque wrench pokayoke

Catcon torquing, battery earthing
Hand break coupler connection

ME-04 Brake oil filling Brake oil grade confirmation

Brake oil filling process
completion interlock

ME-05 Filling of fuel in fuel tank Diesel filling interlock

ME-07 Coolant filling coolant filling process completion

Dome nut torquing interlock

ME-09 BS IV flashing, water filling in water tank, Diesel priming interlock

LSPV connection, brake switch connection & Water filling interlock
vaccum cleaning

ME-10 Service panel assy, OMS torquing,

Grommet fitment

ME-13 Brake pedaling, steering wheel spoke alignment Torque wrench pokayoke
& torquing

WA Wheel alignment Test results interfaced with SAP

Head light aiming

RBT Roll and brake test Test results interfaced with SAP

TORQUE:
It is the tendency of a force to rotate an object about an axis, fulcrum. Just as a force is push or
pull, a torque can be thought of as twist to an object.
Devices used for application of torque:
Torque wrench:
A torque wrench is a tool used to apply precisely a specific torque to a fastener such as a nut or
bolt. It is usually in the form of a socket wrench with special internal mechanisms.

Torque wrench types:

Nut Runners:
These are devices that use electrical or pneumatic power for torque application. Torque values
are not very precise but reduce human effort.
Roll and Break Test:
A roller brake tester is a method of allowing the dynamic assessment of the braking system of
a motor vehicle, whilst the vehicle itself is in a static condition. Roller brake testers consist of a
mechanical floor unit which contains electrical motors, two independent sets of three measuring
rollers, brake force transducers and additional safety sensors.
Tests carried out in roller brake test:
Brake Force Test:
o Brake force test is the force applied by the braker system to slow down and stop the
vehicle. Higher the brake force more effective is the brake system.
o The brake force must be between 600 to 1200N for front wheel and 170 to 330N for rear
wheel
o Ideally Break force at LH and RH wheels must be equal but actually it is not possible,
hence some deviation is allowed.

Pedal Force:
o It is the force applied by driver foot on brake pedal. This is measured by brake pedal
sensor. For Ace Zip pdal force must be between 10 kgf to 20 kgf.

Drag Force:
 o Drag is a force that acts parallel and in the same direction as the airflow. The drag
coefficient of an automobile impacts the way the automobile passes through the
surrounding air reducing the drag coefficient in an automobile improves the performance
of the vehicle as it pertains to speed and fuel efficiency.

Parking Brake test:

o It measures the brake force when parking brake is applied. It should be between 800N to
1100N when vehicle is accelerated up to 20KMPH.

ELECTRICAL SYSTEMS:
Electrical Conduction:
Electrical Conductance is the ease with which an electric current passes. Electrical resistance
shares some conceptual parallels with the notion of mechanical friction. The SI unit
of electrical resistance is the ohm (Ω), while electrical conductance is measured in siemens (S).
Earthing System:

In an electrical installation an earthing system or grounding system connects specific parts of that
installation with the Earth's conductive surface for safety and functional purposes.
Key points for earthing:
o The positive cable is run from battery to the starter providing an uninterrupted
connection.
o A matching size ground cable needs to be connected between the engine and the frame
o All connections should be full metal to metal contact.

In vehicles grounding is of two types:

1)Insulated return uses special wire return which is used for high voltages
2) Earth return that uses chassis earth return would be dangerous where high voltages are used,
but it is safe for 6-12 Volts.
Current Leakage:
Leakage current is the current that flows through the protective ground conductor to ground. In
the absence of a grounding connection, it is the current that could flow from any conductive part
or the surface of non-conductive parts to ground if a conductive path was available.
BATTERY:
Function of a Battery:
An electric battery is a device consisting of one or more electrochemical cells with external
connections provided to power electrical devices such as cars. When a battery is
supplying electric power, its positive terminal is the cathode and its negative terminal is
the anode The terminal marked negative is the source of electrons that when connected to an
external circuit will flow and deliver energy to an external device.

Lead Acid battery:

The storage battery or secondary battery is such a battery where electrical energy can be stored
as chemical energy and this chemical energy is then converted to electrical energy as and when
required.
Charging of batteries:
The discharge of a battery is connected to charger with its output voltage set at 13.6 volts. In
order to recharge a 12 volt battery with a fully charged terminal voltage of 12.6 volts, the charger
voltage should set at higher voltage. During the battery recharge cycle lead sulphate begins to
reconvet to lead and sulphuric acid.
Precautions for charging:
o For charging lead acid batteries an intelligent charging system that can vary the charging
voltage should be used.
o Overcharging leads to release of hydrogen and oxygen, pressure from these gasses will
cause caps to open and vent, resulting in some water loss.
Pre Delivery Inspection (PDI):
Check for
o Engine oil checking
o Spare wheel
o Wiring harness
o Engine oil leakage
o Earthing points
 CONCLUSION

During the training period

Visited the Assembly lines and the Trim lines and studied
their functioning - complete assembly procedure along with
progressive quality checks and man-machine management.

Worked with the SQ team and got acquainted with the

department’s responsibilities, office procedures and work
management. Also, gained hands-on experience working with
systems such as PRR using which numerous issues were
resolved daily.

Visited some ancillaries of TML and thoroughly studied their

manufacturing processes and analysed their methods for defects
reduction.

Worked along with M/s Mitter Fasteners and successfully

eliminated defects arising in part 2632 3120 0126 supplied by
them.

Implemented and ensured daily updation of Quality gates and

SQDCME at Mitter Fasteners.