NITTE MEENAKSHI INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGIEERING

SUBMITTED BY:
SHREESH KAUSHIK C G
MANASI K

INTERNSHIP UNDERTAKEN
AT

                          
                              Construction Equipment  
                                          Peenya, Bangalore    

                                

"A REPORT ON ZERO LEAKAGE PROJECT"
UNDER THE GUIDANCE OF:
Mr. Sanjay Raina Mr. Raghu M
(Plant Head) (Compaction line supervisor)

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 INDEX

 ACKNOWLEDGEMENT

 INTRODUCTION TO VOLCO CE

 VOLVO PRODUCTION SYSTEM

 PRODUCTS

 5S METHODOLOGY

 TOPICS OF STUDY DURING INTERNSHIP

 ZERO LEAKAGE PROJECT

 TYPES OF TORQUE WRENCHES

 COMPACTION ASSEMBLY LINE

 AIM OF PROJECT

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 ABOUT OF PROJECT

 SOLUTIONS

 CONCLUSIONS

Acknowledgement: -
During my internship period from 17th June 2019 to 17th July
2019 at Volvo, I had interactions with several persons to
whom I will eternally be grateful for assisting me in the
understanding the work involved and the work culture
implemented here. I owe a debt of gratitude to the HR head,
Mr. Kishan Cariapa, for accepting my request and assigning
me a supervisor to guide me through the time I would be
devoting at Volvo. I would like to thank Mr. Anil Kumar G for
giving me the opportunity to work in this revered. I am
beholden to my supervisor, Mr. Sanjay Raina, for having
taken time out of his extremely busy schedule and assigning
me work that would help me gain an in depth knowledge and
about the processes and challenges involved in the assembly
line and realising the correlation between the theory from
my study curriculum and the practical approach to it
happening on the factory floor. I am also obliged to Mr.
Raghu for helping me understand the work that goes on in
the production line and to have learnt from the employees
and apprentices themselves was truly knowledge enriching.
My heartfelt regards to them as well as my special thanks to
my fellow student interns whom I befriended, who helped

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me understand in detail the working of the compactors and
pavers, and also making this time much more memorable.

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Introduction to the company
Volvo construction equipment
Volvo construction equipment – Volvo CE – (originally munktells, bolinder-
munktelland Volvo B) is a major international company that develops,
manufactures and markets equipment for construction and related industries.
It is a subsidiary and business area of the Volvo group.
Volvo construction equipment (VCE) was started in 1832 in Eskilstuna, which
makes it the oldest industrial company in the worl still active in construction
machinery. VCE has grown and developed throughout the years through a
number of mergers and acquisitions. The blue Volvo construction equipment
indicates compliance. The company manufactures construction machines such
as articulated haulers, excavators and wheel loaders. VCE is a part of the Volvo
group which has approximately 100,000 employees, production in 25 countries
and operates in more than 185 markets.

Vision: -
To be the most desired and successful transport solution provider in the world

Mission: -
 Driving prosperity through transport solutions
 Modern logistics is a prerequisite for our economic welfare: transport
helps combat poverty.

Volvo contributes to prosperity and makes the wold a better place.

On the road: Volvo products help ensures that people have food on the table
and roads to drive on.
In the city: Volvo products are a part of the daily life. They take people to work,
collect waste and generate power. Volvo group is developing tomorrow’s
public transport solutions.
Off road: Volvo contribute to the extraction of the world’s most important raw
materials, Volvo group’s engines, machines and vehicles can be found at
mining and construction sites and in the middle of the forests.
At Sea: whether at work on a ship, on holiday in your cruise boat or need
urgent help from the sea rescue services.

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 Volvo construction
equipment, Bangalore
Volvo construction equipment pvt. Ltd is a subsidiary of VOLVO AB,
Sweden. The Bangalore facility is one among the Asia operations which
manufactures Road machinery like asphalt compactors, soil compactors,
pavers, pneumatic tiers and also excavators.
Volvo CE, located in peenya, Bangalore is a part of global Volvo
construction equipment under Volvo India pvt ltd entity. Volvo construction
equipment operations facility in Bangalore has a total area of approximately
57000 sq. meters with factory occupying over 27000 sq. meters.
The plant started its operations in the year 1978 to cater to the needs of
the mining industry and road construction sector. The Volvo group took over
this plant in the year 2007 and later expanded to cater to the needs of the
construction equipment industry by manufacturing excavators. Out of 204
permanent employees there are 144 white collars (including P & SM
technology) and 60 blue collars in the facility. Over 58% of the people work in
operations. Women employees contribute 13% of the total white collars.
Peenya facility is certified for QMS/EMS and QHSAS and complies to AB
VOLVO safety and security guidelines. Their core values are safety quality and
environment. With over 15 dedicated dealers spread across India, Volvo sells
approximately 1600 construction equipment machines per annum to various
customers ranging from road building industry, earth moving contractors,
mining etc.

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 VOLVO PRODUCTION SYSTEM (VPS)
VPS was first introduced in 2007 as a way to continuously improve the quality,
delivery and productivity. It contains practical tools that when used correctly
helps the organisation to work towards its shared goals. VPS has 5 core
principles which are to assist and guide the organisation towards its goals.

Just in time: - it is a production strategy to improve the company’s return on

investment by reducing the in-process inventory and its carrying cost. Just in
time refers to the manufacturing and conveyance of only what is needed. This
enhances efficiency and enables quick responses to change. Volvo believes
that the storage of unused inventory is a waste of resources. In Volvo just in
time is built upon the five basic principles of pull systems, continuous flow
processing, flexible manpower, takt time and material supply.

Flexible manpower: - This means preparing a production line so that it can

meet changing production requirements with any number of workers without
lowering productivity. A fixed manpower line is one that’s always requires a
fixed number of workers. No adjustments can be done to it whatsoever to
meet changed in production demands.

Pull system: - one of the basic requirements of just in time. The pull system
refers to the system of manufacturing in which following production processes
withdraw from the processing processes the parts they need, when they need
them, in the exact needed amount.

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Material supply: - it is a fully integrated application designed to close the loop
between you and your supplier by supporting the outsourcing of your
manufacturing. The system facilitates insurance of component materials to
supplier in conjunction with the placement of purchase order.

Takt time: - it is the time which should be taken to produce a component or

complete product.
Takt time=available work time per day/customer demand per day.

Continuous flow processing: - this means eliminating the stagnation of work In

the between processes and carrying out in one piece at a time production.

Values: -
The Volvo group views its corporate culture as a unique asset, since it is
difficult for competitors to copy. By applying and strengthening the expertise
and culture they have built up over the years, they are able to achieve their
vision.
Quality, safety and environmental care are the core values that form the Volvo
groups common base and are the important components of their core culture.
The values have a long tradition and permeate their organization, the products
and also the way of working. The main goal is to maintain a leading position in
these areas.

Quality: -
Quality is an expression of their goal to offer reliable products and services. In
all aspect of their operations, the product development and production to
delivery and customer support, the focus shall be on customer’s needs and
expectations. The goal is to meet or exceed their expectations. With customer
focus based on everyone’s commitment and participation, their main aim is to
be number one in customer satisfaction. This is based on a culture in which all
employees are responsive and aware of what must be accomplished to be the
best business partner.

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Safety: -

Safety pertains to how our products are used in

society. We have had a leading position in issues
regarding safety for a long time; our goal is to maintain
this position. A focus on safety is an integral part of our
product development work. The employees are highly
aware of safety issues, and the knowledge gained from
the internal crash investigations is applied in product
development. The goal is to reduce the risk of
accidents and mitigate the consequences of any work
environment of the drivers of their vehicles and
equipment. The long-term vision is zero accidents.

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 PRODUCTS
Compactors: -
The Volvo DD100 compactor is the ideal roller for asphalt compacting
operations of varying sizes, working in versatile applications. From roadways
and highways to large parking lots and airport runways, this is the compactor
suited to a wide range of conditions and widths. By getting the job done as
efficiently as possible in the fewest amount of passes the DD100 will help us
complete our jobs with greater profitability. DD90B is one more variant in the
class.

Pneumatic tyre: -
The Volvo compactor is the 22-24 tonne pneumatic tyre road roller that
delivers idea smoothness for asphalt compaction finish work. This asphalt
roller features eight air-filler rubber tyres, and is ideal for paving compactors
working in highway applications. The Volvo PT220 compactor, even asphalt
mass with less passes. The PT220 is built by Volvo for dependability and long
operation life. PT240 is an export variant with extra load bars to add up more
weight.

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Soil compactors: -
The Volvo compactors are designed with mind for all of your compaction
applications and features to help you tackle even the most dangerous jobs.
Volvo soil compactors are versatile machines ready to efficiently compact
varying soils and aggregates in application such as highways, utilities, water
retention structures and in large residential, commercial ad industrial site
preparation.
The Volvo SD110 soil compactor is an 11-ton class soil compaction roller built
to help you roll on to more profitable jobs. It’s a very versatile machine ready
to efficiently and effectively compact varying soils and aggregates in
applications such as highways, utilities, water retention structures and in large
residential, commercial and industrial site preparation. For even more
versatility, the SD110 soil compactor is available in a smooth drum with an
optional clamp-on pad foot shell is easy to install and remove.

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Excavators: -
Volvo small and large excavator has your solution for dependable excavating
equipment. On crawler tracks or on road with wheeled versatility, we are on
our way to maximise profit in site preparation, landscaping, trenching,
excavation, demolition, truck loading.
Top features for the range of Volvo excavators include:
Dependable Volvo engines deliver class-leading fuel economy.
Volvo care cabs provide safety and comfort to reduce operator fatigue and
increase productivity.
Ease of service with, ground level access to routine service points, for
maximum availability.
Advanced hydraulic system for highly-responsive performance.
Versatile quick fix systems, for easy bucket and tool change out.
Some of the variants manufactured are EC300DL, EC300X1, EC210D,
EC201X1 and EC210DL.

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Pavers: -
Powerful paving machines for rigorous job-sites, Volvo’s ABG tracked pavers
meet all your paving needs. With ample reserve power, robust and sturdy
design, Volvo ABG tracked pavers are ideal for medium and large-scale
projects. Also wheeled pavers are produced.

Features: -

Designed with global technology and valuable input from our customers.
Ample reserve power, robust and sturdy design and high paving outputs for
maximum reliability and cost-effectiveness.
Unique operating panel-widely recognised as the most intuitive system on the
market.

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 5S METHODOLOGY
The word “5S (five S)” was generalised in 1980’s in a manufacturing sector in
Japan, as Toyota Production System (TPS) became famous in the sector and
“5S activities” were set as one of the bases of TPS.

What is 5S system?
The 5S concept is one of several lean manufacturing (“Lean”) tools designed to
improve workplace efficiency through facility-wide organisation and
cleanliness. Each of the 5S guidelines helps managers and workers to achieve
greater standardisation and efficiency – all while reducing costs and boosting
productivity. Some core principles of the 5S concept involve creating and
maintaining visual order, organisation, cleanliness and standardisation. With
these goals in place, the hope is that workplaces can become more efficient,
organised and equipped to carry out daily tasks in an efficient manner.

1. S – Sort
2. S – Set
3. S – Shine
4. S – Standardise
5. S – Sustain/Self-discipline

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SORT (SEIRI): -
Seiri is sorting through all items in a location and removing all unnecessary
items from the location.

Goals: -
 Reduce time loss looking for an item by reducing the number of items.
 Reduce the chance of distraction by unnecessary items.
 Simplify inspection.
 Increase the amount of available, useful space.
 Increase safety by eliminating obstacles.

Implementation: -
 Check all items in a location and evaluate whether or not their presence
at the location is useful or necessary.
 Remove unnecessary items as soon as possible. Place those that cannot
be removed immediately in a 'red tag area' so that they are easy to
remove later on.
 Keep the working floor clear of materials except for those that are in use
to production.

SET (SEITON): -
Seiton is putting all necessary items in the optimal place for fulfilling their
function in the workplace.

Goals: -
 Make the workflow smooth and easy.

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Implementation: -
 Arrange work stations in such a way that all tooling / equipment is in
close proximity, in an easy to reach spot and in a logical order adapted
to the work performed. Place components according to their uses, with
the frequently used components being nearest to the workplace.
 Arrange all necessary items so that they can be easily selected for use.
Make it easy to find and pick up necessary items.
 Assign fixed locations for items. Use clear labels, marks or hints so that
items are easy to return to the correct location and so that it is easy to
spot missing items.

SHINE (SEISO): -
Seiso is sweeping or cleaning and inspecting the workplace, tools and
machinery on a regular basis.

Goals: -
 Improves the production process efficiency and safety, reduces waste,
prevents errors and defects.
 Keep the workplace safe and easy to work in.
 Keep the workplace clean and pleasing to work in.
When in place, anyone not familiar to the environment must be able to detect
any problems within 50 feet in 5 sec.

Implementation: -
 Clean the workplace and equipment on a daily basis, or at another
appropriate (high frequency) cleaning interval.
 Inspect the workplace and equipment while cleaning.

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STANDARDISE (SEIKETSU): -
Seiketsu is to standardize the processes used to sort, order and clean the
workplace.

Goal: -
 Establish procedures and schedules to ensure the repetition of the first
three ‘S’ practices.

Implementation: -
 Develop a work structure that will support the new practices and make it
part of the daily routine.
 Ensure everyone knows their responsibilities of performing the sorting,
organizing and cleaning.
 Use photos and visual controls to help keep everything as it should be.
 Review the status of 5S implementation regularly using audit checklists.

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SUSTAIN/SELF-DISCIPLINE (SHITSUKE): -

Shitsuke or sustain the developed processes by

self-discipline of the workers. Also translates as
"do without being told".

Goal: -
 Ensure that the 5S approach is followed.

Implementation: -
 Organize training sessions.
 Perform regular audits to ensure that all
defined standards are being implemented and
followed.
 Implement improvements whenever possible.
Worker inputs can be very valuable for
identifying improvements.
 When issues arise, identify their cause and
implement the changes necessary to avoid
recurrence.

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 TOPICS OF STUDY DURING
INTERNSHIP
BILL OF MATERIALS: -

 A bill of materials (BOM) is a list of the parts or the components that

are required to build a product. At its most complex, a BOM is a multi-
level document that provides build data for multiple sub-assemblies,
which are essentially products with products.

 For each item, the BOM includes the manufacturer’s part number (MPN)
an approved manufacturer’s list (AML) and component descriptors. It
may also include attached reference files, such as part specifications,
such as part specifications, Computer Aided Design (CAD) files and
schematics. A production planning and inventory control system for
materials requirement planning (MRP) integrates data from production
schedules with that from inventory and the bill of materials to calculate
purchasing and shipping schedules for the parts or components required
to build a product.

ENGINEERING BILL OF MATERIALS: -

The engineering bill of materials or engineering BOM, defines the finished
product as it was designed. The engineering BOM lists the items, parts,
components, sub-assemblies and assemblies in the product designed by the
engineer. The engineering BOM is often organised by engineers based on a
Computer Aided Design (CAD) drawing. For a finished product there may be
more than one engineering BOM created.

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MANUFACTURING BILL OF MATERIALS: -
The manufacturing bill of materials, also referred to as manufacturing BOM,
contains all the parts and assemblies required to build a complete and
shippable product. This includes all the packaging materials required to ship
the finished product to the customer. The bill of materials will also include any
process that need to be performed on the item before it is completed. The
manufacturing bill of materials stores all the information required for
manufacturing activities. When MRP is run, the bill of materials is exploded for
the finished products that have been ordered by customers. The MRP process
takes the details from the manufacturing bill of materials and calculates, based
on the suggested delivery date to the customer, whether materials are needed
to be purchased and when the manufacturing order needs to be started.

MODULAR BOM: -
BOM’s are of hierarchical nature with the top level representing the finished
product which may be a sub-assembly or a completed item. BOM’s that
describe the sub-assemblies are referred to as Modular BOM’s. An example of
this NAAMS BOM which is used in the automotive industry to list all the
components in an assembly line. The structure of the NAAMS BOM is System,
Line, Tool, Unit and Detail.

CONFIGURABLE BOM: -
A configurable bill of materials (CBOM) is a form of BOM used by industries
that have multiple options and highly configurable projects. Ex: Telecom
systems, data hardware, PC’s and autos. The CBOM is used to dynamically
create “End-Items” that are company cells. The benefit of using CBOM
structure is that it reduces the work effort needed to maintain product
structures.

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 ZERO LEAKAGE PROJECT
TORQUE WRENCHES: -
A “Torque Wrench” is a tool used to apply 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.

A torque wrench is used where the tightness of screws and bolts is crucial. It

allows the operator to set the torque applied to the fastener so it can be
matched to the specifications for a particular application. This permits
proper tension and loading of all parts. A torque wrench uses torque as a proxy
for bolt tension. The technique suffers from inaccuracy due to inconsistent or
uncalibrated friction between the fastener and its mating hole. Measuring bolt
tension (indirectly via bolt stretch) is actually what is desired, but often torque
is the only practical measurement which can be made.

Torque screwdrivers and torque wrenches have similar purposes and

mechanisms.

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TYPES OF TORQUE WRENCHES: -
1. CLICK-TYPE TORQUE WRENCH: -
A more sophisticated method of pre-setting torque is with a
calibrated clutch mechanism. One common form uses a ball detent and spring,
with the spring preloaded by an adjustable screw thread, calibrated in torque
units. The ball detent transmits force until the pre-set torque is reached, at
which point the force exerted by the spring is overcome and the ball "clicks"
out of its socket. This design yields greater precision as well as giving tactile
and audible feedback. The wrench will not start slipping once the desired
torque is reached, it will only click and bend slightly at the head; the operator
can continue to apply torque to the wrench without any additional action or
warnings from the wrench.
A number of variations of this design exist for different applications and
different torque ranges. A modification of this design is used in some drills to
prevent gouging the heads of screws while tightening them. The drill will start
slipping once the desired torque is reached.

2. MECHATRONIC TORQUE WRENCHES: -

Torque measurement is achieved in the same way as with a click-type

torque wrench but, at the same time, the torque is measured as a digital
reading (click and final torque) as with an electronic torque wrench. This
is, therefore, a combination of electronic and mechanical
measurements. All the measurements are transferred and documented
via wireless data transmission. Users will know they have achieved the
desired torque setting when the wrench "beeps."

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 3. HYDRAULIC TORQUE WRENCH: -

Hydraulic torque wrenches are used for tightening large torques with
high accuracy. They are used for aviation and heavy machinery assembly
and are specialized tools. Their general construction varies depending on
manufacturer and torque requirement. Generally, they consist of at least
one hydraulic cylinder operating a drive head ratchet. The cylinder
extends, pushing the drive head round via the pawls, and then retracts
freely over the ratcheting teeth. The process is repeated until the
desired torque is met. Smaller hydraulic torque wrenches have a
reaction arm built into the tool, which rests against another fastener or
part of the assembly to prevent rotation when torque is being applied.
Larger models require other fixing arrangements in order to prevent
rotation.

4. ANGLE WRENCH: -

Torque measurement is conducted in the same way as with an electronic

torque wrench but the tightening angle from the snug point or threshold is
also measured. The angle is measured by an angle sensor or electronic
gyroscope. The angle measurement process enables joints which have already

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been tightened to be recognized. The inbuilt readings memory enables
measurements to be statistically evaluated. Tightening curves can be analysed
using the software via the integrated tightening-curve system (force/path
graph). This type of torque wrench can also be used to determine breakaway
torque, prevail torque and the final torque of a tightening job. Thanks to a
special measuring process, it is also possible to display the yield point (yield
controlled tightening). This design of torque wrench is highly popular with
automotive manufacturers for documenting tightening processes requiring
both torque and angle control because, in these cases, a defined angle has to
be applied to the fastener on top of the prescribed torque (e.g. 50 N-m or
37 lbf-ft + 90° - here the 50 N-m or 37 lbf-ft means the snug point/threshold
and +90° indicates that an additional angle has to be applied after the
threshold).

In 1995, “Saltus-Werk Max Forst GmbH” applied for an international patent

for the first electronic torque wrench with angle measurement which did not
require a reference arm.

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 COMPACTION ASSEMBLY LINE
Compaction assembly line, which consists of SEVEN main stations on the main
assembly line and NINE feeder stations that sub assembles various parts and
send it to the main station line that will be mounted on main frame of the road
machinery.
The standardized process carried out at each work station and feeder is
discussed at the later stages of report.
The feeder time and station assemble time are all synchronized in such a way
that the sub assembled parts from feeder, station arrives to the main station
line at the right time when needed to mount on the main frame of road
machinery.
The road machinery assembly line is monitored by ANDON system.
There are several improvements (KAIZEN) implemented in the assembly line of
road machinery.
Similarly, there are several improvements on POKA – YOKE and KAIZEN
The layout of road machinery assembly line is as follows: -

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The 9 feeder stations of the road machinery assembly line are (in particular
SD110):

1) Feeder Station 1 (F1) –Axle Sub Assembly Area: -

The frame is bought into the feeder. The required valves are prepared and
placed in the frame. The hose pipes are placed at appropriate positions. The
electrical harness (main harness) is placed and fixed, sent to station 1.

2) Feeder Station 2 (F2) – Tank Sub Assembly Area: -

The fuel tank’s i.e. the diesel tank and hydraulic tank are pre-assembled. Swivel
frame is taking and the bolt is fixed into it, sent to the station 2 for fixture.

3) Feeder Station 3 (F3) – Engine Sub Assembly Area: -

The engine imported from Germany is bought into the feeder and the capacity
of the engine is 4 – cylinder, 133 HP, 99 KW, 2200 RPM. The vibration pump
and the steering pump is connected to the shaft. The required hose pipes are
joined. The engine oil is filled (15 litres)

4) Feeder Station 4 (F4) – Console Sub Assembly Area: -

The seat console frame is taken into the feeder and the steering pump and the
fuses is connected to the frame. The seat assembly is attached to the frame.
The required hose pipes are connected.

5) Feeder Station 5 (F5) – Hood Sub Assembly Area: -

The filters are fixed onto hood. Then the hood is attached to its second part of
it.

6) Feeder Station 6 (F6) – Drum Frame & Exhaust Sub Assembly Area: -
The railings are fixed to the main frame. The centre console control system is
fixed (switches). The roof is pre-assembled and fixed in the station 6.

7) Feeder Station 7 (F7) – Ropes, Scrapper, Tyres: -

The ropes mounting is used to fix the roofs. The scrappers of the drum (drum
cleaner). The pre-assembled tyres are bought into the feeder and sent to
station 7.

8) Feeder Station 8 (F8) – Drum Cell: -

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The fabricated and painted (inner) drum is placed in this feeder and the carrier
and spindle alignment, the vibration pump is fixed and the leak test is done
before filling the drum oil.

9) Feeder Station 9 (F9) – Drum Sub Line: -

The components are first washed and the sleeve is inserted into the speed
sleeve. The pin is fixed into it using a journal pressure pin fixture. The speed
sleeve is then attached to the spindle and this assembly is fixed using a nut and
a bolt. The carrier and spindle assembly are done by using templates and cold
as well as hot bearings.

The 7 Main stations of the road machinery assembly line are:

1) Main Station 1 (S1) –Main Frame and axle Installation: -

The rear axle is bought and placed on the main assembly line and the main
frame is placed onto it and it is fixed. The required hose and harness are fixed
and sent to next station.

2) Main Station 2 (S2) –Tanks and Swivel Frame Installation: -

The sub-assemblies of the swivel frame and the tanks are bought into the
assembly line and assembled. The swivel frame is fixed using a hydraulic
torque wrench. The appropriate hose pipes and harness are connected and
sent to next station

3) Main Station 3 (S3) –Engine Installation: -

The engine assembly is bought into the assembly line and it is aligned to the
desired position in the frame and it is assembled. The required hose and
harness are connected and sent to station 4.

4) Main Station 4 (S4) –Battery and Silencer Installation: -

The pre-assembled battery is placed and connected to the engine. The silencer
is connected to the exhaust of the engine. The seating console is bought into
the assembly line and assembled into the frame.

5) Main Station 5 (S5) - Cowling, Hood, Hydraulic Piping Installation: -

The hydraulic piping is installed into with the swivel frame and it is attached to
the hydraulic tank. The engine hood is fixed to the engine. The hood locking is
aligned using a template and drilled and fixed to the hood.

6) Main Station 6 (S6) –Drum Frame, Ropes and Railing Installation: -

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The fabricated drum frame is moved to the assembly line, aligned and then
fixed with a plate to hold it with the swivel frame. The fabricated ropes are also
moved, aligned and fixed to the main frame at its appropriate position in the
frame. The railings near the seating console are aligned and fixed to the frame.

7) Main Station 7 (S7) –Scrapper, Tyre, Electrical Battery Routing

Installation: -
The assembled drum is moved to the assembly line, aligned to the drum frame
and fixed to the drum frame using a hydraulic torque wrench. The tyres are
bought into the assembly line and fixed to the rear axle of the machine. All the
left-over hosing and harness connection is done. Including the head light, tail
light, and the number plate (front and back). Then it is sent for test driving.

SD 110 BA: -
Segregating the light assembly parts from heavy assembly parts: -

 Manually we went to each station and feeder and collected the

process sheets for the particular model.
 We listed down the Light assembly parts, Heavy assembly parts
and hoses separately.
 Each table consisted of part number, part name, sequence and
quantity.
 A soft copy was made for the same using Excel sheets.
 This method was done to improve kit standardization.

UPDATING THE PICK LIST: -

 Manually comparing the pick list and the process sheet and noting
down the missing part numbers, part names, quantities and the
sequence.
 This method was time consuming and less effective.
 The comparison was found to be effective when done digitally.
The method VLOOKUP was employed to successfully accomplish
the tasks.

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DD 90 B: -
Segregating the light assembly parts from heavy assembly parts: -

 We listed down the Light assembly parts, Heavy assembly parts

and hoses separately in excel sheet.
 Each table consisted of part number, part name, sequence and
quantity.
 This method was done to improve kit standardization.

Updating the pick list: -

 The missing assembly parts in the pick list was entered in an excel
sheet under the following heading; part numbers, part names,
quantities and the sequence.
 The comparison was done digitally. The method VLOOKUP was
employed to successfully accomplish the task.
 The process of VLOOKUP was as explained in SD110BA.

SOLUTIONS OR IDEAS FOR SMALL PROBLEMS FOUND IN RM ASSEMBLY LINE:-

 Files containing process sheets where getting misplaced between SFs
 Assigning colour code for each station and feeder. The files
containing process sheets and the pouch for placing the files for
respective stations should have the particular colour code.
 Not available parts in store for the particular model on that day
Temporary solution: -
 Store person itself brings the printout of not available parts on the
day, for a model # in line and gives it to the operators in the
respective station.
 Main problem is that, operators don't get enough time to write
down the part number and name which are not available. Solution
is that the operators can write down the date / model sequence
no. on the model, particular SF and the store persons list(parts)
which he brings along with the kit.

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 AIM OF THE PROJECT

The main aim of this project is

to achieve “Zero Leakage”
with respect to any machine
which is being fabricated in
the shop floor in accordance
with the values associated
with Volvo, i.e., Quality,
Safety and Environmental
Care.

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 ABOUT THE PROJECT
 Leakage is one major phenomenon which is prevalent in
almost all fields during work aspects in a company as
well as one common in a small sector producing a
certain amount of parts per day.
 The play comes into picture when the Torque Wrenches
being used are not of the required torque value, the
workers use the tools available to them based on
experience and misalignment of certain parts during the
assembly process which causes it either to be under-
tight or over-tight leading to leading to leakages which
eventually cause harm to the environment.
 We intend to segregate the wrenches according to a
specific sequence which would be helpful for the
workers as well as provide an overall advantage to the
company in increasing its production and in need the
profits which would have a remarkable rise.
 Each torque wrench would have a specific value
assigned with a certain ID number which is unique.
Calibration is done on a monthly basis in order to
achieve minimum amount of leakages as the markings
of torque values on the wrenches is erased with
constant use leaving the workers in a dilemma leading
too choose the wrench based on their experience.

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DD 90 B: -

SD 110 D: -

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SD 110 BA: -

SOLUTIONS: -
 The torque wrenches need to calibrated as and when the markings are
erased in order to achieve the best of advantages with the machine.
 By assigning a specific colour to one particular machine, colour coding
can be incorporated in the stations so that the workers have required
knowledge about the various colour codes used for the machines being
fabricated as well as idea to use specific torque wrenches for specific
machine parts only.
 Engraving of the values on the torque wrenches would provide a lasting
supply in order to use the torque wrench as this eliminates the issue of
the markings erased with a period of time.
 Based on our project provided the proper colour coding for each
machine which can be altered and segregating the torque wrenches
based on their ID numbers, the proper engravement is possible which
reduces the effort of the workers in finding the torque wrench required
for the specific application.

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 CONCLUSION
PROS OF VOLVO CE GROUP: -
 Digitalized station movement (semi-automated) is efficient. Operators
are very supportive. Friendly work environment. We found the CIM
(computer integrated manufacturing) asynchronous system effective.
 Floor detailing like green path for walking, blue path for movement of
fork list carrying work parts and also work instruction) this ensures
safety in the assembly shop.
 Boards are provided for correct assembly guidance for the operators.
 Tea break is given thrice a day which is a form of relaxation.
 Every Monday safety instructions are provided to the operators, by the
experienced staff member for awareness.
 Safety board’s such as MSDS are provided.

As an intern I was able to get a clear picture of the assembly line and its
function. On the other hand, working with staffs gave us a better
understanding of the components, the time and the work involved in making it
the best product in its class. I was involved in the study of lean manufacturing
whose components have been widely publicized over the past few years and
how the specific improvement efforts operate to form an efficient outcome is
no secret.
Not just the mechanical engineering perspective but I also had a short insight
on Production Planning and Control, Material Management and Supply Chain,
gave me a picture on how these things influence the engineering world.
Overall, it was a good opportunity to put in practice and develop production
skills and refresh some concepts in Science and Economy required for the
management of production. Last but not least, it was a great opportunity for
developing personal networking activities and making contacts which may
prove of value in the near future and to work with a fantastic team of very
hard-working people including managers, engineers and also floor operators.

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