MANUFACTURING EVENT

Foreword:
Manufacturing Event is conducted with the motive to inculcate the industrial approach of
manufacturing process within the students and make them industry-ready. The event also
ensures that the teams are able to visualize the manufacturing process in detail and their
design is meeting the manufacturing norms.
Manufacturing Event is an attempt to help students learn the manufacturing processes in
detail, importance of Bill of Materials, inspection methods and necessary manufacturing
details involved during the prototype and mass production of a product or sub-system.

Problem Statement:
The objective is to check how well the team understands what manufacturing techniques and
processes has gone into the development of the part or sub-system from design release stage
to final manufacturing. Team must prepare the manufacturing details of a particular sub-
system in the mass production stage. The sub-system selected for BAJA SAEINDIA 2022 event
is Drivetrain System.
The list of drive train items consists of coupling of engine and transmission assembly in detail,
connection from transmission to differential and to wheel ends at front and rear. These drive
the CVT, UJ, propeller shaft, drive-axle, differential case, satellite gears and pinion, wheels
etc. Teams are expected to do a thorough study of all drivetrain components on their shop
floor with process sheets, drawings, layout of machines and machines to be used for
manufacturing of those items including material handling and storage systems.

Mass Manufacturing
In this section, it is considered that the team is awarded a contract to manufacture 4000 units
per year of Drivetrain System for the next 5 years. For example, the gearbox casing in the
mass production will be casted part and therefore the teams must prepare the manufacturing
documents considering the operations involved in casting.
The manufacturing details of the sub-assembly in the report should include but not limited
to:

● Layout of Drive Train Components – Inhouse activities which includes machining,

component cells, process groups and assembly lines.
● Proposed Shop Area & Schematic Layout
● Bill of Material Coverage: It should include major parts and components for sub
assembly and main assembly of Drive train aggregates i.e. – Gear Box, Transfer Case,
Rear Driveshaft, along with Propeller Shaft, Differential Assembly & Front Driveshaft
for AWD/4WD teams.
● Manufacturing Processes Involved, Workflow Organization
● Raw material Selection Criteria
● Parameters for “Make or Buy” decision
● Supplier Selection Criteria
 ● Part Drawings, Process/Assembly Drawings
● Inspection Methods, Gauging Preparation
● Jigs and Fixtures requirement and preparation
● Identification of Critical Quality Control parameters along with the process failure
modes.
● Process Flow Chart/Control Chart
● PFMEA/MFMEA
● Welding parameters, torquing sequence, alignment processes, dimension inspection
report.
● Tools and gauges check sheets, inspection, assembly, and process check sheet.

Rules:
● Participation in this event is compulsory for the teams participating in BAJA
SAEINDIA 2022 event.
● Manufacturing Report File should be in PDF format and named in the following
format: TeamID_Team Name_Manufacturing Event Report.
● Deadline for submitting the report for the Manufacturing Event is 1st December,
2021 by 23:59 IST.
● Please click on the following link for online submission for Manufacturing Event:
https://bit.ly/ManufacturingSubmission
● The scores received in this event would be considered for calculating the Overall
Scores.

Note:
1) Teams will not be allowed for Manufacturing Event Evaluation if the report is not
submitted within the deadline.
2) All files submitted in the pdf format should have the following information: Team
Name, Team Number, College, Email Id

Manufacturing Report Guidelines

Teams have the flexibility regarding the format of the report however teams should ensure
that maximum no. of pages allowed is 25+5 (for 4WD teams only). Within the allocated pages,
teams should ensure that they are covering the parameters mentioned above in their report.
Teams can refer sample BOM template, Manufacturing Operations Sheet Template and
Process Flowchart template from the link: http://bit.ly/ManufacturingTemplate

Note: Teams can modify the templates as per their requirement.

Presentation Guidelines
Teams have the flexibility regarding the format and pages of presentation, but teams should
ensure that presentation should be explained within 25 minutes in front of a panel consisting
of judges from the automotive industry. The presentation will be done virtually over an online
platform. The schedule for the presentation slotting will be released separately on the BAJA
SAEINDIA forum.
 Presentation Format:
● Each team will be evaluated over a 35 minutes time period which includes
Presentation Setup, Introduction, Presentation, Q&A and feedback by the judges.
● Maximum of 5 team members are allowed for the presentation showing teamwork.

ALL THE BEST!!