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ABSTRACT
This internship report documents the experience of working under the supply chain department in Lumax
Cornaaglia Auto Technology from January to May. During the internship, I worked on the sequencing
vehicle released system, which involved managing the process of releasing vehicles from the assembly line
to the customers.
The report begins by introducing Lumax Cornaaglia Auto Technology and its supply chain department. It
then provides an overview of the sequencing vehicle released system, its importance in the supply chain,
and the challenges associated with managing it.
The bulk of the report focuses on the intern's experience in working on the sequencing vehicle released
system. This includes a detailed description of the process of releasing vehicles, from the assembly line,
and the role of technology in managing this process. The report also discusses the challenges faced by the
team, including the need to balance production efficiency with customer demand, and the solutions that
were implemented to address these challenges.
In addition, the report includes a section on the intern's personal development during the internship. This
includes an evaluation of the skills acquired, such as project management, data analysis, and problem-
solving, and the challenges faced while working in a multicultural team.
The report concludes by summarizing the key findings and insights gained from the internship. This
includes a deeper understanding of the role of supply chain management in the automotive industry, the
importance of effective communication and collaboration within a team, and the impact of technology on
supply chain operations. The report also highlights the ethical implications of supply chain management,
including the need to ensure fair labor practices and responsible sourcing.
Overall, this internship provided valuable insights into the field of supply chain management, specifically
the sequencing vehicle released system. The experience allowed the intern to apply theoretical knowledge
in a real-world setting, while also developing new skills and expanding their professional network.
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TABLE OF CONTENTS
Title Page No.
Candidate Declaration 2
Acknowledgement 3
Industry Certificate 4
Abstract 5
Table of Content 6
List of Figures 7
List of Tables 8
List of Abbreviation 9
Chapter : 1 Introduction 10
Chapter : 2 Company Profile 11-34
Chapter : 2.1 Company Vision

Chapter : 2.2 Mission and values
Chapter : 2.3 Product development Process
Chapter : 2.4 Main customer
Chapter : 2.5 Main Product
Chapter : 3 Functioning of Various Department 35-45
Chapter : 4 What I Have Learned 46-59
Chapter : 3.1 SVR System

Chapter : 5 Conclusion 60
Appendices 61-65
a. All MRP
b. Report QR code
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LIST OF FIGURES
Fig. No. Title Page

No.
Fig. 1 Suction Moulding Machine 25
Fig. 2 Injection Blow Moulding Machine 26
Fig. 3 2D Blow moulding Machine 27
Fig. 4 Drilling Machine 28
Fig. 5 Notching Machine 28
Fig. 6 3D Blow Moulding Machine 30
Fig. 7 Hot Plate Wielding Machine 31
Fig. 8 Implementation Stages SVRS 53
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LIST OF TABLES
TABLE Title Page

No. No.
TABLE. 1 Customer and Product 15
TABLE. 2 Manufactured Product 19
TABLE. 3 Manufacturing Cycle 20
TABLE. 4 Supplier and Sourcing 23
TABLE. 5 Inventory Management sheet or BoP Sheet 24
TABLE. 6 Assembly line for intake system 34
TABLE. 7 Assembly Line for Exhaust System 34
TABLE. 8 Product Deliver to TML under SVRS 53
TABLE. 9 Production Planning for TML under SVRS 56
TABLE. 10 Packaging or Box sizes 57
TABLE. 11 1st phase of dispatch planning for TML 58
TABLE. 12 2nd phase of dispatch planning for TML 58
TABLE. 13 3rd phase of dispatch planning for TML 59
TABLE. 14 Overview of 1st Month 61
TABLE. 15 Overview of 2nd Month 62
TABLE. 16 Overview of 3rd Month 63
TABLE. 17 Overview of 4th Month 64
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LIST OF ABBREVIATIONS
Abbreviation Full form
CAD Clean Air Duct
DAD Dirty Air Duct
AF Air Filter
UT Urea Tank
SPD Spare Part Distribution
OEM Original equipment Manufacturer
EXP Export
TML Tata Motors Limited
IBMM Injection Blow Moulding Machine
SBMM Suction Blow moulding Machine
SVRS Sequencing Vehicle Released System
AFA/AAF Assemble Air Filter or Air filter Assembly
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CHAPTER 1 : INTRODUCTION
This internship report documents the experience of working under the supply chain department in Lumax
Cornaglia Auto Technology from January to May. During the internship, I worked on the sequencing
vehicle released system, which involved managing the process of releasing vehicles from the assembly
line to the customers ultimately.
The report begins by introducing Lumax Cornaaglia Auto Technology and its various department. It then
provides an overview of the sequencing vehicle released system and its importance in the supply chain,
and the challenges associated with managing it. The report then discusses the role of the intern i.e myself
in the project, including the tasks assigned, the skills required, and the training provided.
The bulk of the report focuses on the intern's experience in working on the sequencing vehicle released
system. This includes a detailed description of the process of releasing vehicles, from the warehouse of
raw product/component to the assembly line, and the role of technology in managing this process. The
report also discusses the challenges faced by the team, including the need to balance production efficiency
with customer demand, and the solutions that were implemented to address these challenges.
In addition, the report includes a section on the intern's personal development during the internship. This
includes an evaluation of the skills acquired, such as project management, data analysis, and problem-
solving, and the challenges faced while working in a multicultural team.
The report concludes by summarizing the key findings and insights gained from the internship. This
includes a deeper understanding of the role of supply chain management in the automotive industry, the
importance of effective communication and collaboration within a team, and the impact of technology on
supply chain operations. The report also highlights the ethical implications of supply chain management,
Overall, this internship provided valuable insights into the field of supply chain management, specifically
the sequencing vehicle released system. The experience allowed me to apply theoretical knowledge in a
real-world setting, while also developing new skills and expanding their professional network.
10
CHAPTER 2: COMPANY PROFILE
Lumax Cornaglia Auto Technology Private Limited is an Indian manufacturing company that operate in
automotive industry. This company was formed as a 50-50 joint venture between Lumax Auto
Technologies Private limited and Cornaglia group of Italy.
The joint venture between two happen on date of June 14, 2007 as non-governmental company and
registered within Company Act
About partnership between two. Lumax has expertise in manufacturing whereas Cornaglia has its expertise
in technology. The main production plant of company located near the city of Pune, in western India. The
plant equipped with advanced machinery and equipment to ensure high quality products and efficient
production process. LCAT also has an in-house research and development team that focuses on developing
new product ad technologies to meet the evolving needs of the automobile industry.
LCAT is specialized in manufacturing of exhaust and intake systems for car and commercial vehicle
LCAT has a strong customer base that include leading automotive manufacturer of India as well other part
of globe. The company is committed to providing its customers high quality product, timely delivery, and
excellent after sale services. With its focus on innovation, quality and customer satisfaction LCAT is
polished to become a leading player in global automotive industry.
In year 2009, LCAT start its supplies for Air intake system to major automobile manufacturer like Tata
Motor Limited, Fiat and Volkswagen followed by General Motor in 2011.
In year 2011 LCAT start using 3d Blow moulding Machin for manufacturing some components.
Although LCAT is private profitable organization but it has its own moral compulsion and duty toward
environment for that the R&D team of LCAT introduce new generation product like selective catalyst
reductor i.e Urea tank and CAD/DAD air filter which help their customer to meet the requirement of BS-
6 (Bharat stage 6) norms of government to reduce pollution
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COMPANY VISION
• Building an ADMIRED HIGH PERFORMANCE Global Organisation in whom all stakeholders

have ABSOLUTE TRUST
• Customer- Refocus on profitable market segments by anticipating trends and needs, by creating
value adding partnerships based on mutual trust and confidence, granted by solid network of
relationships
• Process -Provide a steadily growing consolidated sales volume supported by a strong internal
efficiency and by an integrated supply chain that can ensure a competitive cost structure whilst
offering a "best in class" service level
• Learning and growth - Estabilish a meritocratic work enviroment that constantly offers new
challenges and opportunities to a team of flexible, curios and committed resources spokepersons
of Cornaglia group core values
MISSION
• LCAT aims to attract, involve and retain high profile resources, partners to the Group, by prizing
the excellence of the performance along with the ability to personify the founding corporate values
of honesty, mutual trust and social attention.
VALUE
• Respect Integrity Passion Excellence

• We deliver PRIDE and PROGRESS with POSITIVITY
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PRODUCT DEVELOPMENT PROCESS
•This is the initial stage of the product development process, where the
Concept
company defines the scope of the project and identifies customer
Development needs and market trends.
•In this stage, the company's design and engineering teams work
Design and
together to create a detailed product design, including specifications,
Engineering materials, and manufacturing processes.
•Once the design is complete, the company creates a prototype of the

Prototyping product, which is then tested and refined until it meets all the required
specifications and standards.
•The company conducts a series of tests to ensure that the product

Testing and
meets all safety, quality, and performance standards. This includes
Validation physical testing as well as computer simulations.
•Once the product has been fully tested and validated, it moves into
Production production. This involves setting up manufacturing processes, sourcing
raw materials and components, and assembling the final product.
•The final stage of the product development process involves launching

Launch and
the product and promoting it to customers. This includes advertising,
Marketing sales promotions, and other marketing activities.
According to mentioned process LCAT develop generation 1 product which was according to the
requirement of BS-6 norm which not only help their business or customer growth also help environment
and also help in achieving UNDP sustainable environment goal.
GEN-1 product specially developed for tata Altroz and Hornbill
In the year, 2021 research and development team of LCAT has develop the product for the biggest buyer
of LCAT named TML (Tata Motor Limited).
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CUSTOMER
Lumax Cornaglia Auto Technology's customers include automotive manufacturers, distributors, dealers,
and end-users who rely on the company for a wide range of products and services.
Automotive manufacturers: Lumax Cornaglia Auto Technology supplies automotive components and
systems to major vehicle manufacturers, including Maruti Suzuki, Tata Motors, and Mahindra & Mahindra,
among others. The company's products include lighting systems, mirrors, air intake systems, and other
components that are critical to vehicle performance and safety.
Distributors and dealers: Lumax Cornaglia Auto Technology also works with distributors and dealers to
ensure that its products are widely available to customers across India and around the world. The company
has an extensive distribution network that includes more than 200 dealers across India, as well as
partnerships with distributors in other countries.
LCAT deliver its product in India as well across the world include Italy, South Africa, Germany, Poland
etc in both form SPD (spare part distribution) and OEM (original equipment manufacturer).
TABLE – 1 CUSTOMER AND PRODUCT
•Resonator: •Clean Air Duct •Air filter •Air filter(EXP)

•Air filter •Dirty Air Duct •CAD (EXP)
•Clean Air Duct •Air filter •DAD (EXP)
•Dirty Air Duct •Resonator: •Intake Pipe
•Urea tanks
Mahindra &
Tata Motors Fiat Skoda
Mahindra
•Air filter (EXP) •Clean Air Duct

•Clean Air Duct •Dirty Air Duct
•Dirty Air Duct •Air filter
Volkswagen PSA
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PRODUCT
Lumax Cornaglia Auto Technology has a manufacturing facility located in Pune, India that produces a
range of automotive components and systems. Some of the key products manufactured at the Pune facility
include:
1) Air intake systems: Lumax Cornaglia Auto Technology also designs and manufactures air intake
systems for vehicles. An air intake system is responsible for delivering clean air to the engine, which is
necessary for proper combustion and engine performance. The system typically includes several
components, such as the air filter, air intake duct, throttle body, and intake manifold.Air intake systems
are designed to improve engine performance and fuel efficiency while also meeting regulatory
requirements for emissions. The company uses advanced manufacturing processes and materials to
produce intake systems that are durable, lightweight, and resistant to corrosion.
a. Air Filter - An air filter is an essential component of an air intake system in vehicles, HVAC systems,
and other machinery that requires air intake for proper functioning. The primary function of an air filter
is to prevent harmful particles and debris from entering the engine or machinery, which could cause
damage or reduce performance.In vehicles, the air intake system typically includes an air filter that is
located in the air intake duct or air box. The air filter traps dust, dirt, pollen, and other small particles,
preventing them from entering the engine and causing damage to internal components, such as the
cylinders and pistons.Over time, air filters can become clogged with debris, reducing airflow and
potentially causing engine performance issues. It is important to replace air filters regularly to maintain
optimal engine performance and prevent damage to internal components.
In summary, an air filter in an air intake system plays a crucial role in protecting the engine or
machinery from harmful particles and debris, maintaining optimal performance, and extending the life
of the equipment.
b. Clean Air Duct (CAD) – A clean air duct is an important component of an air intake system in a vehicle.
The air intake system is responsible for delivering clean air to the engine, which is necessary for proper
combustion and engine performance. The clean air duct is typically a component of the air intake system
that delivers the clean air to the engine. The clean air duct is designed to be a sealed system that prevents
dirt, dust, and other contaminants from entering the engine. The air duct typically includes an air filter
that removes contaminants from the incoming air, as well as an air intake duct that delivers the clean
air to the engine. The air filter is a critical component of the clean air duct because it helps prevent
contaminants from entering the engine and causing damage or reducing performance. Overtime, the air
filter in the clean air duct can become dirty and clogged with contaminants, which can reduce the
efficiency of the engine and potentially cause damage. Regular maintenance and replacement of the air
filter is important to ensure that the clean air duct is functioning properly and delivering clean air to the
engine.
Overall, the clean air duct is an important component of the air intake system in a vehicle, helping to
ensure that the engine receives a consistent supply of clean air for optimal performance and efficiency.
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2) Air exhaust system - Lumax Cornaglia Auto Technology also designs and manufactures air exhaust
systems for vehicles. An air exhaust system is responsible for removing exhaust gases from the engine and
reducing emissions. The system typically includes several components, such as the exhaust manifold,
catalytic converter, muffler, and exhaust pipe. Air exhaust systems are designed to meet global emission
standards while also improving engine performance and fuel efficiency. The company uses advanced
manufacturing processes and materials to produce exhaust systems that are durable, lightweight, and
resistant to corrosion.
a. Dirty Air Duct - A dirty air duct in a vehicle can cause a variety of problems with the engine and overall
performance. The air duct is a component of the air intake system, which is responsible for delivering
clean air to the engine. If the air duct becomes dirty, it can reduce the amount of clean air that reaches
the engine, which can negatively impact engine performance. When the air duct becomes dirty, it can
become clogged with dirt, dust, and other contaminants. This can restrict the flow of air to the engine,
which can cause the engine to work harder to draw in air. This extra workload can lead to decreased
fuel efficiency and reduced engine performance. Additionally, a dirty air duct can also cause increased
wear and tear on engine components, which can result in costly repairs.
Regular maintenance of the air duct is important to ensure that it remains clean and functioning
properly. This can include regular replacement of the air filter, as well as cleaning the air duct itself. If
the air duct becomes excessively dirty, it may need to be replaced to ensure proper airflow to the
engine.
Overall, a dirty air duct can cause a variety of problems with engine performance and efficiency.
Regular maintenance and cleaning of the air duct is important to ensure that the engine receives a
consistent supply of clean air for optimal performance.
b. Resonator - A resonator is a component in an air exhaust system that is designed to reduce the noise
produced by the exhaust system. It is typically installed in the exhaust pipe and consists of a hollow
chamber with an opening at each end. As exhaust gases flow through the chamber, sound waves are
reflected back and forth between the two openings, canceling out certain frequencies of noise. In
addition to reducing noise, a resonator can also improve engine performance by helping to reduce back
pressure in the exhaust system. This can improve the flow of exhaust gases and reduce the load on the
engine, resulting in improved horsepower and torque. Resonators come in a variety of shapes and sizes,
and can be made from a variety of materials, including stainless steel, aluminum, and titanium. They
are commonly used in performance exhaust systems for vehicles, particularly those designed for racing
or high-performance driving.It's worth noting that a resonator is different from a muffler, which is
another component in the exhaust system that is designed to reduce noise. While both resonators and
mufflers are designed to reduce noise, a resonator typically has a more specific frequency range that it
targets, while a muffler is designed to reduce overall noise levels across a broader frequency range.
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3) Urea tank - A urea tank is a component of the Selective Catalytic Reduction (SCR) system in diesel
engines. The urea tank stores Diesel Exhaust Fluid (DEF), which is a urea solution that is used to reduce
nitrogen oxide (NOx) emissions from diesel engines. In the SCR system, the urea solution is injected into
the exhaust stream before it enters the SCR catalyst. The high-temperature exhaust gases react with the
urea solution in the presence of the SCR catalyst, breaking down the NOx into nitrogen gas and water
vapor. The nitrogen gas and water vapor are then released into the atmosphere, reducing harmful
emissions. The urea tank is typically made of plastic and is located in the engine compartment or under
the vehicle. It is connected to the SCR dosing unit, which injects the urea solution into the exhaust stream.
The urea tank has a sensor that measures the level of DEF in the tank and sends a signal to the vehicle's
engine control module (ECM) to alert the driver when it needs to be refilled.
It's worth noting that the urea solution is not a fuel additive and does not affect the engine's performance
or fuel economy. It is used solely for emissions control and must be replenished periodically, typically
every 5,000 to 10,000 miles depending on the vehicle's usage.
a. Remote UT 18L OR 25L - A remote urea tank is a storage container used to store diesel exhaust fluid
(DEF) or urea. Urea is a chemical compound that is commonly used in diesel engines to reduce
emissions of nitrogen oxides (NOx) by converting them into harmless nitrogen and water. The remote
urea tank is typically located away from the engine and connected to it via a series of hoses and pipes.
This allows for easier and more efficient use of urea in diesel engines, as it eliminates the need for
frequent refilling of the tank and reduces the risk of spills and contamination. Remote urea tanks are
often used in large commercial vehicles, such as trucks and buses, that require frequent use of urea for
emissions control.
b. Direct UT 18L OR 25L - A direct urea tank is a storage container that is directly connected to a diesel
engine's exhaust system to supply the engine with diesel exhaust fluid (DEF) or urea. The direct urea
tank is usually located near the engine and is designed to hold enough urea to last for several thousand
miles of driving before needing to be refilled. Diesel engines that use selective catalytic reduction (SCR)
technology require a constant supply of urea to reduce the emissions of nitrogen oxides (NOx) produced
during combustion. The direct urea tank is designed to provide a continuous supply of urea to the SCR
system, which then converts NOx into harmless nitrogen gas and water. Direct urea tanks are commonly
used in modern diesel-powered vehicles, including cars, trucks, and buses. They are an essential
component of the emissions control system, which helps to reduce the environmental impact of diesel
engines by reducing harmful emissions.
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TABLE – 2 PRODUCT
Product
Air intake Air

system exhaust
system
CAD AF
DAD Resonator
UREA TANK
UT UT
REMOTE DIRECT
18L RUT 25L RUT 18L DUT 25DUT
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TABLE -3 PRODUCT MANUFACTURING PROCESS
Production
Sourcing
Planning
Inventory/Raw
Manufacturing
Material
Quality
Assembly Line
Inspection
Packaging Testing
Dispatch
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1. PRODUCTION PLANNING
Production planning is a critical function in Lumax Cornaglia Auto Technologies Private Limited as it
helps the company ensure that its manufacturing process is efficient, cost-effective, and able to meet
the demands of its customers. overview of the production planning process
a. Demand forecasting: The first step in the production planning process is to forecast the demand
for the company's products. This is done by analyzing market trends, customer needs, and
historical sales data.
b. Capacity planning: Once the demand for the products has been forecasted, the company
determines its production capacity. This includes assessing the availability of resources such
as raw materials, labor, and equipment.
c. Production scheduling: Based on the demand forecast and the production capacity, the
company creates a production schedule that outlines the production plan for a specific period.
This includes determining the quantities of each product to be produced and the timelines for
production.
d. Material planning: The production plan is then used to determine the raw materials required for
production. The company determines the quantities of raw materials required, the delivery
timelines, and the suppliers.
e. Production execution: Once the raw materials are available, production is executed according
to the production schedule. The assembly lines are set up, and the manufacturing process
begins.
Overall, the production planning process in Lumax Cornaglia Auto Technologies is designed to ensure
that the manufacturing process is efficient, cost-effective, and able to meet the demands of its
customers. The company's commitment to continuous improvement and its use of advanced
technology and techniques help it to stay ahead of the competition and to provide products that meet
the evolving needs of the market.
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2. Sourcing
Sourcing is a critical function in Lumax Cornaglia Auto Technologies Private Limited as it helps the
company to ensure the timely availability of high-quality raw materials and components required for
its manufacturing processes. Here's an overview of the sourcing process in Lumax Cornaglia Auto
Technologies:
a. Supplier identification: The first step in the sourcing process is to identify potential suppliers.
The company looks for suppliers who can provide high-quality raw materials and components
at a competitive price.
b. Supplier evaluation: Once potential suppliers are identified, Lumax Cornaglia Auto
Technologies evaluates them based on various criteria, including their quality standards,
manufacturing capabilities, financial stability, and delivery timelines.
c. Negotiation: After evaluating suppliers, the company enters into negotiations with them to
agree on pricing, payment terms, delivery schedules, and other contractual terms.
d. Contracting: Once the terms of the agreement have been negotiated and agreed upon, Lumax
Cornaglia Auto Technologies enters into a contract with the supplier.
e. Quality control: The company establishes and enforces strict quality control standards to ensure
that the raw materials and components received from suppliers meet the required quality
standards.
f. Continuous improvement: The sourcing process is continually reviewed and refined to ensure
that it is efficient, cost-effective, and able to meet the changing needs of the company.
Overall, the sourcing process in Lumax Cornaglia Auto Technologies is designed to ensure the timely
availability of high-quality raw materials and components required for its manufacturing processes.
The company's commitment to quality control and supplier performance evaluation helps it to maintain
high-quality standards and to ensure the reliable and consistent supply of raw materials and
components.
The sourcing team of LCAT work to secure more than 280 products including raw material and child
parts. The table shown here are only for example for souring and some main product of lcat which they
need regulsr basis.
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TABLE – 3 PURCHASING AND SUPPLIER
S. No. Child Part/ Raw Material Suppilerr

1. Rubber Grommet
Aasra Industries
2. Metallic spacer
3. RAT cap
4. Filter paper roll 157mm
Filter paper roll 156 mm SV Metatech India PVT. Ltd.
Filter paper roll 116 mm
5. Polybag Okay industries

6. Gasket 1.6 MPI GVK industries
7. VENT VALVE FOR UT GVK industries
8. STONE GUARD GVK industries
9. FITLER NECK UT GVK industries
10. O RING LEVEL SENSOR GVK industries
11. HM HDPE-LUPOLEN 4261AG
12. STRENGHTENIG RING
13. POLYPROPYLENE
Plaast industries Private limited
14. SANTORPRENE
15. TAROPRENE
16. HYTREL RM GRADE GRANNULE
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4) Raw material/ Inventory
The company has to manage inventory to ensure that it has enough raw materials and finished goods to
meet the demand from its customers. Here are some key points to consider when writing about inventory
management in Lumax Cornaglia Auto Technology:
a. Inventory Tracking: The company uses an inventory tracking system to monitor the level of raw
materials and finished goods in its warehouses. The system allows the company to quickly identify any
shortages or surpluses in inventory levels, which helps to ensure that the company has enough inventory
to meet customer demand without overstocking.
b. Safety Stock: The company maintains a safety stock of raw materials and finished goods to ensure that
it has enough inventory to meet unexpected increases in demand or disruptions in the supply chain. The
safety stock is regularly reviewed and adjusted to ensure that it remains appropriate for the current
business conditions.
c. Inventory Turnover: The company aims to optimize its inventory turnover ratio, which is the number
of times inventory is sold and replaced in a given period. A higher inventory turnover ratio indicates
that the company is selling its inventory quickly, which helps to minimize inventory holding costs and
maximize profits.
d. JIT Inventory: Lumax Cornaglia Auto Technology also implements a just-in-time (JIT) inventory
management system, which allows the company to minimize inventory holding costs by receiving raw
materials and components from suppliers just in time for production.
Overall, Lumax Cornaglia Auto Technology's inventory management practices aim to ensure that the
company has enough inventory to meet customer demand without overstocking, while also minimizing
inventory holding costs and maximizing profits.
Given table only show example
TABLE – 4 INVENTORY MAINTAINING SHEET (BOP SHEET)

S. Product name Daily stock Required Incoming Today usuage
No. available stock stock
1 Hytrel 3000kg X quantity Y quantity Z quantity
With the help of this table we were not require extra effort for product management daily quantity
available determine by total usage and incoming stock but for clear record daily stock maintained
through human effort sometime it taken by me also with the of employees
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5) PRODUCTION
a. SUCTION MOULDING MACHINE- This machine utilizes a process where a thermoplastic sheet is
heated until it becomes pliable and is then placed over a mold. The air between the sheet and the mold
is then evacuated through small perforations in the mold, creating a vacuum that causes the sheet to
conform tightly to the mold's shape. The benefits of suction molding machines include high accuracy
and repeatability, low tooling costs, and the ability to produce large quantities of parts quickly and
efficiently. Additionally, these machines are highly automated, which reduces the need for manual
labor and increases productivity.
In this machine the mould for various company prepared
i. 1.2 NGTC DAD

ii. HOUSING
iii. COVER
iv. X451 DAD
v. HOUSING
vi. COVER
vii. KITE 5 DAD
viii. HOUSING
ix. COVER
x. VW 684 DAD
FIGURE – 1 SUCTION MOULDING MACHINE
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b. Injection moulding machine - This machine works by heating plastic resin pellets to a molten state,
which is then injected into a mold cavity under high pressure. Once the plastic cools and solidifies, the
mold is opened, and the finished product is ejected.Injection molding machines are highly versatile
and can produce parts with complex geometries, tight tolerances, and high volumes. They are highly
used in a wide range of industries, including automotive, medical, consumer products, and
electronics.The reason of using injection molding machines include high production rates, low labor
costs, and the ability to produce parts with consistent quality and high repeatability. Additionally, the
machines can operate continuously for long periods, reducing downtime and increasing productivity.
In this machine initial part for Volkswagen and different company being prepared
i. Volkswagen 1.o litre housing/ cover

ii. Volkswagen 1.6 litre housing/ cover
iii. Volkswagen 1.5 litre housing/ cover
FIGURE -2 INJECTION BLOW MOULDING MACHINE
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c. 2D BLOW MOULDING MACHINE
A 2D blow moulding machine is a type of plastic extrusion machinery that is used to produce hollow
plastic parts with a two-dimensional shape. It is a specialized type of blow moulding machine that is
ideal for producing parts such as UREA TANK The 2D blow moulding process involves melting plastic
resin pellets and extruding the molten plastic through a die in the shape of the desired part. The plastic
is then stretched and blown into a mould cavity using compressed air, where it cools and solidifies into
the final shape.
In this machine tank for urea tank is being prepared and further more process also involved associated
with formation of urea tank.
FIGURE – 3 2D BLOW MOULDING MACHINE
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PROCESS ASSOCIATE WITH UREA TANK MANUFACTURING
i) Drilling -In the manufacturing industry, drilling is a common machining operation used to create holes
in a wide range of materials. The drilling process in manufacturing typically involves the use of
computer-controlled drilling machines, known as
CNC (Computer Numerical Control) machines,
that automate the drilling process for increased
accuracy and efficiency.
FIGURE – 4 DRILLING MACHINE
ii) Notching Notching is a machining process used in manufacturing to remove material from a workpiece,
typically to create a groove, notch, or cutout. Notching is used in a wide range of industries, including
metalworking, woodworking, and construction, to create components and structures with complex
shapes and features. In the manufacturing industry, notching typically involves the use of specialized
machines, such as notching presses,
nibblers, or notchers, that use a cutting tool
to remove material from the workpiece.
iii) Defleshing /flesh cutting – It is type of
finishing process in which rough surface or
similar kind of thing cut from tank to make
it smooth
iv) Vacuum cleaning- it is done to suck all
water which remain inside during waterjet
cleaning this process done on tank.
v) Waterjet cleaning- Waterjet cleaning is a
process that uses high-pressure water jets to
clean surfaces and remove unwanted
material or contaminants.
FIGURE – 5 NOTCHING MACHINE
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d) 3d blow moulding machine –
The 3D blow moulding machine industry refers to the production and sale of machines that are used
in the blow moulding process to create three-dimensional shapes or objects. Blow moulding is a
manufacturing process that involves melting plastic and then shaping it into a hollow form or object
using compressed air or gas.3D blow moulding machines are designed to create complex three-
dimensional shapes. Manufacturers of 3D blow moulding machines typically offer a range of models
with varying capabilities, depending on the specific needs of their customers. These machines may be
designed for high-volume production, small-scale manufacturing, or specialized applications.
In this machine various part of different company are being prepared including
i) 1.2 NGTC CAD
ii) KITE 5 CAD
iii) HOSE AIR CLEANER
iv) CONNECTING PIPE
v) INTAKE PIPE
vi) MG DIESEL/GASOLINE CAD
vii) X451 CAD
viii) VW CAD
FIGURE – 6 3D BLOW MOULDING MACHINE
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SEPARATE PROCESS IS ALSO ASSOCIATED WITH THIS MACHINE
i) HOT PLATE WEILDING

Hot plate welding is a manufacturing process that is used to join two plastic parts together using heat
and pressure.
The hot plate welding process involves heating two plastic parts to a molten state using a hot plate. The
hot plate is usually made of metal and is heated to a specific temperature using electric heating elements.
Once the plastic parts are heated to the appropriate temperature, they are pressed together using a
hydraulic press or other type of mechanical press. The pressure applied to the parts causes them to fuse
together, creating a strong and durable bond.
In this at top body cover of kite5/vw 1.0l/1.6l/1.5 SDE placed and at bottom filter body of same is placed
to attached.
FIGURE – 7 HOT PLATE WEILDING
30
1) Quality inspection
Quality inspection is an important process in Lumax Cornaglia Auto Technologies Private Limited to
ensure that the products manufactured meet the required quality standards. The quality inspection process
typically involves the following steps:
a) Incoming Inspection: The raw materials used in the manufacturing process are inspected to ensure that
they meet the required specifications.
b) In-Process Inspection: The products are inspected at various stages of the manufacturing process to
identify any defects or deviations from the required standards.
c) Final Inspection: The finished products are inspected before they are released for shipment to ensure
that they meet the required quality standards.
d) Quality Assurance: The quality assurance team is responsible for ensuring that the quality standards
are met throughout the manufacturing process.
e) Testing: The products may be subjected to various tests to ensure that they meet the required
specifications. For example, a product may be tested for durability, strength, and performance.
f) Documentation: The inspection results are documented to provide a record of the quality inspection
process. This documentation is useful for identifying trends and making improvements to the
manufacturing process.
g) Employee Training: The company provides regular training to its employees on quality inspection
processes and techniques. The training helps to ensure that the employees are knowledgeable about
the required quality standards and can perform their job duties effectively.
Overall, quality inspection is a crucial process in Lumax Cornaglia Auto Technologies Private Limited to
ensure that the products manufactured are of high quality and meet the required specifications. The
company takes great care to ensure that the quality standards are met throughout the manufacturing
process, from raw materials to finished products.
31
2) ASSEMBLY LINE
Assembly is a critical process in Lumax Cornaglia Auto Technologies Private Limited, where various
components are brought together to create a finished product. The assembly process typically involves
the following steps:
a) Component Preparation: The components required for assembly are prepared and inspected for
quality. This includes checking for any defects or damage that could impact the final product.
b) Assembly Line Setup: The assembly line is set up with all the necessary tools, equipment, and
workstations to complete the assembly process. The line is designed to minimize waste and optimize
efficiency.
c) Assembly: The components are assembled on the assembly line in a sequence that follows the product
design. This involves a combination of manual and automated processes, depending on the
complexity of the product.
d) Testing: Once the product is assembled, it undergoes a series of tests to ensure that it meets the
required specifications. This includes functional testing, leak testing, and electrical testing, among
others.
e) Inspection: The finished product is visually inspected for defects, and any issues are addressed before
it is released for shipment.
f) Packaging and Shipment: The finished product is packaged and labeled according to the customer's
specifications and is then shipped to the customer.
g) Overall, Lumax Cornaglia Auto Technologies Private Limited takes great care to ensure that the
assembly process is efficient, high-quality, and meets the required standards. The company uses a
combination of manual and automated processes, testing, and inspection to ensure that the finished
product is of the highest quality.
There are various assembly lines in produce different product for different company. Each and every line
follow a similar pattern of assembly. And there 4 section in each line
i) TATA GEN 1 –
ii) TATA 1.2/ 1.5 RESONATOR
iii) TATA 1.5 CRAIL/1.3 SDE/1.3 MULTIJET –
iv) TATA X451 –
v) TATA 1.2 NGTC –
vi) TATA KITE5 –
vii) SAVW 1.0L/1.5 KW/1.6 EVO/ 1.6 MPI
viii) SAVW 1.6 PETROL
ix) PSA CC21/CC24
32
Process of assembly for all cad, dad and air filters were same threr were different assembly line according
to customer and their specific requirement of engine or vehicle model
TABLE -4 ASSMBLY LINE OF GEN. 1
S.NO. ASSEMBLY LINE NAME PRODUCT RAW MATERIAL/CHILD PARTS
STAGE/SECTION 1 STAGE/SECTION 2
1) TATA GEN 1 ALTROZ a HOUSING d GROMMET
b DAD/CAD e SPACER
c FILTER ELEMENT f BODY COVER
HORNBILL a HOUSING d GROMMET

b DAD/CAD e SPACER
c FILTER ELEMENT f BODY COVER
SCOOP a HOUSING d GROMMET
b DAD/CAD e SPACER
c BODY COVER f FILTER ELEMENT
TABLE -4 ASSMBLY LINE OF RESONATOR

S.NO. ASSEMBLY LINE NAME PRODUCT RAW MATERIAL/CHILD PARTS
STAGE/SECTION 1 STAGE/SECTION 2
1.2 a. FILTER HOUSING f. FOAM RETAINING
1) TATA RESONATOR b. FILTER ELEMENT WASHER
c. FILTER COVER g. GROMMET
d. DAD h. BODY COVER
e. SEALING FOAM i. SPACER
1.5 a. FILTER HOUSING f. FOAM RETAINING
b. FILTER ELEMENT WASHER
c. FILTER COVER g. GROMMET
d. DAD h. BODY COVER
e. SEALING FOAM i. SPACER
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CHAPTER 3 : FUNCTIONING OF VARIOUS DEPARTMENT
1) The Human Resources department in Lumax Cornaglia Auto Technologies Private Limited is
responsible for managing the company's workforce. The department performs a wide range of
functions, including:
a) Recruitment and Selection: The HR department is responsible for recruiting and selecting new
employees for the company. This includes identifying job vacancies, advertising job openings,
screening resumes, and conducting interviews.
b) Training and Development: The HR department is responsible for providing training and
development opportunities to employees. This includes orientation training for new employees, skills
training, leadership development programs, and other types of training as needed.
c) Compensation and Benefits: The HR department is responsible for developing and administering the
company's compensation and benefits programs. This includes determining salaries and wages,
administering employee benefits such as health insurance and retirement plans, and ensuring
compliance with applicable laws and regulations.
d) Employee Relations: The HR department is responsible for managing employee relations, which
includes handling employee grievances, resolving conflicts, and promoting positive employee morale
and engagement.
e) Performance Management: The HR department is responsible for developing and implementing
performance management programs to evaluate and improve employee performance. This includes
setting performance goals, conducting performance evaluations, and providing feedback and
coaching to employees.
f) Compliance: The HR department is responsible for ensuring compliance with labor laws, regulations,
and company policies. This includes maintaining personnel records, administering employee benefits,
and ensuring that the company's hiring and employment practices are in compliance with applicable
laws and regulations.
Overall, the HR department in Lumax Cornaglia Auto Technologies Private Limited plays a critical
role in managing the company's workforce and ensuring that the company's employees are engaged,
productive, and aligned with the company's goals and objectives.
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2) Finance and Accounting- The Finance and Accounting department in Lumax Cornaglia Auto
Technologies Private Limited is responsible for managing the company's financial resources. The
department performs a wide range of functions, including:
a) Financial Planning and Analysis: The Finance and Accounting department is responsible for
developing and implementing financial plans and strategies to help the company achieve its financial
goals. This includes budgeting, forecasting, and financial analysis.
b) Accounting: The department is responsible for maintaining accurate and complete financial records
for the company. This includes recording financial transactions, preparing financial statements, and
managing accounts payable and accounts receivable.
c) Tax Management: The Finance and Accounting department is responsible for managing the
company's tax obligations. This includes preparing and filing tax returns, managing tax audits, and
ensuring compliance with applicable tax laws and regulations.
d) Financial Reporting: The department is responsible for preparing and distributing financial reports to
company stakeholders, including senior management, shareholders, and regulatory bodies.
e) Cash Management: The Finance and Accounting department is responsible for managing the
company's cash flows, including managing cash balances, monitoring cash inflows and outflows, and
forecasting cash needs.
f) Risk Management: The department is responsible for identifying and managing financial risks faced
by the company. This includes managing foreign currency risks, interest rate risks, and credit risks.
Overall, the Finance and Accounting department in Lumax Cornaglia Auto Technologies Private
Limited plays a critical role in managing the company's financial resources, ensuring compliance
with financial regulations and laws, and providing accurate financial information to stakeholders.
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3) Sales and Marketing- The Sales and Marketing department in Lumax Cornaglia Auto Technologies
Private Limited is responsible for promoting and selling the company's products to customers. The
a) Market Research: The Sales and Marketing department is responsible for conducting market research
to identify customer needs and preferences, as well as market trends and competitive landscape.
b) Product Development: The department works closely with the R&D department to identify and
develop new products that meet customer needs and preferences.
c) Sales Management: The Sales and Marketing department is responsible for managing the company's
sales activities, including setting sales targets, developing sales strategies, and managing the sales
team.
d) Advertising and Promotion: The department is responsible for developing and implementing
advertising and promotional campaigns to create awareness and generate interest in the company's
products.
e) Brand Management: The Sales and Marketing department is responsible for managing the company's
brand image and reputation. This includes developing and implementing brand guidelines, managing
social media presence, and ensuring consistency in brand messaging.
f) Customer Relationship Management: The department is responsible for managing relationships with
customers, including identifying new customers, maintaining existing customer relationships, and
resolving customer complaints.
Overall, the Sales and Marketing department in Lumax Cornaglia Auto Technologies Private Limited
plays a critical role in promoting and selling the company's products to customers, developing new
products, and managing customer relationships. The department works closely with other
departments in the company, including R&D and Manufacturing, to ensure that the company's
products meet customer needs and preferences.
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4) Research and Development (R&D)- The Research and Development (R&D) department in Lumax
Cornaglia Auto Technologies Private Limited is responsible for developing new products and
technologies, as well as improving existing ones. The department performs a wide range of functions,
including:
a) Product Design and Development: The R&D department is responsible for designing and developing
new products, as well as improving existing products. This includes conducting research, developing
prototypes, and testing new products.
b) Technology Innovation: The department is responsible for identifying new technologies and
innovations that can be incorporated into the company's products. This includes keeping up-to-date
with technological advances and trends in the industry.
c) Quality Control: The R&D department is responsible for ensuring that the company's products meet
quality standards. This includes developing quality control processes and procedures, as well as
testing and analyzing products to identify defects and improve quality.
d) Intellectual Property Management: The department is responsible for managing the company's
intellectual property, including patents, trademarks, and copyrights. This includes conducting patent
searches, filing patent applications, and protecting the company's intellectual property rights.
e) Collaboration with Other Departments: The R&D department works closely with other departments,
including Manufacturing and Sales and Marketing, to ensure that products are designed to meet
customer needs and can be manufactured efficiently.
Overall, the R&D department in Lumax Cornaglia Auto Technologies Private Limited plays a critical
role in developing new products and technologies, improving product quality, and protecting the
company's intellectual property. The department is essential in maintaining the company's
competitive edge in the industry by constantly innovating and improving its products.
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5) PRODUCTION PLANNING AND CONTROL- The Production Planning and Control (PPC)
department in Lumax Cornaglia Auto Technologies Private Limited is responsible for planning and
coordinating the production process to ensure that products are manufactured efficiently and on time.
The department performs a wide range of functions, including:
a) Production Planning: The PPC department is responsible for developing production plans based on
customer demand, inventory levels, and manufacturing capabilities. This includes scheduling
production runs and determining the quantity of raw materials needed.
b) Material Planning and Control: The department is responsible for managing the inventory of raw
materials and ensuring that materials are available when needed. This includes developing material
requirements planning (MRP) systems and managing vendor relationships.
c) Capacity Planning: The PPC department is responsible for ensuring that manufacturing capacity is
adequate to meet production requirements. This includes managing machine and labor capacities and
identifying bottlenecks in the production process.
d) Production Control: The department is responsible for monitoring the production process to ensure
that products are manufactured according to specifications and quality standards. This includes
managing the flow of work through the manufacturing process, monitoring production schedules, and
identifying and resolving production issues.
e) Performance Analysis: The PPC department is responsible for analyzing production data to identify
opportunities for improvement. This includes monitoring production costs, identifying areas of waste
and inefficiency, and developing and implementing process improvement initiatives.
Overall, the Production Planning and Control department in Lumax Cornaglia Auto Technologies
Private Limited plays a critical role in ensuring that products are manufactured efficiently and on
time, and that the production process is continuously improved to meet changing customer needs and
market demands. The department works closely with other departments, including R&D, Sales and
Marketing, and Finance and Accounting, to ensure that production plans are aligned with overall
company strategy and goals.
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6) PURCHASE DEPARTMENT- The Purchase department in Lumax Cornaglia Auto Technologies
Private Limited is responsible for sourcing, procuring and managing the inventory of raw materials,
equipment and services needed for the company's production process. The department performs a wide
range of functions, including:
a) Sourcing: The Purchase department is responsible for identifying and selecting vendors who can
supply the company with the required raw materials, equipment and services. This includes
evaluating vendors based on factors such as price, quality, delivery time, and reliability.
b) Negotiation: The department negotiates with vendors to secure the best possible terms for the
company. This includes negotiating prices, delivery schedules, and payment terms.
c) Purchase Order Processing: The department is responsible for processing purchase orders and
ensuring that all documentation is accurate and complete. This includes tracking and monitoring
delivery schedules and resolving any issues that arise.
d) Inventory Management: The Purchase department is responsible for managing inventory levels of
raw materials, equipment and other goods needed for the company's production process. This includes
developing and maintaining inventory control systems and managing inventory levels to ensure that
production is not disrupted due to shortages.
e) Vendor Management: The department is responsible for managing vendor relationships and ensuring
that vendors meet the company's standards for quality, delivery time, and reliability. This includes
evaluating vendor performance and taking corrective actions when necessary.
Overall, the Purchase department in Lumax Cornaglia Auto Technologies Private Limited plays a
critical role in ensuring that the company has a steady supply of raw materials, equipment and services
needed for production. The department works closely with other departments, including Production
Planning and Control and Finance and Accounting, to ensure that procurement activities are aligned
with overall company strategy and goals
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7) PRODUCTION DEPARTMENT- The Production department in Lumax Cornaglia Auto Technologies
Private Limited is responsible for the manufacturing of various automotive components and parts. The
a) Production Planning: The department is responsible for developing production plans and schedules
that ensure that the company's manufacturing operations run smoothly and efficiently.
b) Manufacturing: The department is responsible for the actual manufacturing of automotive
components and parts, which involves a variety of processes, such as machining, welding, assembly,
and painting.
c) Quality Control: The department is responsible for ensuring that all manufactured products meet the
company's quality standards through the implementation of quality control measures such as
inspection, testing, and process control.
d) Maintenance: The department is responsible for maintaining the manufacturing equipment and
facilities to ensure that they are operating efficiently and reliably.
e) Continuous Improvement: The department is responsible for identifying areas for improvement in
the manufacturing process and implementing changes to improve efficiency, reduce costs, and
enhance product quality.
Overall, the Production department plays a critical role in ensuring that Lumax Cornaglia Auto
Technologies Private Limited's products are manufactured efficiently, cost-effectively, and to the
highest quality standards. The department works closely with other departments, including
Production Planning and Control, Engineering, and Quality Assurance, to ensure that manufacturing
operations are aligned with overall company strategy and goals.
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8) QUALITY AND CONTROL DEPARTMENT- The Quality Control department in Lumax Cornaglia
Auto Technologies Private Limited is responsible for ensuring that the company's products meet the
highest quality standards. The department performs a wide range of functions, including:
a) Inspection and Testing: The department inspects and tests products throughout the manufacturing
process to ensure that they meet the company's quality standards. This includes testing of raw
materials, work-in-progress, and finished products.
b) Documentation and Record Keeping: The department maintains records of all inspections and tests
performed, as well as documentation related to quality control processes.
c) Root Cause Analysis: The department investigates quality issues to determine the underlying causes
and implements corrective and preventive actions to prevent similar issues from occurring in the
future.
d) Quality System Management: The department manages the company's quality system, including the
development and implementation of quality policies, procedures, and standards.
e) Supplier Quality Management: The department works with suppliers to ensure that their products and
services meet the company's quality standards and requirements.
Overall, the Quality Control department plays a critical role in ensuring that Lumax Cornaglia Auto
Technologies Private Limited's products meet the highest quality standards. The department works
closely with other departments, including Production, Engineering, and Supply Chain, to ensure that
quality control processes are aligned with overall company strategy and goals.
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9) MAINTENANCE DEPARTMENT- The Maintenance department in Lumax Cornaglia Auto
Technologies Private Limited is responsible for ensuring that all machinery and equipment in the
company's production process are in good working condition and operating at optimal levels. The
a) Preventive Maintenance: The Maintenance department is responsible for developing and
implementing preventive maintenance schedules for all machinery and equipment. This includes
scheduling regular inspections, lubrication, cleaning, and replacement of parts as needed.
b) Reactive Maintenance: The department is responsible for responding to equipment breakdowns and
malfunctions. This includes identifying the root cause of the problem and taking corrective action to
repair or replace damaged parts.
c) Predictive Maintenance: The department is responsible for using predictive maintenance techniques
to identify potential equipment problems before they occur. This includes using techniques such as
vibration analysis, thermal imaging, and oil analysis to detect early signs of equipment wear and tear.
d) Calibration and Testing: The Maintenance department is responsible for calibrating and testing all
equipment to ensure that they are operating within their required specifications. This includes
performing tests such as load testing, torque testing, and pressure testing.
e) Facility Maintenance: The department is responsible for maintaining the company's production
facilities, including HVAC systems, lighting, and other building systems.
Overall, the Maintenance department in Lumax Cornaglia Auto Technologies Private Limited plays
a critical role in ensuring that all machinery and equipment in the production process are functioning
at optimal levels. The department works closely with other departments, including Production
Planning and Control and Quality Control, to ensure that equipment maintenance activities are
aligned with overall company strategy and goals.
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10) Store department- The Store department in Lumax Cornaglia Auto Technologies Private Limited is
responsible for managing the company's inventory of raw materials, finished goods, and other supplies.
The department performs a wide range of functions, including:
a) Receiving: The Store department is responsible for receiving incoming shipments of raw materials,
finished goods, and other supplies. This includes verifying that the shipment matches the purchase
order and inspecting the goods for damage.
b) Storage: The department is responsible for storing inventory in an organized manner to maximize
space utilization and ensure that inventory is easily accessible when needed.
c) Issuing: The department is responsible for issuing inventory as needed to other departments,
including Production and Maintenance.
d) Record Keeping: The Store department is responsible for maintaining accurate records of inventory
levels, stock movements, and inventory transactions.
e) Inventory Control: The department is responsible for managing inventory levels to ensure that the
company has adequate inventory to meet production needs while minimizing excess inventory and
associated costs.
f) Overall, the Store department plays a critical role in ensuring that the company has the necessary
inventory to support its production process. The department works closely with other departments,
including Production Planning and Control and Purchasing, to ensure that inventory management
activities are aligned with overall company strategy and goals.
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11) Dispatch/Shipping/Logistics department- the Shipping department or the Logistics department is
responsible for managing the transportation of finished products from the company's facilities to their
customers. The department performs a wide range of functions, including:
a) Order Processing: The department receives and processes customer orders, determines the most
efficient and cost-effective shipping method, and prepares shipping documentation.
b) Shipment Tracking: The department tracks shipments throughout the transportation process to ensure
timely delivery and to identify and resolve any potential issues that may arise during transit.
c) Carrier Management: The department works with carriers to ensure that they have the necessary
resources to transport products, including arranging for equipment and coordinating schedules.
d) Customs Compliance: The department ensures that all international shipments comply with customs
regulations, including preparing the necessary documentation and working with customs officials to
resolve any issues that may arise.
e) Cost Control: The department works to minimize transportation costs by negotiating rates with
carriers and optimizing shipping routes.
Overall, the Shipping/Logistics department in Lumax Cornaglia Auto Technologies Private Limited
plays a critical role in ensuring that finished products are delivered to customers on time and in good
condition. The department works closely with other departments, including Sales and Production
Planning and Control, to ensure that shipping activities are aligned with overall company strategy
and goals.
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CHAPTER 4 : WHAT I HAVE LEARNED
MONTHLY OVERVIEW OF INTERNSHIP ACTIVITIES

From January to May
DATE NAME OF THE TOPIC/MODULE COMPLETE

09-01-2023 Overview Of Pune Plant
1 10-01-2023 Overview Of Pune Plant
S 11-01-2023 Overview of department
T 12-01-2023 Research and development Department
M 13-01-2023 Production planning and control
O 14-01-2023 Production Department
N 17-01-2023 Manufacturing process
T 18-01-2023 3D blow moulding machine
H 19-01-2023 Suction blow moulding machine
R 20-01-2023 Injection moulding machine
E 21-01-2023 2D blow moulding machine
P 25-01-2023 Assembly line (9 Different) process
O 02-02-2023 Warehouse overview
R 03-02-2023 Salient feature, History of Plant
T 04-02-2023 Inventory maintaining (balance of plant sheet maintenance)
06-02-2023 Inventory maintaining (balance of plant sheet maintenance)
Date NAME OF THE TOPIC/MODULE COMPLETE

2 11-02-2023 Inventory maintaining (balance of plant sheet maintenance)
N 13-02-2023 Inventory maintaining (balance of plant sheet maintenance)
D 14-02-2023 Inventory maintaining (balance of plant sheet maintenance)
M 15-02-2023 Inventory maintaining (balance of plant sheet maintenance)
O 16-02-2023 Inventory maintaining (balance of plant sheet maintenance)
N 17-02-2023 Inventory maintaining (balance of plant sheet maintenance)
T 18-02-2023 Inventory maintaining (balance of plant sheet maintenance)
H 20-02-2023 Warehouse Management and procurement
R 21-02-2023 Warehouse Management and procurement
E
22-02-2023 Warehouse Management and procurement
P
O
R
T
45
Date NAME OF THE TOPIC/MODULE COMPLETE
04-03-2023 Production Data management (PPC)
3 14-03-2023 Production Data management (PPC)
R 15-03-2023 Supply chain department
D 16-03-2023 Balance of material management - FG inventory
M 17-03-2023 Balance of material management - FG inventory
O 18-03-2023 Balance of material management - FG inventory
N 20-03-2023 Balance of material management - store inventory
T 21-03-2023 Balance of material management - store inventory
H 22-03-2023 Balance of material management - store inventory
R
23-03-2023 Supply Management – Customer identification
E
P
O
28-03-2023 Supply Management – Vehicle management
R
T
03-03-2023 Supply Management – Packaging
4th Date NAME OF THE TOPIC/MODULE COMPLETE

M 10-04-4023 Introduction to SVRS
O 12-04-4023 About SVRS
N 15-04-4023 Implementation on TML requirement
T 18-04-4023 Product identification
H 22-04-4023 Problems faced and solving
R 28-04-4023 Data collection
E 01-05-4023 Sheet preparation
P 05-05-4023 Practical implementation
O 09-05-4023 Practical Implementation
R
T
46
Inventory maintaining (Balance of Plant Sheet Management)
I was responsible for maintaining inventory and updating the balance of plant (BOP) sheet. This involved
tracking equipment, materials, and supplies required for the company's power plant operation. To begin
my work, I familiarized myself with the company's inventory management system and the BOP sheet. One
of the first tasks I performed was conducting a physical inventory count of all the equipment and supplies
in the warehouse. I compared the results of the count with the BOP sheet and made necessary corrections.
Another significant aspect of my work involved tracking the usage of inventory items. I regularly checked
the usage of supplies and predicted future needs based on historical data. This helped to avoid stockouts
or overstocking, ensuring that the plant had the necessary items available at all times. Throughout my
internship, I communicated regularly with the team members responsible for maintaining inventory and
the BOP sheet. In conclusion, my internship experience in maintaining inventory and updating the BOP
sheet was highly rewarding. It provided me with valuable insights into the importance of maintaining an
accurate inventory record and the challenges associated with doing so.
Special thanks for Mr. Santosh for helping me in this assignment who trained and help me.
Warehouse Management
I was responsible for managing the company's warehouse. This involved overseeing the receipt, storage,
and distribution of products. To begin my work, I familiarized myself with the company's warehouse
management system and the standard operating procedures. One of the first tasks I performed was
conducting a physical inventory count of all the products in the warehouse. I compared the results of the
count with the inventory records and made necessary corrections. Another significant aspect of my work
involved optimizing the storage of products in the warehouse. I reviewed the layout of the warehouse and
reorganized it to maximize space utilization and improve the efficiency of picking and packing operations.
In addition to this, I implemented a system for receiving and dispatching products. I ensured that all
products were properly labeled and checked for quality before being stored in the warehouse. I also
implemented a first-in-first-out (FIFO) system for managing inventory, which helped to prevent product
spoilage and ensure that the oldest products were used first.
Throughout my internship, I communicated regularly with the team members responsible for warehouse
management. I provided regular updates on the inventory levels, product movements, and any changes
made to the warehouse layout or processes. This helped to ensure that everyone was on the same page and
had access to the most accurate and up-to-date information.
In conclusion, my internship experience in warehouse management was highly rewarding. It provided me
with valuable insights into the importance of maintaining an efficient and well-organized warehouse, and
the challenges associated with doing so.
Special thanks for warehouse head Mr. Sujeet sir and Mr. Nilesh for his assistance
47
Production Data management
I was responsible for managing production data to ensure that accurate and up-to-date information was
available to the production team. This involved collecting, organizing, and storing data related to the
production process, and making it easily accessible to relevant stakeholders.
To begin my work, I familiarized myself with the company's production processes, equipment, and quality
standards. I then worked closely with the production team to identify the types of data that needed to be
collected and the best methods for doing so.
Using various data management tools and software, I collected data on a daily basis, including production
rates, downtime, and quality metrics. I then organized the data into spreadsheets and databases, ensuring
that it was properly labeled and categorized for easy retrieval.
I also developed a system for monitoring data quality, ensuring that the data was accurate, complete, and
consistent. This involved regularly reviewing the data and verifying its accuracy with the production team.
Another significant aspect of my work involved creating reports and dashboards to present the data in a
meaningful and easily digestible way. I used various visualization tools to create graphs, charts, and other
visual aids, which helped stakeholders to quickly identify trends and patterns in the data.
Throughout my internship, I communicated regularly with the production team and other stakeholders to
ensure that everyone had access to the most accurate and up-to-date information. I also worked closely
with the team to develop new and improved methods for collecting and managing data, ensuring that the
production process ran smoothly and efficiently.
In conclusion, my internship experience in production data management was highly rewarding. It provided
me with valuable insights into the importance of data management in manufacturing, and the challenges
associated with collecting, organizing, and storing large amounts of production data
48
❖ SEQUENCING VEHICLE RELEASED SYSTEM
A specific type of delivery or logistics process used in supply chain management that is similar to the
milk-run vehicle process.
The SVRS is a delivery method in which a single vehicle collects different materials or parts and
consolidating them for delivery to a manufacturing plant or assembly line. This process helps to optimize
delivery routes and reduce customer inventory space.
SVRS system somewhat similar to process used in logistics industry i.e milk run vehicle process
While both systems involve the use of vehicles to transport goods, they serve different purposes and are
used in different industries. The milk-run system is commonly used in logistics and transportation, while
the sequencing vehicle released system is used in manufacturing and assembly processes.
Sequencing Vehicle Released (SVR) is a process used in the manufacturing industry to control the
production of vehicles on an assembly line. It is a system that determines the order in which vehicles are
released for production based on customer demand and available inventory.
The SVR system takes into account a variety of factors, including the types of vehicles being produced,
the availability of parts and components, and the production schedule. The system uses this information
to determine the optimal sequence in which vehicles should be released for production.
The goal of the SVR system is to ensure that the production line operates at maximum efficiency, with
the right mix of vehicles being produced at the right time. By sequencing the release of vehicles in this
way, the system can minimize downtime, reduce inventory costs, and improve overall production
efficiency.
The SVR system is typically used in large-scale manufacturing facilities that produce a high volume of
vehicles, such as automotive assembly plants. It is an important tool for manufacturers who need to
balance customer demand with production capacity and inventory levels.
Overall, the SVR system plays a critical role in ensuring that manufacturing operations run smoothly
and efficiently, helping companies to meet customer demand while maximizing productivity and
profitability.
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❖ Advantage of SVRS
1. Improved production efficiency: By sequencing the release of vehicles for production based on demand
and inventory levels, the SVR system helps to optimize production efficiency. This ensures because
of increase in demand.
2. Reduced inventory costs: By minimizing the amount of inventory held in stock, the SVR system helps
to reduce inventory costs. This is because the system ensures that the right product are produced at the
right time, reducing the need to hold excess inventory.
3. Increased customer satisfaction: The SVR system helps to ensure that customer demand is met in a
timely and efficient manner. This improves customer satisfaction as customers receive their vehicles
on time and in the correct specifications.
4. Improved supply chain management: The SVR system helps to improve supply chain management by
ensuring that parts and components are ordered and delivered on time to support the production
schedule. This reduces the risk of delays and ensures that the production line runs smoothly.
5. Better decision-making: The SVR system provides real-time data and insights into the production
process, allowing manufacturers to make better-informed decisions. This helps manufacturers to
identify areas for improvement and optimize their operations to maximize efficiency and profitability.
❖ Disadvantage of SVRS
1. Complexity: The SVR system is a complex system that requires sophisticated software and hardware,
as well as skilled personnel to manage and operate it. Implementing and maintaining the system can
be expensive and time-consuming.
2. Limited flexibility: The SVR system is designed to optimize production based on demand and
inventory levels, which can limit flexibility. For example, if demand suddenly changes or a supply
chain disruption occurs, the system may not be able to quickly adapt to the new situation.
3. Risk of errors: The SVR system relies on accurate data inputs, and any errors or inaccuracies in the
data can lead to production issues or delays. It is important to ensure that the data used by the system
is reliable and up-to-date.
4. Integration challenges: The SVR system may require integration with other systems and processes in
the manufacturing plant, such as inventory management and supply chain management systems.
Integration challenges can arise, particularly if these systems were not originally designed to work
together.
5. High initial investment: Implementing an SVR system can require a significant initial investment in
hardware, software, and personnel. This investment may be difficult to justify for smaller
manufacturing plants or those with lower production volumes
50
❖ CONVENTIONAL SUPPLY CHAIN METHOD
TML MANUFACTURER
To manufacture 1 car. TML require

X,Y,Z PRODUCT FROM LCAT
LCAT SENT PRODUCT IN 3

DIFFERENT VEICLE
Resulted into over-stock in

customer as well supplier end
❖ AFTER SEQUENCING VEHCLE RELEASED SYSTEM
TML MANUFACTURER
To manufacture 1 car. TML require X,Y,Z PRODUCT

FROM LCAT
LCAT SENT PRODUCT IN A KIT ACCORDING TO TML

PRODUCTION REQUIREMENT
NO OVER STOCKING
•PRODUCTION OF CUSTOMER INCREASE WHICH
RESULTED IN INCREASE IN DEMAND
51
❖ IMPLEMENTATION STAGE
BOP INSPECTION
PLANNING PRODUCTION DISPATCH
SCHEDULING AND
AND PLANNING PLANNING
PACKAGING
SOURCING
NOTE – In the mention method example for analysis is taken for TML. Product sent by LCAT to TML
were considered, scheduling is also explain considering TML as centric, for souring only product were
assumed which LCAT sent to TML so is for production planning and dispatch planning.
TABLE 5 PRODUCT DELIVER TO TML
S. NO. PART NO. PRODUCT REQUIREMENT

1 61028544 Air filter assembly ALTROZ 300
2 61028584 Air Intake scoop 300
3 61028545 Air filter ASSEMBLY HORNBILL 600
4 61028543 Clean Air Duct 900
5 61028610 Rubber Grommet 2700
52
1) Scheduling
Scheduling involves creating a detailed plan for the production process, including the allocation of
resources such as machines, materials, and personnel.
a) Determining Production goals: The first step in scheduling is to determine the production goals, such
as the quantity of products to be produced and the timeframe for production.
b) Breaking down production into smaller tasks: The next step is to break down the production process
into smaller tasks, such as ordering materials, setting up machines, and performing quality checks.
c) Estimating time and resource requirements: Once the tasks have been identified, it is necessary to
estimate the time and resource requirements for each task. This includes the amount of time required
to complete each task and the resources needed, such as machines, materials, and personnel.
d) Sequencing tasks: The next step is to sequence the tasks in the order in which they need to be
completed. This takes into account any dependencies between tasks and ensures that the production
process runs smoothly.
e) Creating a production schedule: The final step is to create a detailed production schedule that includes
the start and end times for each task, as well as the resources required.
Scheduling plays a critical role in ensuring that production processes are executed efficiently and
effectively. By creating a detailed plan for production, manufacturers can optimize their use of resources,
minimize downtime, and ensure that products are delivered on time and to the required quality standards.
SCHEDULING FOR LACT - One-day production requirement of buyer + one-day finished good
inventory at buyer end + 3 days finished good inventory at supplier end
2) Sourcing and Inventory management

The process of identifying and procuring the raw materials, parts, components, and equipment needed
to produce a finished product. Effective sourcing is critical to the success of manufacturing operations,
as it helps to ensure that the right materials and equipment are obtained at the right time, at the right
quality, and at the right price.
The sourcing process in manufacturing typically involves the following steps:
a) Identifying sourcing needs: The first step in sourcing is to identify the materials, parts, components,
and equipment needed to produce the finished product.
b) Supplier identification: Once the sourcing needs have been identified, the next step is to identify
potential suppliers that can provide the required materials or equipment. This may involve conducting
market research, soliciting bids from suppliers, and evaluating supplier capabilities and performance.
53
c) Negotiating terms: The next step is to negotiate the terms of the sourcing agreement, including the
price, delivery terms, quality standards, and other contractual terms.
d) Establishing relationships: Once an agreement has been reached with a supplier, it is important to
establish and maintain a positive relationship with the supplier. This may involve regular
communication, collaboration, and the establishment of mutually beneficial goals and objectives.
e) Managing supplier performance: Finally, it is important to monitor and manage supplier performance
to ensure that they meet the agreed-upon quality standards, delivery schedules, and other contractual
obligations.
SOURCING FOR LCAT done by various company including Plast auto India limited, okay industries
etc.
3) Production planning
Production planning is a critical process in manufacturing that involves the systematic planning,
scheduling, and coordination of resources needed to manufacture a product. The goal of production
planning is to optimize production processes to ensure efficient use of resources, reduce costs, and
improve product quality.
The production planning process typically involves the following steps:
a) Forecasting demand: The first step in production planning is to forecast the demand for the product.
This involves analyzing historical data, market trends, and other factors to predict the expected
demand for the product.
b) Determining production capacity: Once the demand has been forecasted, the next step is to determine
the production capacity needed to meet that demand. This involves evaluating the available resources,
such as labor, equipment, and materials, and determining how much production can be achieved.
c) Creating a production schedule: The production schedule outlines the sequence of operations needed
to manufacture the product. It includes information on the start and end dates for each operation, the
resources required, and the expected output.
d) Allocating resources: After the production schedule has been created, the next step is to allocate the
necessary resources to each operation. This includes determining how much labor, equipment, and
materials are needed for each operation.
e) Monitoring and adjusting the plan: Once production has begun, it is important to monitor the
production plan and make adjustments as needed. This includes tracking progress, identifying any
issues or delays, and making changes to the production schedule as needed.
Effective production planning can help manufacturers to reduce costs, improve product quality, and
increase efficiency. By optimizing the use of resources and ensuring that production processes are well-
coordinated, manufacturers can improve their ability to deliver high-quality products on time and meet
the demands of their customers.
54
TABLE 6 PRODUCTION SHEET
S.NO. PRODUCT PER DAY Forcasted

Requirement Requirement
1 Air filter assembly ALTROZ 300
2 Air Intake scoop 300 Depend on day and

3 Air filter ASSEMBLY 600 buyer’s
HORNBILL
4 Clean Air Duct 900
5 Rubber Grommet 2700
4) INSPECTION
The inspection process in Lumax Cornaglia Auto Technology typically involves the following steps:
f) Receiving inspection: The first step in the inspection process is to inspect the raw materials and
components received from suppliers to ensure that they meet the required specifications.
g) In-process inspection: During the manufacturing process, components are inspected at various stages
to ensure that they are being produced to the required quality standards.
h) Final inspection: Once the components have been produced, a final inspection is carried out to ensure
that they meet the required quality standards before they are shipped to customers.
i) Testing: Lumax Cornaglia Auto Technology also conducts testing on its components to ensure that
they meet the required performance standards. This may involve testing for durability, strength, and
other performance metrics.
j) Continuous improvement: Lumax Cornaglia Auto Technology is committed to continuous

improvement in its manufacturing processes. The company uses data and feedback from the
inspection process to identify areas for improvement and implement changes to improve product
quality and efficiency.
Effective inspection is critical to the success of Lumax Cornaglia Auto Technology's manufacturing
operations. By maintaining high quality standards through rigorous inspection and testing, the
company is able to deliver high-quality components to its customers, while also reducing waste,
improving efficiency, and increasing customer satisfaction.
55
(5) Packaging
Packaging helps to protect products during transportation, storage, and handling, while also providing
branding and marketing opportunities. Packaging can be designed to meet specific requirements such as
durability, moisture resistance, and temperature control.
a. Designing packaging: The first step in the packaging process is to design packaging that meets the
specific requirements of the product. This includes determining the size, shape, and material of the
packaging.
For TML a specially designed box been used
b. Packaging products: After the packaging materials have been procured, the next step is to package
the products. This may involve using automated packaging equipment or manual labour.
c. Labelling and branding: Finally, packaging provides an opportunity for branding and marketing.
Manufacturers may choose to label their products with branding and product information to increase
consumer awareness.
TABLE 7 PRODUCT DISTRIBUTION IN BOXES
S.NO. PRODUCT Box size QUANTITY PER

BOX
1 Air filter assembly ALTROZ 1200*1000*1100 MM 24
2 Air filter assembly ALTROZ 1200*1000*1100 MM 100
3 Air filter ASSEMBLY HORNBILL 1200*1000*1100 MM 24
4 Clean Air Duct 600*400*280 MM 70
5 Rubber Grommet 600*400*280 MM 500
6) Dispatch planning
Dispatch planning is an essential process in logistics and supply chain management that involves the
systematic planning and coordination of resources needed to deliver products to customers. The goal of
dispatch planning is to optimize the use of resources, reduce costs, and improve the efficiency of the
delivery process.
The dispatch planning process typically involves the following steps:
(a) Determining delivery requirements: The first step in dispatch planning is to determine the delivery
requirements, including the delivery destination, delivery schedule, and product quantity.
(b) Allocating resources: Once the delivery requirements have been determined, the next step is to
allocate the necessary resources to fulfill the delivery. This includes assigning delivery personnel,
vehicles, and equipment.
(c) Creating a delivery schedule: The delivery schedule outlines the sequence of deliveries and the
expected delivery times. It includes information on the delivery personnel, vehicle, and product
56
quantity for each delivery. Monitoring and adjusting the plan: Once the delivery process has begun,
it is important to monitor the progress and make adjustments as needed. This includes tracking
delivery times, identifying any issues or delays, and making changes to the delivery schedule as
needed.
Effective dispatch planning can help companies to improve the efficiency of their delivery processes,
reduce costs, and increase customer satisfaction. By optimizing the use of resources and ensuring that
the delivery process is well-coordinated, companies can improve their ability to deliver products on time
and meet the demands of their customers.
Dispatch planning to TML done 3 different phases
TABLE 8 1ST ROUND OF DISPATCH PLANNING FOR TML
Vehicle type S.NO. PRODUCT REQUIREMENT Total boxes in

and size vehicle
1 Air filter assembly ALTROZ 300 4
2 Air Intake scoop 300 1
TATA 1109-19 3 Air filter ASSEMBLY 600 13

FEET HORNBILL
(2791-2133)
4 Clean Air Duct 900 6
5 Rubber Grommet 2700 4
TABLE 9 2ND ROUND OF DISPATCH PLANNING FOR TML

and size vehicle
TATA 407 3 Air filter ASSEMBLY 288 6

LPT HORNBILL
(4267*1828)
) 4 Clean Air Duct 480 4
57
TABLE 10 3RD ROUND OF DISPATCH PLANNING FOR TML

and size vehicle
TATA 407 3 Air filter ASSEMBLY 144 6

LPT HORNBILL
(4267*1828)
) 4 Clean Air Duct 200 4
58
CHAPTER 5: CONCLUSION
This industrial internship provides an excellent opportunity for me to gain practical

experience and develop the skills necessary to succeed in the field of logistics and supply.
The experience that I gained during this industrial internship can be invaluable in terms
of professional development and career advancement.
One of the most significant benefits for me of this industrial internship is the ability to
apply theoretical knowledge to practical problems in the workplace. By working
alongside experienced professionals, interns gain hands-on experience and develop
critical thinking and problem-solving skills. This experience can also provide a deeper
understanding of the industry and how it operates.
• I gained knowledge of working of some rare machine like 2d, 3d, suction blow
moulding machine.
• Practical implementation of SVRS system and challenges faced during its
implementation
• How Production planning and souring or purchasing being done
In addition to technical skills, this industrial internship also provide opportunity for me
to develop valuable soft skills like teamwork, time management, are all highly sought-
after skills in any workplace setting. Apart for the industrial knowledge or experience I
also gained interpersonal skills like
• Time management and discipline

• Analytical skills and socialization
This industrial internship is a valuable experience that provides opportunities for

professional development and personal growth. Through hands-on experience, the
opportunity to learn from experienced professionals, and the development of technical
and soft skills. By this internship I can gain a deeper understanding of the industry and
trying to develop the tools necessary for a successful career. By reflecting the experiences
that I gained during this period I’m able to identify areas of strength and weakness, and
set goals for future success.
59

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4

Title Page No.

Chapter : 2 Company Profile 11-34

Chapter : 2.1 Company Vision

Chapter : 4 What I Have Learned 46-59

Chapter : 3.1 SVR System

Fig. No. Title Page

Fig. 2 Injection Blow Moulding Machine 26

Fig. 3 2D Blow moulding Machine 27

Fig. 4 Drilling Machine 28

Fig. 5 Notching Machine 28

Fig. 6 3D Blow Moulding Machine 30

Fig. 7 Hot Plate Wielding Machine 31

Fig. 8 Implementation Stages SVRS 53

TABLE Title Page

TABLE. 2 Manufactured Product 19

TABLE. 3 Manufacturing Cycle 20

TABLE. 4 Supplier and Sourcing 23

TABLE. 5 Inventory Management sheet or BoP Sheet 24

TABLE. 6 Assembly line for intake system 34

TABLE. 7 Assembly Line for Exhaust System 34

TABLE. 8 Product Deliver to TML under SVRS 53

TABLE. 9 Production Planning for TML under SVRS 56

TABLE. 10 Packaging or Box sizes 57

TABLE. 11 1st phase of dispatch planning for TML 58

TABLE. 12 2nd phase of dispatch planning for TML 58

TABLE. 13 3rd phase of dispatch planning for TML 59

TABLE. 14 Overview of 1st Month 61

TABLE. 15 Overview of 2nd Month 62

TABLE. 16 Overview of 3rd Month 63

TABLE. 17 Overview of 4th Month 64

Abbreviation Full form

CAD Clean Air Duct

DAD Dirty Air Duct

SPD Spare Part Distribution

OEM Original equipment Manufacturer

TML Tata Motors Limited

IBMM Injection Blow Moulding Machine

SBMM Suction Blow moulding Machine

SVRS Sequencing Vehicle Released System

AFA/AAF Assemble Air Filter or Air filter Assembly

• Building an ADMIRED HIGH PERFORMANCE Global Organisation in whom all stakeholders

• Respect Integrity Passion Excellence

•Once the design is complete, the company creates a prototype of the

•The company conducts a series of tests to ensure that the product

•The final stage of the product development process involves launching

TABLE – 1 CUSTOMER AND PRODUCT

•Resonator: •Clean Air Duct •Air filter •Air filter(EXP)

•Air filter (EXP) •Clean Air Duct

Air intake Air

18L RUT 25L RUT 18L DUT 25DUT

S. No. Child Part/ Raw Material Suppilerr

5. Polybag Okay industries

TABLE – 4 INVENTORY MAINTAINING SHEET (BOP SHEET)

1 Hytrel 3000kg X quantity Y quantity Z quantity

In this machine the mould for various company prepared

i. 1.2 NGTC DAD

FIGURE – 1 SUCTION MOULDING MACHINE

i. Volkswagen 1.o litre housing/ cover

FIGURE -2 INJECTION BLOW MOULDING MACHINE

FIGURE – 3 2D BLOW MOULDING MACHINE

FIGURE – 4 DRILLING MACHINE

FIGURE – 5 NOTCHING MACHINE