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Pithampur Industrial Area, District Dhar, Pithampur, Madhya Pradesh, Pin code-
454775
Training duration -30 Days (5th June 2018 to 4th July 2018)
Project topic
To eliminate the problem come into the A.C. ventilation (nozzle) or
the R.P.M. meter fouling in Trax vehicle.
Submitted by: Submitted to Guide:
2. Acknowledgement 2
3. Certificate 3
4. Company profile 4
5. History and 5
heritage
6. Overseas presence 6
7. Vehicles 7-8
8. Pithampur plant 9
11. Conclusion 33
DECLARATION
I hereby declare that this Project on “To eliminate the problem come into
the A.C. ventilation (nozzle) or the R.P.M. meter fouling in Trax
vehicle’’ has been prepared by me, under the guidance & supervision of
Mr.O.P. Gorkhe / Mr.Pankaj Bairagi, FORCE MOTORS LIMITED. As a
part of my course B.E and all the work submitted by me is my original work.
Through the suggestion our mind creation there was a lot of sources that
helped me in understanding the working system and theoretical aspects of
the industry.
SANDEEP RAGHUVANSHI
B.E (Automobile Engineering)
Medicaps, Indore (M.P)
ACKNOWLEDGEMENT
I would like to extend my thanks and regards to Mr. R. Sinnarkar , Mr. O.P.
Gorkhe for assigning me with valuable projects that helped to gain a lot
during my training and for being such an inspirational guide.
I would also like to thank all the acquaintances of Force Motors Limited who
supported us directly or indirectly and solved queries and made us stay
pleasant.
Sincerely,
SANDEEP RAGHUVANSHI
CERTIFICATE
Force Motors was established in 1958 by Shri. N. K. Firodia, with the vision
to provide affordable commercial transport for the masses by harnessing the
best available technology and offering economical, reliable and efficient
products.
Today, its range includes Small Commercial Vehicles (SCV), Multi-Utility
Vehicles (MUV), Light Commercial Vehicles (LCV), Special Utility
Vehicles (SUV) and Agricultural Tractors. So no matter what the need be,
Force has a solution to offer.
FULLY VERTICALLY
INTEGRATED
Force Motors is fully vertically integrated, making its own engines, chassis,
gear boxes, axles, bodies etc. for the entire product range.
Force provides appropriate solutions for transport –both goods, as well as
passenger - rugged, reliable and efficient transport solutions for every need -
rural or urban, long distance or local, over good roads or bad tracks.
The foundation of the Group was laid by Late Shri. N. K. Firodia freedom
fighter and pioneering industrialist.
He gave India two paradigms - the concept of 'low cost public transport' - the
Autorikshaw (a word he coined that now finds a place in the Oxford
Dictionary).The Tempo Matador was the first diesel light commercial
vehicle in India. The word Tempo (a registered trade mark of Daimler) is
now generic for any small goods carrier in India
Over the last five decades it has partnered with leading global automotive
names like Daimler, ZF, Ricardo, Bosch and MAN etc. Through these
associations it has developed necessary expertise in-house to harness the
latest advances in technology and developing relevant mobility solutions.
OVERSEAS PRESENCE
Force Motors is a highly flexible automotive company that has the capability
to cater to different types of markets, by providing customized 'country
specific' solutions.
Over the last five decades it has partnered with leading global automotive
names like Daimler, ZF, Ricardo, Bosch and MAN etc. Through these
associations it has developed necessary expertise in-house to harness the
latest advances in technology and developing relevant mobility solutions.
The company exports its complete range of world class products to various
countries Middle east , Asia, Latin America,and Africa.
BRANDS
BALWAN(AGRICULTURAL VEHICLE)
PRODUCTION FLOW
RAW MATERIAL
(METAL SHEETS ETC. )
PRESS SHOP
BODY SHOP
PAINT SHOP
ENGINE SHOP
POWERTRAIN
GEAR BOX SHOP SHOP
DISPATCH
GANG WAY
TRAXFINAL LINE
STORES
TRIM-1 TRIM-2
RBT WHEEL
ALIGNMENT
OPERATION WISE LINE STRATIFICATION
matting fitment
Station11
speaker covering
ENGINE
Model FM 2.0 CR
Emission BS – IV
Displacement 1947 CC
TRANSMISSION
Type Synchromesh
AXLES
Front Independent
SUSPENSION
Front Independent with solid torsion bar, hydraulic telescopic shock ab
Rear Semi Elliptical Two Stage Leaf Springs with Hydraulic telescopic
STEERING
Type Mechanical / Power Steering (Optional)
BRAKES
Service Brakes Hydraulic, Dual Circuit, Vacuum Assisted, (ABS with EBD) optio
Front Disc Brakes
DIMENSIONS
Wheel Base (mm) 3050
WEIGHTS
( KG )
CAPACITY
Fuel Tank 63.5 Litres
SEATING CAPACITY
Seating Capacity 11+D
TECHNICAL SPECIFICATIONSOF TRAX
TOOFAN DELUXE
ENGINE
Model FM 2.6 CR
Emission BS IV
Displacement 2596 CC
TRANSMISSION
Type Synchromesh
AXLES
Front Independent
SUSPENSION
Front Independent with solid torsion bar, Hydraulic Telescopic Shock
Rear Semi Elliptical two stage leaf springs with Hydraulic Telescopic
STEERING
Type Power Steering
BRAKES
Service Brakes Hydraulic- Dual Circuit, Vacuum assisted, (ABS with EBD) optio
DIMENSIONS
Wheel Base (mm) 3050
WEIGHTS
( KG )
SEATING CAPACITY
Seating Capacity 11+D
PROJECT TOPIC-
To eliminate the problem come into the A.C. ventilation (nozzle) or
the R.P.M. meter fouling in Trax vehicle.
DESCRIPTION OF PROBLEM
4W1H
D.
Who is complaining Internal costumer.
Evaporation: You may have noticed that if you rub a little surgical spirits
on the back of your hand, then your hand will feel cold. Why is that? It's
evaporation. It is because the spirits on the back of your hand start to
evaporate. As the spirit evaporates, it takes away heat from the surface of
your skin.
Condensation: Have you ever noticed when somebody walks in from the
cold into a take-away wearing glasses, their glasses steam up? Why is that?
It's condensation. The moist air of the take-away cools as it contacts the cold
surface of the glasses and the air has less capacity to hold moisture, so it
condenses into water on the glasses.
Heat of Compression: Have you ever noticed when you pump up a bicycle
tyre with a hand pump, that the end of the pump gets hot? This is because the
energy that you have put into the air by pumping it has not only compressed
it, but has also caused the air molecules to push closer together so giving off
heat with the friction.
Cooling by Expansion: Going back to the deodorant, you will notice also
how cold it feels that's because the propellant has just expanded in volume
quickly.
Hard tubing and flexible hoses connect all the actual components of the air
conditioning in your car. Evaporation and condensation, expansion and
compression are the physics of why it works. There are five main
components to the whole system, namely the Compressor, Condenser,
Receiver-dryer, Expansion valve, and the Evaporator.
The fluid that passes around the
whole system is the refrigerant.
The refrigerant can evaporate at a
low temperature, and then
condense again at a higher
pressure. In the bad old days, R-12
was the refrigerant used in almost
all cars. It was widely available,
however it was found to be a
contributor to the hole in the
earth's ozone layer as it was a
chlorofluorocarbon (CFC). These
refrigerants were discontinued,
and all cars after 1996 use a non-
CFC fluid called R-134A which is
kinder to the environment.
So, here is how all the various parts of a car's air conditioning works:
GRILLE
A grille is a device for supplying or extracting air vertically without
any deflection.Grilles and diffusers may be mounted in ceilings, floors, walls, doors and
in ducts. Some are suitable for horizontal or vertical mounting while floors grilles tend
to be especially strong to withstand foot traffic.
Types of Grille
Bar Grille
The blades of this type of grille are shaped as a bar compared to a narrow blade.
The bar profile may be ‘T’ shaped to reduce ‘see through’ visibility.
Some linear bar grilles have adjustable blades or angled blades to reduce ‘see through’.
Transfer Grille
These are often used in doors and walls to provide ventilation but stop the spread of
smoke and fire should it occur. An intumescent fire damper is incorporated in some
Transfer grilles as a means of isolation in the event of a fire.
SUGGESTION
The left side of A.C grille will fit on to the right side.
The right side of A.C grille will fit on the lift side.
The nozzle will stuck into the duct of the A.C we will change the design of the
A.C duct.
To change the shape of the nozzle of the A.C grille.
R.P.M METER
A tachometer (revolution-counter, tach, rev-counter, R.P.M gauge) is an instrument
measuring the rotation speed of a shaft or disk, as in a motor or other machine. The
device usually displays the revolutions per minute (R.P.M) on a calibrated analogue
dial, but digital displays are increasingly common. The word comes
from Greek ταχος (tachos"speed") and metron ("measure"). Essentially the words
tachometer and speedometer have identical meaning: a device that measures speed. It is
by arbitrary convention that in the automotive world one is used for engine and the
other for vehicle speed. In formal engineering nomenclature, more precise terms are
used to distinguish the two.
SUGGESTION
The position of the R.P.M meter will be change. The old position of the meter is
in the lift side of the driver. It’s to be change on the right side of the driver on the
just beside the cluster.
The connection of the terminal of the R.P.M meter will not so tight. So we can
provide a connecter to extend the connection wire or a locking arrangement on to
the terminal of the R.P.M meter
OLD POSITION OF THE R.P.M METER
The R.P.M meter is located at the bottom panel of the dash board. And the switch
of the A.C is located at the center of the A.C grille.
1) Poka Yoke –
Poka-yoke is a Japanese term that means "mistake-proofing" or "inadvertent error
prevention".
2) Kaizen -
Kaizen, also known as continuous improvement, is a long-term approach to work
that systematically seeks to achieve small, incremental changes in processes in
order to improve efficiency and quality.
3) Cycle time –
Cycle time is the total time from the beginning to the end of your process, as
defined by you and your customer. Cycle time includes process time, during
which a unit is acted upon to bring it closer to an output, and delay time, during
which a unit of work is spent waiting to take the next action.
4) Take time –
Takt time may be thought of as a measurable “beat time,” “rate time” or “heartbeat.”
In Lean, takt time is the rate at which a finished product needs to be completed in
order to meet customer demand.
5) Lead time –
the time between the initiation and completion of a production process.
6) Throughput time –
throughput time is the amount of time required for a product to pass through a
manufacturing process, thereby being converted from raw materials into finished
goods. The concept also applies to the processing of raw materials into a component
or sub-assembly.
7) 5S
Removing all unnecessary items
Sort (Seiri)
from the workplace
Set In Creating a specific location for
(Seiton)
Order everything
Shine (Seiso) Clean the work area
Standardise the best practice
Standardise (Seiketsu)
within the workplace
Never slip back into the old
Sustain (Shitsuke)
ways
8) 4M
Man
a. Skill
b. Technology
c. Organization
d. Resources
e. Communications
Machine
f. Design
g. Installation
h. Supplier
Methods
i. Schedule
j. Procedure
Material
k. Design
l. Quality
9) 3M
Muda (waste), Muri(overburden) and Mura(unevenness)
10) PDCA
The plan–do–check–act cycle (Figure 1) is a four–step model for carrying out
change. Just as a circle has no end, the PDCA cycle should be repeated again and
again for continuous improvement.
11) 7 QC Tools
Histograms
Cause and Effect Diagram
Check Sheets
Pareto Diagrams
Graphs
Control Charts
Scatter Diagrams
The Quality Control Story (QC Story) method represents, for the automotive
industry companies, a problem-solving method based on considering the facts and
data, without speculation, for a problem caused by several factors. QC Story method
is applicable not only to quality problems, but also to problems of productivity,
costs, logistics, and energy. This paper presents the improvement in the customer
complaints process achieved by an effective use of the QC Story methodology. It is
presented the QC Story methodology and its performance in influencing the
customer complaints management process throughout a case study in the automotive
industry
TEAM FORMATION
ANALYSIS
STANDARISE