Project Report of Training

On

e-Learning Module
(Manufacturing Operations)

18-JUNE-2019 to 17-JULY-2019

Submitted by:
MAHESH SINGH NEGI
UTU.160030104020
(AMRAPALI INSTITUTE OF TECHNOLOGY & SCIENCES, LAMACHAUR
HALDWANI)
 e-Learning Module

CERTIFICATE
This is to certify that

Mr. Mahesh Singh Negi

Student of Amrapali Institute of Technology & Sciences

Has successfully completed his Industrial training at Tata Motors. He

has submitted

A report on

“e-Learning Module (Manufacturing Operation)”

In Digital manufacturing Department, TATA

Motors, Pantnagar
From 18-june-2019 to 17-july-2019
During his training He was sincere & dedicated to his work.

We wish him all the best for the future.

DATE:
PLACE:
PANTNAGAR

Mr. Sumit Saini &

Mr. Vipul Sharma Mr. Pawan Vishwakarma
Project Guide Mentor

2
 e-Learning Module

DIGITAL MANUFACTURING DEPARTMENT TATA MOTORS

ACKNOWLEDGEMENT
I take this opportunity to express my profound gratitude and
deep regards to the guide of my project Mr. Sumit Saini sir &
Mr. Vipul Sharma for his guidance, help and motivation and a
special thanks to all those peoples at Digital Manufacturing
Dept. Without their support it would not be possible for me
to complete this report.
I thank TATA MOTORS LIMITED, PANTNAGAR for considering
me for an internship in their prestigious organization and to
my College Amrapali institute of technology & sciences for
giving me a chance to learn and gather experience.
This report could not have been written without the
generous assistance of countless individuals who shared their
knowledge and expertise. To you all, I extend my deep
appreciation.
In the end I would like to thank Mr. Pawan Vishwakarma Sir
& Mr. Brijlal Arora Sir for providing me the opportunity to
add a new dimension in my knowledge which would help me
in the future.
During training, TATA MOTORS made my stay pleasant and
memorable.

3
 e-Learning Module

CONTENTS
SR.NO INDEX PAGE NO.

01 ACKNOWLEDGEMENT 3

02 TATA MOTORS PROFILE 5

03 INTRODUCTION 23

04 SCOPE 24

05 LEARNING 26

06 TOOLS USED 30

08 SHOPS VISITED 33

09 OTHER THINGS LEARNT 36

10 CONCLUSION 42

4
 e-Learning Module

TATA MOTORS PROFILE

Every business organization exists because it is able to fulfil society’s

needs for some goods or services. TATA motors engaged in an
Industry, which is vital for the progress of a developing country. The
commercial vehicle industry plays a vital role in the efficient
movement of people, agricultural product, raw materials and
finished products. The company always placed a major emphasis on
the satisfaction of its customer’s needs by producing their
requirement at the fairest prices backed by effective after sales
services.

Tata Motors Group (Tata Motors) is a $45 billion organisation. It is a

leading global automobile manufacturing company. Its diverse
portfolio includes an extensive range of cars, sports utility vehicles,
trucks, buses and defence vehicles. Tata Motors is India’s largest and
the only original equipment manufacturer (OEM) offering extensive
range of integrated, smart and e-mobility solutions.

Product range of the company includes

1. Commercial vehicles
 Tata Intra
 Tata Ace
 Tata Super Ace
 Tata Ace Edge intra
 Tata TL/Telco line/207 pick-up truck
 Tata 407 Ex and Ex2
 Tata 709 Ex

5
 e-Learning Module

 Tata 807 (Steel cabin chassis, cowl chassis, medium bus chassis,
steel cabin + steel body chassis)
 Tata 809 Ex and Ex2
 Tata 909 Ex and Ex2
 Tata 1210 SE and SFC (Semi Forward)
 Tata 1210 LP (Long Plate)
 Tata 1109 (Intermediate truck/ LCV bus)
 Tata 1512c (medium bus chassis)
 Tata 1515c/1615 (medium bus chassis)
 Tata 1612c/1616c/1618c (heavy bus chassis)
 Tata 1618c (semi low-floor bus chassis)
 Tata 1623 (rear- engined low-floor bus chassis)
 Tata 1518C (Medium truck) 10 ton
 Tata 1613/1615c (medium truck)
 Tata 1616/1618c (heavy duty truck)
 Tata 2515c/2516c,2518c (heavy duty 10 wheeler truck)
 Tata Starbus(branded buses for city, intercity, school bus, and standard
passenger transportation)
 Tata Divo(Hispano Divo)
 Tata CityRide(12- to 20-seater buses for intracity use)
 Tata 3015 (heavy truck)
 Tata 3118 (heavy truck) (8×2)
 Tata 3516 (heavy truck)
 Tata 4018 (heavy truck)
 Tata 4923 (ultra heavy truck) (6×4)
 Tata Novus (heavy truck designed by Tata Daewoo)
 Tata Prima (Tata Daewoo)
 Tata Ultra (ICV Segment)
 Tata Winger – Maxivan

2. Military vehicles

 Defence Combat Light Armored Multi Role Vehicle(Lamv)

 Defence Light Support Vehicle (LSuV)
 Defence Futuristic Infantry Combat Vehicle (FICV)
 Defence Combat Wheeled Armored Amphibious Platform (WHAP)

6
 e-Learning Module

 Defence Combat Light Armored Multi Role Vehicle (Lamv)

 Defence Light Support Vehicle (LSuV)

3. Tata LSV (Light Specialist Vehicle)

 Tata Mine Protected Vehicle (4×4)
 Tata 2 Stretcher Ambulance
 Tata 407 Troop Carrier
 Tata LPTA 713 TC (4x4)
 Tata LPT 709 E
 Tata SD 1015 TC (4x4)
 Tata LPTA 1615 TC (4x4)
 Tata LPTA 1621 TC (6x6)
 Tata LPTA 1615 TC (4x2)
 Tata LPTA 5252 TC (12x12)
 Tata Sumo 4x4
 Tata Xenon
 Tata 207
Tata Motors proposed overhaul of armoured fighting vehicles and
infantry main combat vehicles in 2015. The inter-ministerial
committee was chaired by Secretary in the Department of Industrial
Policy and Promotion (DIPP) approved most of the proposals from
the defence manufacturing sector in India.

4. Electric vehicles
Tata Motors has unveiled electric versions of the Tata
Indica passenger car powered by TM4 electric motors and
inverters, as well as the Tata Ace commercial vehicle, both of which
run on lithium batteries.
Tata Motors' UK subsidiary, Tata Motors European Technical Centre,
has bought a 50.3% holding in electric vehicle technology firm
Innovation of Norway for US$1.93 million, and plans to launch the
electric Indica hatchback in Europe next year. In September 2010,
Tata Motors presented four CNG–Electric Hybrid low-floored Star
buses to the Delhi Transport Corporation, to be used during

7
 e-Learning Module

the Commonwealth Games. These were the first environmentally

friendly buses to be used for public transportation in India.

Joint ventures:
Tata Marcopolo
Tata Marcopolo is a bus-manufacturing joint venture between Tata
Motors (51%) and the Brazil-based Marcopolo S.A. (49%). The joint
venture manufactures and assembles fully built buses and coaches
targeted at developing mass rapid transportation systems. It uses
technology and expertise in chassis and aggregates from Tata
Motors, and know-how in processes and systems for bodybuilding
and bus body design from Marcopolo. Tata Marcopolo has launched
a low-floor city bus which is widely used by transport corporations in
many Indian cities. Its manufacturing facility is based in Dharwad,
Karnataka State, India.

Fiat-Tata
Fiat-Tata is an India-based joint venture between Tata and Fiat
Automobiles which produces Fiat and Tata branded passenger cars,
as well as engines and transmissions. Tata Motors has gained access
to Fiat's diesel engine and transmission technology through the joint
venture .The two companies formerly also had a distribution joint
venture through which Fiat products were sold in India through joint
Tata-Fiat dealerships. This distribution arrangement was ended in
March 2013; Fiats have since been distributed in India by Fiat
Automobiles India Limited, a wholly owned subsidiary of Fiat.

Tata Hitachi Construction Machinery

Tata Hitachi Construction Machinery is a joint venture between Tata
Motors and Hitachi which manufactures excavators and other

8
 e-Learning Module

construction equipment. It was previously known as Telcon

Construction Solution.

Plants

9
 e-Learning Module

Pantnagar
This is Tata Motors ACE small truck plant. The plant had setup in
2007. The plant is spread over approximately 1000 acres land area.

The company has set up a plant for its mini-truck Ace and the
passenger carrier Magic (based on the Ace platform) at Pantnagar in
Uttarakhand. The plant began commercial production in August
2007. This is the company’s fourth plant, after Jamshedpur
(commercial vehicles), Pune (commercial vehicles and passenger
vehicles) and Lucknow (commercial vehicles). The plant is spread
over 1000 acres, of which 337 acres is occupied by the vendor park.
State-of-the-art facilities include weld shops, paint shops, engine and
gear box shops and assembly lines.

Jamshedpur
Established in 1945, the Jamshedpur unit is spread over an area of
822 acres and happens to be the Company's first manufacturing unit.
The Jamshedpur Plant's engine factory is responsible for the in-house
manufacture of Tata 697/497 Naturally Aspirated and Turbo Charged
engines, and the 6B series engines manufactured at Tata Cummins.

The Company also manufactures all major Axles components such as

Front Axle Beam, Stub Axles, Front & Rear Wheel Hubs, Differential,
Axle Gears (Crown Wheel, Pinion, and Bevel Gear & Shaft Gear),
Banjo Axle Beam, Swivel Heads, and Constant Velocity Shafts etc. HV
Axles Ltd. is a leading manufacturer of automotive transmissions,
components, gearboxes and engineering applications for a wide
range of medium & heavy commercial vehicles.

10
 e-Learning Module

Pune
The Pune unit is spread over two geographical regions - Pimpri (800
acres) and Chinchwad (130 acres). It was established in 1966 and has
a Production Engineering Division with one of the most versatile tool
making facilities in the Indian sub-continent. Our Pune facility rolls
out all makes of Tata Engines in both Diesel and CNG fuel options
and also has a dedicated assembly line for LCV Bus chassis. It is
engaged in the design and manufacture of sophisticated press tools,
jigs, fixtures, gauges, metal pattern and special tools, as well in the
design of models for development of new ranges of buses and
coaches.

Industry experts rate the fully automated Foundries at Chinchwad

and Maval among the best, worldwide.

Lucknow
Established in 1992 Tata Motors Lucknow is one of the youngest
production facilities of the Company and was set up to meet the
demand for Commercial Vehicles in the Indian market. The state-of-
the-art plant is strongly backed by an Engineering Research Centre
and Service system to support and cater to the complexities of
automobile manufacturing with latest technology. The Fully Built
Vehicle business, which is one of the fast growing business segments,
is also established in Lucknow.

The Lucknow plant rolls out commercial vehicles and is specialised in

the design and manufacture of a range of modern buses as well as
chassis including Low-floor, Ultra Low-floor, CNG & Rear Engine

11
 e-Learning Module

Buses. The Lucknow facility also specialises in manufacturing the

HCBS (High capacity Bus System) buses.

Sanand
Tata Motors in June 2010 rolled out the first Nano cars from its main
manufacturing plant at Northcote Cattle Farm. The construction time
was a record breaking 14 months. During the starting period the
production plant employed 2,400 staff. Including the indirect jobs
around the plant there were about 10,000 people depending on the
initial production.

The plant has a capacity to manufacture 250,000 cars a year in the

first phase, which will be scaled up to 500,000 cars a year. The
project, including Tata Motors plant, vendor facilities and a railway
transportation hub near Nidhrad Village, will together generate over
20,000 direct and indirect jobs. This plant uses Land of Gujarat
Agricultural University which was in the name of Government of
Gujarat.

Dharwad
The Dharwad manufacturing facility in Karnataka is the production
house for of Tata – Marcopolo buses. The state-of-the-art production
unit caters to India’s need for fully built buses for intra-city and inter-
city transportation with comfort, quality and safety that would meet
international standards.

The plant produces a comprehensive range of buses. The ‘Starbus’

range manufactured here includes 16 to 54-seater standard buses. B

12
 e-Learning Module

ABOUT TATA MOTORS PANTNAGAR

The Tata Motors' plant at Pantnagar is the site where the best-selling
Tata Ace - the mini one-tonne truck, and its variants are
manufactured. The plant is a world-class project that is spread across
1,000 acres in Uttarakhand's State Industrial Development
Corporation.

The Pantnagar plant has been built with state-of-the-art facilities and
is a key enabler of Tata Motors' leadership in the mini-truck
segment. It also produces a few SUV models as well as medium and
heavy vehicles.

The plant has been designed to enhance speed and efficiency in

manufacturing. It is the company's first plant with an integrated
vendor park, which occupies 337 acres of the plant's total area. This
helps keep inventory low and ensures 'just-in-time' (JIT) supplies. The
73 vendors based here account for nearly 75 percent of the items
supplied to the plant.

The general office at Pantnagar is a gold-rated green building, a

testament to the unit's efforts to reduce energy consumption and
boost energy efficiency. The plant has an Integrated Management
System (IMS) certification, which includes ISO TS: 16949, OHSAS
18001, ISO 14001, and ISO 50001.

The Company has set up a plant for its mini-truck Ace and the
passenger carrier Magic (based on the Ace platform) at Pantnagar in
Uttarakhand. The plant began commercial production in August
2007. This is the company's fourth plant, after Jamshedpur

13
 e-Learning Module

(commercial vehicles), Pune (commercial vehicles and passenger

vehicles) and Lucknow (commercial vehicles). The plant is spread
over 953 acres, of which 337 acres is occupied by the vendor park.

Models of Tata Ace produced in Tata Motors

Pantnagar:
ACE
The standard Ace HT is powered by a two-cylinder 702 cc engine,
delivering 16 hp (12 kW) at 3200 rpm and a torque of 3.8 kgf⋅m
(37 NM) at 2000 rpm. It has a permissible loading capacity of 750 kg
(1650 lb). It is equipped with a four-speed manual gearbox and has a
top speed of 60 km/h (37 mph). The Ace HT has a modern cabin
compared to its three-wheeler rivals. It is best suited for use by
villagers in carrying goods over short distances.
The Ace EX adds a five-speed gearbox, stop-start and larger wheels
(13" over 12") and wider tires (155 rather than 145), and a top speed
of 70 km/h.

SUPER ACE
The Tata Super Ace is a 1 Ton diesel mini truck aimed for Intra City
Applications and Last Mile Distribution, it has a loading deck length
of 2630 mm (the longest in its class) and a top speed of 125 km/h
(78 mph). The Super Ace has a miserly turning radius of 5.1 m and
boasts a mileage of 14 km/L (8.75 mpl), which gives it maximum
range of 440 km per its 38 L fuel tank. It has a three-way drop load
body which provides a mere 60 cm height for comfortable loading
and unloading.

MAGIC

14
 e-Learning Module

In June 2007 Tata Motors launched the passenger variant of the Ace,
named Magic featuring an all-steel cabin. It offers a flexible seating
capacity of 4-7 passengers with adequate legroom. Powered by a
16 bhp (12 kW), 702 cc water-cooled diesel engine, the Magic offers
high fuel efficiency and very low maintenance. The Magic's turning
radius of 4.3 metres (14.1 ft.) is nimble enough to navigate the by
lanes and traffic of India's crowded cities. The Magic has a clearly
visible instrument cluster, utility tray and a digital clock in the
dashboard and also a provision for fitting a radio. The Magic meets
BS-III emission norms and has been developed for use in any market
— be it urban, semi-urban or rural. It is backed by a 36,000 km/12-
month warranty. The Magic range starts at Rs 2.60 lakh (ex-
showroom, Pune).

INTRA
Tata Intra, the all-new small commercial vehicle (SCV)
from Tata Motors. The new compact trucks will be available
in two variants - V10 and V20, priced at ₹ 5.35 lakh and ₹
5.85 lakh (ex-showroom India) respectively. The new Tata
Intra compact truck is a premium offering and will be
positioned in India above the company's existing range of
Ace mini trucks, Both variants come with two trim levers,
with higher trim having HVAC, music system, LED tail lamps
along with enriched and colour coordinated interiors. Tata
INTRA is powered by future ready engines, which are
scalable to BSVI norms. The INTRA V20 comes with 1400
cc DI Engine with 52KW (70 HP) & INTRA V10 is powered
with 800 CC DI Engine delivering 30KW (40hp), offering
quick acceleration, faster trips and low turnaround time. The
vehicle has a standard power steering fitment and with low
turning circle radius of 4.75m.
It ensures easy manoeuvrability even on narrow and
congested roads. The power train is tuned to suit various
duty cycles using Gear Shift Advisor or economy switch,
leading to enhanced fuel efficiency. INTRA also has a 5-

15
 e-Learning Module

speed gearbox with cable shift mechanism offering a

pleasurable driving experience.

Shops at TATA motors pantnagar

The various shops at TATA motors Pantnagar
plant are-
1. Power Train
2. BIW(Body in White)
3. TCF(Assembly Shop)
4. Paint Shop
5. PDI(Pre Dispatch Inspection)

The flow of procedure with respect to various units at Pantnagar

plant can be expressed as per the following diagram:

It can be easily seen from above figure that the input of BIW unit is
directly dependent on market demands and design of the required
vehicle. The output of this unit act as the input for paint shop. The

16
 e-Learning Module

output of the paint shop and power train is further sent to the final
unit of the process in TCF.

BIW
 BIW means “BODY IN WHITE”.
 BODY IN WHITE is the stage in automobile design in which car
body sheet metal components have been welded together but
before moving parts (doors, hoods & deck lid as well as
fenders) the motors, chassis sub-assemblies or trim has been
added before painting.
 BIW- has shop capacity of 300 shell/day: 3 shift basis.
 This shop has 2 assembly lines:
a) ML-1: under body main line.
b) ML-2: framing main line.
 There are about 13 stations at ML-1 and 19 stations at ML-2.
 There are about 15 sub assembly welding fixtures and 7
inspection fixtures.
 In this shop types of welding is performed:
a) Spot welding
b) Co2 welding

17
 e-Learning Module

PAINT SHOP
An asset for TML Pantnagar is its paint shop. The largest paint shop
in Asia. This unit takes body in white as input from the weld shop and
then it completes the weld process of painting the whole body. The
basic function of this unit is as the name suggests cleaning and
colouring the vehicle body coming from weld shop. Paint shop is
divided into 2 parts:
 PTCED: Pre-treatment and cathode electrode deposition
 Top Coat

1. PTCED the welded body from BIW is received at this

department. Again synchronizers are used for demounting the
body from conveyors at the top level to the working area of
paint shop.
PTCED is further divided into 2 parts:
a. PT DEPT- Pre-treatment deposition
b. CE DEPT- Cathode electrode deposition

2. Top Coat when the body is processes from PTCED Department,

it comes to Top Coat. The process in this unit are mentioned
below:-

Colour Selection- The colour for different bodies are selected here.

Booth- The colouring area is commonly known as Booth. The process

in this area are:

18
 e-Learning Module

 Primer Coating
 Cleaning
 Painting

Oven- After colouring is completed on the body, it is sent to the oven

to get baked so the colours can settle properly.

Polishing Line- After the completion of painting, the body is sent to

polishing where it gets glassy look.

Wax line/ Blackout- Waxing is done in the area of the body. Black
paint is also applied in the special area like over engine fixture to
absorb heat. Now output of paint shop is ready and it is dispatched
to the TCF through the conveyor. The body is mounted using
synchronizer.

POWER TRAIN
In a motor vehicle, the term power train refers to the group of
components that generate power and deliver it to the road surface,
water, or air. This includes the engine, transmission, drive shafts,
differentials, and the final drive (drive wheels, continuous track like
with tanks or Caterpillar tractors, propeller, etc.). Sometimes “Power
Train” is referred as simply the engine and transmission, including

19
 e-Learning Module

the other components only if they are integral to the transmission. In

a carriage or wagon, running gear designates the wheels and axles in
distinction from the body.
A motor vehicle’s driveline consists of the parts of the drive train
excluding the engine and transmission. It is the portion of a vehicle,
after the transmission that changes depending on whether a vehicle
is front - wheel drive, rear-wheel drive, four-wheel drive, or the more
exotic Six-wheel drive.
In a wider sense, the power train includes all of its components used
to transform stored (chemical, solar, nuclear, kinetic, potential, etc.)
energy into kinetic energy for propulsion purposes. This includes the
utilization of multiple power sources and non-wheel based vehicles.
The power train comprises of mainly 2 shops:
 GEAR BOX SHOP
 ENGINE SHOP

TCF-ASSEMBLY SHOP
This is last centre for the manufacturing process. TCF is commonly
known as assembly shop. There are total three TCF units at TATA
recognized as Assembly shop A, Assembly shop B, Assembly shop C.
There are total three sources of input for this section, they are-
 Vendors
 Paint shop
 Power train
The painted body of the vehicle is received from paint shop. The
power train provides the engine gear assembly and other parts come
from vendor.
The whole TCF unit is divided into three main sections-
 Trim line

20
 e-Learning Module

 Under body line

 Mechanical line

1. TRIM LINE- This line is further subdivided into various stations

where each stations has been assigned a particular job. The basic
function of this unit is to receive the painted body from the
conveyors with the help of synchronizers. Then the gate from the
body is removed and is sent to door assembly line. With the removal
of the gate whole body is covered properly to avoid any harm to the
paint and outer report. In trim line, the assembly of front and rear
end of the vehicle is completed. The complete circuitry, insulation
etc., of a dash board is done here. All kinds of tube connectivity are
completed in this section. Here glasses, stencils are also fitted in the
body. In the door assembly line complete door is assembled. The
rubber padding, handles, locks etc., are completed and then it is sent
to the end of trim line where it is attached to the body before
preceding it to under body line. Hence at the output of the trim line
the assembly of the front and back part is completed.

2. UNDER BODY LINE- This is very critical line in this unit as the under
body of the vehicle i.e., engines, front axle, rear axle, brake wire and
suspension, are assembled in this section. The engine gear assembly
which is sent by the power train is received and fit into the body of
vehicle. At this unit the assembly of the vehicle is completed.
3. MECHANICAL LINE- In this unit the vehicle is checked as
mechanical aspects. Here engine oil, coolant, petrol are fed into
vehicles, tyres fitment is done and flashing of ECU is also done in this
line. Other mechanical aspects are also checked and are rectified if
some error is encountered. In this unit all the lines and stations are
interconnected. The movement among them is handled through
conveyors and fixtures which are controlled by PLCs.

21
 e-Learning Module

4. END OF LINE-these are the stations which are responsible of bolt

tightening, 30-30 angle setting and RBT (roll and break test) of
vehicle from here the vehicle is sent to shower testing and then it is
finally tested on test track from where if OK then the vehicle is sent
to dispatch yard otherwise it is sent to rework/repair department for
error verification and solving.

22
 e-Learning Module

INTRODUCTION
Introduction to Digital Manufacturing:
Digital manufacturing is the application of digital technologies to
manufacturing. It is all about having the right information, at the
right place, at the right time. The goal is to link disparate systems and
span processes across all departments and functions within the value
chain. By doing so, the entire product lifecycle is impacted – from
design to production to servicing of the final product(s) .These
systems are based on the digital factory/manufacturing concept,
according to which production data management systems and
simulation technologies are jointly used for optimizing
manufacturing before starting the production and supporting the
ramp-up phases. With digital manufacturing systems, each
stakeholder gains quicker access to more accurate data.

Manufacturing facility planning capabilities

• Digital simulation and virtual planning
• Facility planning, installation and start up
• Development of jigs and fixtures

Digital tools to support such work are used, in particular:

• Delmia Quest (facility planning) Creation of conceptual layouts and
simulations of throughput to establish capacity constraints and
process bottlenecks, based on initial volumes and estimated cycle
times.
• Press panel feasibility
• Body In White (BIW), part sub-assembly and BIW body assembly

23
 e-Learning Module

• Paint technology
• Trim and final assembly techniques
• Powertrain manufacture
• Launch management
• Manufacturing leadership and management
SCOPE
The recent growth of digital manufacturing institutes across the
country talks its growth in one way published close to 25k jobs for
digital manufacturing for the first half of this year digital
manufacturing is relatively less expensive compared to conventional
marketing Growth of smart phones and the easy access to internet
pave way to digital manufacturing faster So we can expect this
industry would go higher levels in coming years.

PRODUCTIVITY GROWTH CHART

Digital manufacturing has just taken first step in India. Industry 4.0 is
still to come in India. With international companies putting their
manufacturing plants in India, scope will increase, but I personally
suggest you to invest your time and money in practical
manufacturing knowledge instead of learning data science and
software. Manufacturers have to think harder than most to find new

24
 e-Learning Module

ways of increasing revenue. Global demand for manufactured

products is growing, but not fast enough. Digital Transformation
Innovation Stock - June 2016 Accenture reports that 86% of
manufacturing companies say technology will increase “rapidly” or
“at an unprecedented rate” between 2017 and 2020. Output is
predicted to increase by just 3.4% in 2017, according to the
International Monetary Fund. Brexit concerns and political
uncertainties are dampening expectations.
It’s an uneasy world to live in – and one that requires constant
innovation to stay ahead. Digitisation provides it. By improving
processes, saving time and money and creating closer Connections
with customers, it’s changing the future of manufacturing – it’s
happening now. But digitisation comes at a price. To take full
advantage, businesses have to invest in new operating models,
training and equipment. Digital technologies can improve
manufacturing operations. By automating processes, identifying
weaknesses and bottlenecks in the production chain and pre-testing
new ideas before implementing them, your business can save time
and money, while using employee time more effectively. Initiatives
like e-sourcing, automatic stock replenishment, KPI monitoring and
predictive disruption analytics give you the freedom to monitor
factory performance as it happens, and make improvements quickly
where needed. It’s a smoother, slicker way of working. Innovate
more easily A digital factory design is a far more flexible workplace.
Instead of the traditional, linear approach, where machinery is built
based on designers’ sketches and development cycles are soloed,
digitisation makes it possible to plan and develop in tandem. That
way, potential weaknesses can be identified and fixed as you go,
rather than in hindsight. Exciting new technologies like 3D modelling
systems and data connectivity enable factories to be configured and
reconfigured faster and more easily than ever before – for less
money.
There’s a lot of ingenious, well-engineered machinery out there.
However, the original designs –and the reasons for creating them –
are often locked inside the heads of only a few people. As time

25
 e-Learning Module

passes and personnel changes, those vital insights and secrets are
lost. Ultimately, no one in your organisation might know why a
particular machine is configured a certain way – making upgrades
and replacements more complex to carry out.

LEARNING

PROJECT OBJECTIVE
1. To study the process and to create a short a short video of a
particular process which is also known as Digital WIS (Work
Instruction Sheet).
2. For better understanding of an operator for the particular fitment
process.
3. To reduce the time of training of a new operator who is newly
coming in industry.

PROJECT REQUIREMENT
The project is required for the new coming operators as well for the
ones who are already working. When a new operator joins the
industry they don’t know about the different running processes in
the industry. At the first they are send to TRAINING DIVISION, where
they are divided into different department according to their interest
or as per the industry need. With the help of TRAINING DIVISION
team they are well trained accordingly, but it is time consuming
process. Hence to improve the learning process e-Learning comes in
role. e-Learning stands for electronic learning and typically means
delivering all or part of a course digitally. e-Learning is not bound to
geography or time , you can control training’s impact on production
by training people during down times and it enables much faster
delivery of learning.

26
 e-Learning Module

CROSS FUNCTIONAL TEAM

A group of people with different functional experience working
towards a common goal. Typically includes employees from all the
levels of an organisation. Each member offers an alternative
perspective to the problem and potential solution to the task.
The different group of people from different department who
worked on the project were
1. DIGITAL MANUFACTURING DEPARTMENT- All the raw
data collected is the compiled with the help of video compiling
tool (xyz) and the final outcome is produced from the
department in the form of e-learning videos.

2. PRODUCTION DEPARTMENT – It brings together resources

including materials, manpower, tools, equipment, technology,
and facilities in a structured organised manner to produce the
finished product. The raw data in the form of videos or images
are captured in the production department.

3. HR (Learning and Development) – Are the people who make up

the workforce of an organisation. Helps in creating the bridge
between the digital manufacturing and production department.

4. SAFETY DEPARTMENT – They help us in mentioning the

different point in the fitment process for the learning of the user.

DATA GATHERING AND COMPILATION

27
 e-Learning Module

1. After gathering the information from the shops, the raw

data must be compiled so that the data can be broken into
respective parts and segments.
2. Data cleaning performed before the analysis which is
very important to fetch desirable results.

The steps for DATA GATHERING AND COMPILATION are

1. Identify the fitment process
2. Understanding the process
3. Selective desirable method
4. Plan an approach and method
5. Collect and filter the data
6. Compile the data and recheck
7. Final work in output

Hence the DATA GATHERING AND COMPILATION are in three stages

a) QUANTITATIVE
b) QUALITATIVE
c) MIXED

KEY CHALLENGES
The challenge in something new and difficult which requires great
effort and determination,
While working in a project the key challenges we faced were:
1. Line was running so the pace of work have to be maintained
with the line.
2. There should not be any kind of odd material in the background.
3. To ensure tools, table, safety PPE’s used, should be in good
condition.

28
 e-Learning Module

4. Operator should not be disturbed during the fitment process to

avoid any production loss.

KEY LEARNING
Time in a project at which learning takes place, topics about how the
process is performed.

The key points that we have learned during an activity:

1. Different fitment process we worked on.
2. Different tools and equipment used in the fitment.
3. Step by step process for a particular fitment process.
4. Defects which can come over a particular fitment.
5. About the safety PPE’s.
6. Rules and regulations in the shop.
7. Making of e-Learning modules which can be used for learning
of any physical process.

DELIVERABLES
Through the project we were able to deliver easy learning. As virtual
learning is better than primitive techniques of learning.

BENEFITS
The benefits of the project we worked on are
1. Better understanding of the processes.
2. Learning made easy for new operators.
3. When in trouble, the solutions can be found in the videos.
4. DO’S and DON’T’S are mentioned in the video.
5. Safety measures and precautions related to the process are
mentioned in the video.
6. Safety, quality, quantity for the process to be known.
7. Reduces lead time for any new product development.

29
 e-Learning Module

8. Reduce the rework time.

9. Facilitates the team to validate all the new or revised products
over the fixture.
10.Precise dimensional observation and report sharing can be
done which also helps the product design team.
11.Best and fastest way for feasibility study of a new product over
time.

TOOL USED
The project we worked on used different tools.
1. MANUFACTURING TOOLS
2. SOFTWARE TOOLS

1. MANUFACTURING TOOLS
Tools used physically to complete the particular process. Some
of the tools used were common in most of the fitment process.
The general tool used in most of the process are Pneumatic
gun, battery gun, torque wrench, mallet hammer, sockets etc.

Battery Gun

30
 e-Learning Module

SPANNER

PNEUMATIC GUN

SOCKET

31
 e-Learning Module

MALLET HAMMER

2. SOFTWARE TOOLS - A computer program that is used by

Digital Mfg. Team for creating, editing, maintaining, supporting
etc. PLM, team centre, video compiling tools (xyz), used in the
project.
 Video compilation tool - A software suite, created and
published by a renowned software company, for creating video
tutorials and presentations directly via screencast, or via a
direct recording plug-in to Microsoft PowerPoint. The screen
area to be recorded can be chosen freely, and audio or other
multimedia recordings may be recorded at the same time or
added separately from any other source and integrated in the
component of the product. Both versions of tool started as
enhanced screen capture programs and have evolved to
integrate screen capture and post-processing tools targeted at
the educational and information multimedia development
marketplace
 PLM -As an information strategy, PLM builds a coherent data
structure by consolidating systems. As an enterprise strategy,
PLM lets global organizations work as a single team to design,
produce, support and retire products, while capturing best
practices and lessons learned along the way. PLM empowers

32
 e-Learning Module

your business to make unified, information-driven decisions at

every stage in the product lifecycle.

SHOPS VISITED IN TATA MOTORS PANTNAGAR

BIW
BIW means “BODY IN WHITE”.
BODY IN WHITE is the stage in automobile design in which car body
sheet metal components have been welded together but before
moving parts (doors, hoods & deck lid as well as fenders) the motors,
chassis sub-assemblies or trim has been added before painting. Weld
shop BIW- has shop capacity of 300 shell/day: 3 shift basis.
This shop has 2 assembly lines:
o ML-1: under body main line.
o ML-2: framing main line.
There are about 13 stations at ML-1 and 19 stations at ML-2.There
are about 15 sub assembly welding fixtures and 7 inspection fixtures.
In this shop types of welding is performed are:
a) Spot welding
b) Co2 welding

33
 e-Learning Module

TCF- ASSEMBLY SHOP

This is last centre for the manufacturing process. TCF is commonly
known as assembly shop. There are total three TCF units at TATA
recognized as Assembly shop A, Assembly shop B, Assembly shop C.
The painted body of the vehicle is received from paint shop. The
power train provides the engine gear assembly and other parts come
from vendor. The whole TCF unit is divided into four main sections-
 Trim line
 Under body line
 Mechanical line
 End of line
1. Trim line- This line is further subdivided into various stations
where each stations has been assigned a particular job. The basic
function of this unit is to receive the painted body from the
conveyors with the help of synchronizers. Then the gate from the
body is removed and is sent to door assembly line. With the removal
of the gate whole body is covered properly to avoid any harm to the
paint and outer report. In trim line, the assembly of front and rear
end of the vehicle is completed. The complete circuitry, insulation
etc., of a dash board is done here. All kinds of tube connectivity are
completed in this section. Here glasses, stencils are also fitted in the
body. In the door assembly line complete door is assembled. The
rubber padding, handles, locks etc., are completed and then it is sent
to the end of trim line where it is attached to the body before
preceding it to under body line.
2. Under body line - This is very critical line in this unit as the under
body of the vehicle i.e., engines, front axle, rear axle, brake wire and
suspension, are assembled in this section. The engine gear assembly
which is sent by the power train is received and fit into the body of
vehicle. At this unit the assembly of the vehicle is completed.

34
 e-Learning Module

3. Mechanical line- In this unit the vehicle is checked as mechanical

aspects. Here engine oil, coolant, petrol are fed into vehicles, tyres
fitment is done and flashing of ECU is also done in this line. Other
mechanical aspects are also checked and are rectified if some error is
encountered. In this unit all the lines and stations are
interconnected. The movement among them is handled through
conveyors and fixtures which are controlled by PLCs.
4. End of line-these are the stations which are responsible of bolt
tightening, 30-30 angle setting and RBT (roll and break test) of
vehicle from here the vehicle is sent to shower testing and then it is
finally tested on test track from where if OK then the vehicle is sent
to dispatch yard otherwise it is sent to rework/repair department for
error verification and rectification.

POWER TRAIN
In a motor vehicle, the term power train refers to the group of
components that generate power and deliver it to the road surface,
water, or air. This includes the engine, transmission, drive shafts,
differentials, and the final drive (drive wheels, continuous track like
with tanks or Caterpillar tractors, propeller, etc.). Sometimes “Power
Train” is referred as simply the engine and transmission, including
the other components only if they are integral to the transmission. In
a carriage or wagon, running gear designates the wheels and axles in
distinction from the body.
A motor vehicle’s driveline consists of the parts of the drive train
excluding the engine and transmission. It is the portion of a vehicle,
after the transmission that changes depending on whether a vehicle
is front - wheel drive, rear-wheel drive, four-wheel drive, or the more
exotic Six-wheel drive.
The power train comprises of mainly 2 shops:

35
 e-Learning Module

 GEAR BOX SHOP

 ENGINE SHOP

OTHER THINGS LEARNT

5s
The 5S Methodology;
5S is a system to reduce waste and optimize productivity through
maintaining an orderly workplace and using visual cues to achieve
more consistent operational results. Implementation of this method
"cleans up" and organizes the workplace basically in its existing
configuration, and it is typically the first lean method which
organizations implement.

36
 e-Learning Module

The 5S pillars are to provide a methodology for organizing, cleaning,

developing, and sustaining a productive work environment. In the
daily work of a company, routines that maintain organization and
orderliness are essential to a smooth and efficient flow of activities.
This lean method encourages workers to improve their working
conditions and helps them to learn to reduce waste, unplanned
downtime, and in-process inventory.

DIFTR
Do It First Time Right (DIFTR) is a theory from managerial accounting
that relates to just-in-time (JIT) inventory where a company only
receives goods as they are needed to cut down on inventory
costs and production management. The idea behind DIFTR is that
management wants all of the processes that makeup the JIT
philosophy to be done correctly and efficiently, so there are no
delays in the production process.

37
 e-Learning Module

BREAKING DOWN ‘Do It First Time Right- DIFTR’

The importance of Do It Right the First Time (DRIFT) arises from the
fact that a JIT production system is heavily reliant on the movement
of parts and information along the production process.
Subsequently, if there is the slightest error at one of the stages of
production, the whole production process will be affected. By "doing
it right the first time" a company is able to run a smooth production
process without the need to carry excessive inventory, which will
help diminish the costs of production

QCOS
Over view of QCOS (Quality control operation system)
Torque Qcos is a standardized practice applied to all threaded
fasteners operation with the no. of ensuring torque control. All
fasteners require a minimum level of control. Some critical fasteners,
determined by product engineering, require a higher level of control.
PURPOSE:

38
 e-Learning Module

To ensure that each torque process is capable of meeting its defined

product quality standards facility.
1. To detect process or product failure early in the system to prevent
disruption in a manufacturing facility.
2. to deliver a safe, reliable, and high quality vehicle to our
customers.
SCOPE:
All threaded fasteners secured in an assembly lines. Torque wrench
with calibration date.
Qcos Scoring Parameters Points earned by any torque process is
calculated by summing up all points earned on the following
parameters
1 Tooling
2 Inspection
3 Error detection
4 Process monitoring

QCOS FOR TORQUE PROCESS

QCOS for torque process is a standardized practice applicable to the
Manufacturing shops where torque application is done to join the
two Components / Assemblies by threaded fasteners.
Vehicle assembly –All fastening joints
BIW –Door hinge, Side gate, Tail gate joints
Transaxle –All fastening joints

39
 e-Learning Module

All fasteners require a minimum level of control. Some critical

fasteners, determined by Product Engineering require a higher level
of control. QCOS helps in achieving adequate torque control.
The QCOS Plan is developed by Central Manufacturing Engineering
based on data provided by Product Engineering and Quality. QCOS
Implementation is a Plant responsibility.

FIRST IN FIRST OUT METHOD (FIFO)

The first in, first out (FIFO) method of inventory valuation is a cost
flow assumption that the first goods purchased are also the first
goods sold. In most companies, this assumption closely matches the
actual flow of goods, and so is considered the most theoretically
correct inventory valuation method. The FIFO flow concept is a
logical one for a business to follow, since selling off the oldest goods
first reduces the risk of obsolescence
Under the FIFO method, the earliest goods purchased are the first
ones removed from the inventory account. This results in the
remaining items in inventory being accounted for at the most
recently incurred costs, so that the inventory asset recorded on
the balance sheet contains costs quite close to the most recent costs
that could be obtained in the marketplace. Conversely, this method
also results in older historical costs being matched against current
revenues and recorded in the cost of goods sold; this means that
the gross margin does not necessarily reflect a proper matching of
revenues and costs. For example, in an inflationary environment,
current-cost revenue dollars will be matched against older and
lower-cost inventory items, which yields the highest possible gross
margin.
The FIFO method is allowed under both Generally Accepted
Accounting Principles and International Financial Reporting
Standards. The FIFO method provides the same results under either
the periodic or perpetual inventory system.

40
 e-Learning Module

The Advantages of FIFO

 It is easy to apply.
 The assumed flow of costs corresponds with the normal
physical flow of goods.
 No manipulation of income is possible.
 The balance sheet amount for inventory is likely to
approximate the current market value.
All the advantages of FIFO occur because when a company sells
goods, the first costs it removes from inventory are the oldest unit
costs. A company cannot manipulate income by choosing which unit
to ship because the cost of a unit sold is not determined by a serial
number. Instead, the cost attached to the unit sold is always the
oldest cost. Under FIFO, purchases at the end of the period have no
effect on cost of goods sold or net income.
The disadvantages of FIFO
1. The recognition of paper profits.
2. A heavier tax burden if used for tax purposes in periods of
inflation. We discuss these disadvantages later as advantages of
LIFO.

TWO –BIN

41
 e-Learning Module

What is a 'Two-Bin Inventory Control'?

Two-bin inventory control is an inventory control system used to
determine when items or materials used in production should be
replenished. The two-bin inventory control method is mainly used
for small or low-value items. For example, when items in the first bin
(working stock) have been depleted, an order is placed to refill or
replace these items. The second bin is supposed to have enough
items to last until the placed order arrives. The first bin has a
minimum of working stock and the second bin keeps reserve stock or
remaining material. Bin cards and store ledger cards are used to
record the inventory.
If you regularly use small parts, you can significantly reduce the cost
by making use of the Kanban, or two-bin, system. Agricultural
machinery and ship equipment manufacturers, the automobile and
basic metal industries, and manufacturers of machines for the food
industry make extensive use of this logistics system. ‘Never short of
parts’ is the key to this system. The 2-bin system is simple: first, the
content and location are determined at the same time in the
warehouse (centrally) or on the work floor (de-centrally). After that,
we determine various parameters like; visit frequency, seasonal
peaks, packaging units, product value and quantity, the contents of
the bins. If the bin is empty, then the second bin is automatically
used while the first is removed. At robot, the empty bins are scanned
and refilled.

42
 e-Learning Module

CONCLUSION
This was the first time when Tata motors gave me a chance to do
industrial training in their prestigious organization where I gained
practical knowledge. With the help of e-Learning modules
(manufacturing operations) the user will find it easy to learn
different processes. While working on the project I was able to
understand different assembly processes and it was easily concluded
that virtual studying is easier than primitive studies. And with the
help of e-Learning modules time will be saved and smart work will be
done. I came here with theoretical knowledge but will go home with
practical experience and companions. The thing that I would like to
mention is that from the first day in the plant I was repeatedly taught
about safety, discipline and workplace ethics. I am glad that I came
here for my training and I would like to come here again if given
opportunity.

43