Documente Academic
Documente Profesional
Documente Cultură
03.12.2014 - 18.12.2014
NAME: V.JAYAPRAKASH
ROLL NO: 11A118
BRANCH: AUTOMOBILE ENGINEERING
COLLEGE: KARPAGAM COLLEGE OF ENGINEERING
I hereby declare that the report work entitled “IN PLANT TRAINING
REPORT” submitted to KARPAGAM COLLEGE OF ENGINEERING,
COIMBATORE is a record of an original work done by me at Daimler India
Commercial Vehicles private limited.
JAYAPRAKASH V
COIMBATORE
PREFACE
I owe a great thanks to many people who supported me during the project.
For this opportunity I thank:
SYNOPSIS:
EXECUTIVE SUMMARY
COMPANY PROFILE
TRAINING DESCRIPTION
CONCLUSION
EXECUTIVE SUMMARY:
As of 2014, Daimler owns or has shares in a number of car, bus, truck and
motorcycle marques including Mercedes-Benz, Mercedes-AMG, Smart
Automobile, Freightliner, Western Star, Thomas Built Buses, Setra, BharatBenz,
Mitsubishi Fuso, MV Agusta as well as shares in Denza, KAMAZ, Beijing
Automotive Group, Tesla Motors, and Renault-Nissan Alliance. The Maybach
marque was closed at the end of 2012, but was revived in November 2014 as
"Mercedes-Maybach", an ultra luxury edition of the Mercedes-Benz S-Class.
COMPANY PROFILE
Daimler India Commercial Vehicles Pvt. Ltd (DICV), a 100% wholly owned
subsidiary of Daimler AG, on 10th July 2013, rolled out the 5000th truck
from its plant at Oragadam, near Chennai. DICV is stabilizing its production
line of all its launched models. Currently, DICV produces the 2523, 3123,
2528, 914, 1214 & 1217 (Heavy, Medium/Light-duty rigid & tipper trucks)
with several variants.
ON MARCH 6TH 2014, Daimler laid the foundation stone for its new bus
plant.The new Bus manufacturing plant is spread across an area of 27.91
acres will be constructed within the existing premises of DICV. The bus
plant will manufacture and assemble buses under the Mercedes-Benz and
BharatBenz brands and will be completed by the 2nd quarter 2015. The
DICV plant in Oragadam will thus be the only Daimler Truck plant
worldwide, that manufactures three brands of Trucks and Buses, as well as
engines under one roof. Daimler India buses will be offered in 9t, 16t and
above 16t categories in both front and rear engine configurations. An
investment of INR 425 Cr has been earmarked for the bus project in India
for an installed capacity of 1500 units in the initial phase. The capacity can
be further expanded to 4000 units subsequently. On 10th April 2014,
Daimler’s BharatBenz trucks rode on high gear and crossed 10,000 units
sale. In the beginning of 2014, Daimler achieved the following:
Crosses sale of 1,000 units in a month in March 2014
STUDY ON 5’S:
5’S basic powerful tool for improving quality.
5’S is fundamental clean up of the work environment .
Clean up leads to improved efficiencies improved quality and reduced
costs.
5’S is a technique that provides the foundation for visual management.
THE 5’S :
SORT.
SET IN ORDER.
SHINE.
STANDARDIZE.
SUSTAIN.
SORT:
SORT CHECKLIST:
Review and use the Item Disposition List as the criteria for red tagging.
Gather needed supplies, including Red Tags.
Set up a red tag Holding area. Mark the location, identify a red tag holding
area manager, write and post standards and rules for disposition.
Create and implement initial sort plan to purge the for unnecessary items.
Fill out a log sheet listing all items removed from the area.
Continue to Sort, through Red Tagging,as the other 5S System steps are
implemented.
SET IN ORDER:
Analyse the current situation by updating the Workplace Scan Display
Checklist.
Target specific issues.
Decide where things belong.
Make it visually obvious where and how things belong.
SHINE:
Check to see if everything is in its place.
Check to see if you need to replace anything.
Check everything; see if deep cleaning, repair, or replacement is needed.
Shine and inspect through cleaning every shift.
SHINE CHECKLIST:
Systematically determine targets and assignments.
Determine appropriate cleaning methods.
Get the right tools and supplies.
Perform initial cleaning of targets.
STANDARDIZE:
Identify and categorize a condition to standardize.
Assign responsibilities for condition maintenance.
Maintain and monitor those conditions .
STANDARDIZE CHECKLIST:
Prepare the standardization chart.
Identify standardization issues.
Identify and attain desired conditions for Sort, Set in Order, and Shine.
Make all standards clear and obvious.
Monitor and improve all standards.
SUSTAIN:
The first four pillars rely on sustain .
Stick to the rules to keep the workplace well-ordered and run by
agreed-upon standards.
Ensure that all workers have been trained in the procedures.
SUSTAIN CHECKLIST:
Create a plan for Sustaining.
Ensure that you have management support for the plan.
Inform everyone in the area about the 5S standards and their
purposes.
STATIONS IN FULLY BUILT VEHICLE:
STATION-1:
Chassis preparation for vehicle is done here for both HDT (Heavy
Duty Trucks) and MDT (Medium Duty Trucks) Vehicles.
Operation:
1. Workers remove tail lamp by removing bolts .
2. Balata pasting. Balata is aligned properly along the chassis.
3. Workers make note of time in and
Time out vehicle.
4. Documentation checking.
SAFETY MEASURE:
1. Safety gloves.
2. Safety shoes .
TOOLS USED:
1. Balata clam.
2. Torque wrench.
3. Cable tie cutter.
4. Ring spanner.
STATION-2:
Load body is mounted for both MDT and HDT at this station where
respective body for the vehicles are supplied through logistics bay 1.
Operation:
From logistics bay 1 the body is carried to station 2 with a help of
the crane and it is mounted to chassis and it is literally clamped. The various types
body mounted are rock, box and Rigid.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
3. Goggles.
4. Safety helmets.
STATION -3:
In this station clamping of U-Bolt and Mudguard fitment is done.
Operation:
The workers clamp the U-blot by using tools like pneumatic gun and spanners
where the materials are supplied through Logistics Bay. After clamping with the
help of the tools the vehicle is moved to next station using Easy mover.
TOOLS USED:
1. Torque wrench.
2. Ring spanner.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
3. Safety helmets.
STATION-4:
In this station fitted load body fastener tightening is done .
Operation:
The fitted load body is fastener tightening is done using
pneumatic gun and ring spanner along the chassis and fitting of back light is done
which is removed in the station 1 . After clamping with the help of the tools the
vehicle is moved to next station using Easy mover.
TOOLS USED:
1. Torque wrench.
2. Ring spanner.
3. Spanner.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
3. Safety helmets.
STATION -5:
In this station SUPD (Side Under Protective Device ) and Wheel choke Fitment
is done .
Operation:
Fitting protective guards along both sides of vehicle and and
fitting wheel choke along both sides . After clamping with the help of the tools
the vehicle is moved to next station using Easy mover.
TOOLS USED:
1. Torque wrench.
2. Ring spanner.
3. Spanner.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves .
STATION -6:
In this station the clamped mudguard is tightened and quality of the mounted body
is checked.
Operation:
The Mudguard tightening is done using pneumatic spray gun and
quality of the mounted body is checked other than paint all the quality of the
mounted body is checked and after checking the quality it is moved to the next
station.
TOOLS USED:
1. Torque wrench.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
STATION -7:
In these station quality and In-line rework are done.
Operation:
In this station minor rework which can done within 10 minutes are
done at these station and quality of the mounted body is checked . If quality is
checked without any issues then the vehicle comes under FTT. If it is not under the
quality it is moved to rework bay which doesn’t comes under FTT.
TOOLS USED:
1. Hammer.
2. Pneumatic spray gun.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
REWORK BAY:
In this station major rework like painting are done both on the body and along the
chassis and inside the chassis. The rework which cannot be done within 10
minutes are done here.
TOOLS USED:
1. Torque wrench.
2. Ring spanner.
3. Pneumatic spray gun.
4. Hammer.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
3. Goggles .
LOGISTICS BAY:
Through Logistics Bay materials are supplied to the respective station on the
requirements for every station .