A

project Report
on
“Implementation of World class Quality and Safety
Improvement”
At

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 1. INTRODUCTION TO TATA MOTORS COMPANY

Tata Motors Limited (formerly TELCO, short for Tata Engineering and Locomotive
Company) is an Indian multinational automotive manufacturing company
headquartered in Mumbai, Maharashtra, India, and a subsidiary of the Tata Group.
Tata Motors is India’s largest automobile company. Tata Motors Group, a USD 42
billion organisation, is a leading automobile manufacturer with a portfolio that
includes a wide range of cars, sports vehicles, trucks, buses and defence vehicles.
Our marque can be found on and off-road in over 175 countries around the globe. It
is the world's 5th-largest motor vehicle manufacturing company, fourth-largest truck
manufacturer, and second-largest bus manufacturer by volume.

Tata Motors has auto manufacturing and assembly plants in Jamshedpur,

Panthnagar, Lucknow, Sanand, Dharwad, and Pune in India, as well as in Argentina,
South Africa, Great Britain and Thailand. It has research and development centres in
Pune, Jamshedpur, Lucknow, and Dharwad, India and in South Korea, Great Britain
and Spain.
Established in 1945, Tata Motors’ presence indeed cuts across the length and
breadth of India. Over 9 million Tata vehicles ply on Indian roads, since the first
rolled out in 1954. That Supported by a nation-wide dealership, sales, services and
spare parts network comprising about 6,600sales and service points. The company
also has strong auto finance Operation, Tata Motor Finance.

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 IMPORTANT DEFINITIONS:

❖ Gross Combined Weight (GCW): The total weight of a vehicle, including all
its cargo, plus the weight of a trailer and its entire contents.

❖ Gross Combined Weight Rating (GCWR): The maximum allowable weight

of the GCW as specified by the manufacturer. Exceeding this limit
compromises safety. What you need to know: Vehicles that operate above the
GCWR are a potential safety hazard because the engine, frame, suspension,
brakes and tires are not designed for weight above the rating the
manufacturer has set.

❖ Gross Vehicle Weight (GVW): Maximum legal weight at which a vehicle can
be operated. The total weight of a vehicle with driver and passengers, cargo,
fuel, coolant. Any dealer or after-market installed accessories, and tongue
weight if towing.

❖ Gross Vehicle Weight Rating (GVWR): It is the maximum permissible total

weight of the vehicle that may not be exceeded, as designated by the
manufacturer. GVWR is identified on the manufacturer's label, which is
usually located on the driver's door or door jam. What you need to know.
Vehicles that operate above the GVWR are a potential safety hazard because
the engine, frame, suspension, brakes and tires are not designed for weight
above the rating the manufacturer has set.

❖ Curb Weight: The weight of an empty vehicle, without cargo and driver and
passengers, but including maximum amounts of fuel, oil, coolant and standard
equipment including the spare tire and tools.

❖ Payload: The maximum amount of weight, including driver and passengers

that can be carried in the truck’s bed and cabin. Basically, the payload is the
GVWR minus the Curb Weight.

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 ABOUT VEHICLE CLASSIFICATION

In the Commercial Vehicle Business Unit. The models are classified on the basis of
GVW as under:
LCV: Low Commercial Vehicle.
MCV: Medium Commercial Vehicle
HCV: High Commercial Vehicle.
The HCV segment can be further classified into three segments based on gross
vehicle weight as follows:

• ICV: Intermediate Commercial Vehicle with GVW of 8 to10 ton.

• MCV: Medium Commercial Vehicle with GVW of 10 to15 ton.
• HCV: Heavy Commercial Vehicle with GVW of 16 ton and above.

MCV& HCVs are also classified into two categories depending on their usage as
Trucks and Buses. Buses are passenger carriers. Trucks include goods carriers
along with specialized vehicles like dumpers, tractor-trailers etc. The ICVs fall in the
load category of 8 to 10 ton GVW& are often substituted for medium or heavy
commercial vehicles in trunk routes or cities.

NAMING CONVENTIONS:

Any bus or truck will always be named by its classification. The last two digits
multiplied by indicates the Brake Horse Power (BHP) rating of the engine.

The digits in the prior to last two digits indicates the Gross Vehicle Weight (GVW)

GVW= PAYLOAD+ VEHICLE WEIGHT

That is:

607: GVW= 6 Tonnes, 7*10= 70 BHP

LP stands for full forward control bus model.

LPT stands for full forward control truck model.
LPK stands for full forward control tipper.
LPO stands for full forward control with extra overhang.
SFC stands for semi forward control.

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BIW (BODY IN WHITE) SHOP

What is Body in White?

Body in white or BIW refers to the stage in automotive design or automobile

manufacturing in which a car body's sheet metal components have been welded
together - but before moving parts (doors, hoods, and deck lids as well as fenders)
the motor, chassis sub- assemblies, or trim (glass, seats, upholstery, electronics,
etc.) have been added and painting has been done.

The name derives from manufacturing practices before steel unibody or monocoque
bodies when automobile bodies were made by outside firms on a separate chassis
with an engine, suspension, and fenders attached. The manufacturers built or
purchased wooden bodies (with thin, non-structural metal sheets on the outside) to
bolt onto the frame. The bodies were painted white prior to the final colour.

A folk etymology for Body in White suggests the term derives from the appearance of
a car body after it is dipped into a white bath of primer (undercoat paint) despite the
primer's actual grey colour.

In car design, the Body in White phase refers to the phase in which the final contours
of the car body are worked out, in preparation for ordering of the expensive
production stamp die. Extensive computer simulations of crashworthiness,
manufacturability, and automotive aerodynamics are required before a clay model
from the design studio can be converted into a Body in White ready for production.
Types of Fixture:

• Geostationary Fixtures (Geo Fixtures)

• Respot Fixtures
• Inspection Fixtures
• Hemming Fixtures(ROBOT)
Other devices in BIW line:
Gripper, Deposits, Racks, Pallets, Conveyers, Skids, Trolley, Gun stand, Gripper
Stand, Tip dresser, Sealant stand etc.

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The following is the basic process flow diagram for the production of a CAB:

DETAILED STUDY OF CAB line:

❖ Station no: 01 (Firewall & Substructure Assy)

❖ Station no: 02(Front grill Assy & spotting)

❖ Station no: 03(Partial body Assy)

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❖ Station no: 04 (Door aperture & Underbody spotting)

❖ Station no: 05 (Dashboard & Roof fitment)

❖ Station no: 06(Roof &Rear wall spotting)

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❖ Station no: 07(Underbody welding)

❖ Station no: 08(W/S bottom & Rear wall spotting)

❖ Station no:09(Cab unloading)

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❖ Station no: 10(Full welding)

❖ Station no: 11(Door fitment)

❖ Station: Passing

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 Assignment No.1
Implementation of world class quality in E6 BIW

What is WCQ?
Achieving & excelling the world’s benchmark levels to manufacture and deliver the
best quality products to all the customers.
The Culture:
• Quality to be built into the process
• Built in quality to be made DNA of the organization
• Involve all people to strive for Quality Excellence
• Prompt actions for all abnormalities
• Quality culture building training to all the employees & suppliers
Execution of WCQ Culture:
• Developing Quality Culture as DNA in the organization
• WCQ pyramid
• WCQ management system
• BIQ migration strategy
WCQ Pyramid:

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 WCQ Management System:

Continuous Improvement:
• Stabilizes the process to People Involvement:
that continuous
improvements can take • Everyone is responsible
place. for quality.

Short Lead-Time:
• Drives first time quality Standardization:
Thereby, enabling shorter
• Pre-requisite for
lead Times to deliver
achieving built-in
vehicle to the customer.
quality.

Built In Quality:

• Do not accept,
build, ship defects.

Absolutes:-

Quality to be built into the process. WCQ works on five principles are as follows:-
1. People Involvement
2. Continuous Improvement
3. Short Lead Time
4. Standardization
5. Built In Quality

Definitions of absolutes:
1. People Involvement-
a. Vision/mission statement.
b. Values.
c. Health & safety priority.
d. Team concept.
e. People involvement.
f. Open Communication Process.
g. Shop Floor Management.
h. Qualified People.

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 2. Short Lead Time-
a. Simple process flow.
b. Small lot packaging.
c. Fixed period ordering system parts.
d. Controlled external transportation.
e. Scheduled shipping/receiving.
f. Temporary material shortage.
g. Internal pull delivery.
h. Level vehicle order schedule.
i. Supply chain management.

3. Standardization-
a. Work place organization.
b. Management by take time.
c. Standardize work.
d. Visual management.

4. Built In Quality-
a. Product quality standard
b. Manufacturing process validation
c. In-process control and verification
d. Quality feedback / feed forward
e. Quality management system
5. Continuous Improvement-
A Process based on standardization, whereby improvement is made, through a
series of small improvements is called as Continuous Improvements.
Purpose:
To always advance ahead towards an ever more challenging target and make
progress in Safety, Quality, Productivity, Delivery, Cost, Morale and Environment
through the elimination of waste.
7 Absolutes of CI:
a. Problem solving
b. Business plan development
c. Andon concept
d. Lean Design of Facilities, Equipment, Tooling, Layout

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 e. Early Manufacturing and Design Integration
f. Total maintenance system.
g. Continuous Improvement process

BIW Migration Strategy:

Right now Tata motors Pune BIW is at the third stage of WCQ. To reach the next
levels the plant needs to achieve a certain goal that is shown in the diagram.

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5F Process of Problem Solving:

• Problem solving can be applied

to any abnormality in any aspect
of Safety, Quality, Delivery,
Productivity, Cost, Morale or
Environment.
• While the approach may be
different but problem solving is
applies to both chronic as well as
sporadic issues.

5F’S:
1. FIND
2. FOCUS
3. FAST
4. FIX
5. FEEDBACK
• Some examples of problems are listed below:
➢ Unsafe condition / accidents.
➢ Defect / rejection / rework / rectification.
➢ Customer complaints / warranty issues.
➢ Machine breakdowns.
➢ High cycle time / lead-time.
➢ Difficulty in fitment.
➢ Low productivity.
➢ Wastages,
➢ High Cost.
➢ Low morale / participation of employee etc.

Do Why -Why analysis for each probable problems and List out Proposed solution
(Brainstorming method). Plan & Results Trial run of solution. If everything all right
then permanently correct action plan & status.

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DRL (DIRECT RUN LOSS):
The total number of assemblies inspected at the quality gates computes shop Level Direct
Run Loss as total no of defects that have reached a Quality Gates divided.
Factory Level Direct Run Loss is computed by adding defect rate (in DPH) of all the quality
gates within factory. Plant DRL is summation of all the factory level DRL’s

A B C D ….. L

Total defects found at the quality gat e on a 10 34 25 14 28 17

given day

No of assemblies / vehicles gone through the 125 100 152 78 150 170
gates

Defect rate at the gates in DPH 8 34 16 18 19 10

Direct run loss(DRL) 129

Step 1: Defect rate at each Quality gate

∑ 𝐷𝑒𝑓𝑒𝑐𝑡𝑠 𝑎𝑡 𝑡ℎ𝑒 𝑔𝑎𝑡𝑒
𝐷𝐸𝐹𝐸𝐶𝑇 𝑅𝐴𝑇𝐸(𝐷𝑃𝐻) = 𝑋 100
𝑇𝑜𝑡𝑎𝑙 𝑁𝑜. 𝑜𝑓 𝑣𝑒ℎ𝑖𝑐𝑙𝑒𝑠 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑡ℎ𝑒 𝑔𝑎𝑡𝑒

Step 2: Direct Run Loss

Direct Run Loss (DRL) = ΣDPH (A+B+C…...+L)

Counts all defects that are found or flow into inspection gates i.e. a, b… L.

FSO

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DRR (DIRECT RUN RATE):
• Percentage of vehicle that made it through to the End-of-Line inspection
processes with no defects.

TOTALNUMBEROFVEHICLESWHITOUTDEFECT
DRR= 𝑋100
TOTALNUMBEROFVEHICLES INSPECTED

Direct Run Rate= (0.92 X 0.944 X 0.968 X 0.936) X100

= 78.6% Vehicles with no defects.

Group Leader’s Responsibility:

• Understand the defects being detected at each stage.
• Prioritize the problems.
• Review and ensure standardized work is being followed.
• Perform problem solving & implement countermeasures.

Plants Management’s Responsibility:

• Develop DRR targets.
• Develop action plans to meet desired targets.
• Provide necessary resources for effective problem solving.

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 Andon Concept:

• An operational floor process control

system (that can be activated manually
or automatically) to communicate the
need for assistance when abnormal
conditions occur as well as
communicate relevant information.

• The ANDON Concept encourages

employees to call for help when there
is a problem or out of standard
situation, using audio and/or visual
signals to help attract attention.

• The ANDON Concept is an enabler to control quality while keeping the

process going by pulling in support to address issues before they become
problems.

• It gives the worker the ability & empowerment to stop production when a
1. Defect is found
2. Material shortage happen
3. Breakdown or machine problem happen
4. Process problem happen
• The work is stopped until a solution has been found. The alerts are stored in
database so that they can be studied as a part of continuous improvement.

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 Assignment No.-01

1.1 Problem statement:

• Earlier there is problem of wrong Assy on fixture no. 3 i.e. fitment of normal
model sidewall with the sleeper model or non-sleeper model sidewall with the
normal model.
• Once wrong sidewall welded with the cab then it is very difficult to rework that
cab.
• For the rework of that cab around 1-2 persons required to be deployed for
total one shift for rework and sidewall being scrapped.

1.2 Difference between Sleeper & Non-Sleeper:

1) Slipper: This CAB comes with a berth box in which the driver can sleep.
Generally customers who have to nmove large distances prefer the sleeper
model.

2) Non-slipper: This CAB comes without a berth box and is thus smaller as
compared to the Sleeper model.

3) Regular: This cab looks exactly like a Non-slipper cabonly the difference is in
design and in some functions.

1.3 How does Photoelectric Sensor work?

Photoelectric Sensors detect objects, changes in surface conditions, and other items
through a variety of optical properties.

A Photoelectric Sensor consists primarily of an Emitter for emitting light and a

Receiver for receiving light. When emitted light is interrupted or reflected by the
sensing object, it changes the amount of light that arrives at the Receiver. The
Receiver detects this change and converts it to an electrical output. The light source
for the majority of Photoelectric Sensors is infrared or visible light (generally red, or
green/blue for identifying colours).

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The sensors used are Diffuse-reflective Sensors.

Image: Diffuse-reflective Sensors

Features:

• Long Sensing Distance

• Virtually No Sensing Object Restrictions
• Fast Response Time
• High Resolution
• Non-contact Sensing
• Colour Identification
• Easy Adjustment

1. How does Interlocking done ?

• Photo sensor provided on sidewall locating dock and interlocking done with
model selector switch provided on control panel.

• Once the selector switch switched to the required model then photo sensor
will sense the sidewall accordingly.

• Regular sidewall contains fender and Non sleeper or Sleeper does not contain
fender. So photoelectric sensor verifies whether the sidewall is right or wrong.

• If the sidewall is right then clamping will be done and it interlocks the sidewall
with the Assy body and then the operator starts to weld.

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 Fig. Clamping of sidewall

• If wrong sidewall fitted on gate then clamping will not happen and indicator
provided on the CS panel will start to blink.

1. LPT BIW reduction in cost for rework & rejection:

Before installing the sensors:

➢ Normal sidewall LH cost = 4443.32/- (Part No. 2641 6300 010120)

➢ Normal sidewall RH cost = 4512.86/- (Part No. 2641 6300 010220)
➢ Non-Sleeper sidewall LH cost = 3262.19/- (Part No. 2747 6300 Z108)
➢ Non-Sleeper sidewall RH cost = 3270.55/- (Part No. 2747 6300 Z112)

On month of September 5 cabs found with wrong sidewall. Non-Sleeper sidewall

welded with the normal cab sidewall. So total 3 LH & 2 RH normal sidewall scraped.

➢ Total cost of 3 LH s/wall= 3*4443.32=13329/-

➢ Total cost of 2 RH s/wall= 2*4512.68=9025.36/-

To rework one cab required one person for one shift.

➢ So total 5 cabs reworked manpower utilized = 5 men.

➢ So total cost for men=5*1000=5000/-

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In month of February, total 4 cabs found with wrong sidewall. Non-sleeper sidewall
welded with the normal cab sidewall and vice versa. So total 3 RH Non-Sleeper& 1
LH normal sidewall welded.

➢ Total cost of 3 RH Non-Sleeper s/wall = 3*3270.55= 9811.65/-

➢ Total cost of 1 LH normal s/wall= 4443.32/-

To rework one cab required one man for one shift.

➢ So total 4 cabs reworked manpower utilized = 4 men.

➢ So total cost for men=4*1000=4000/-

After installing the sensors:

➢ Pokayoke implemented to avoid wrong Assy. of sidewall.

➢ In the month there is no any defect recorded regarding wrong Assy of
sidewall.
➢ So rejection cost reduced or controlled.
➢ Manpower saved.
➢ No need for Rework.
➢ So total cost saved in the month of
April=13329+9025.36+5000+9811.65+4443.32+4000= 45609.33/-

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1. Advantages:
• Rework eliminated.
• Quality improved.
• Manpower reduced for the rework.
• Rejection cost reduced

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Page 23
 Assignment No.02
Safety improvement

2.1 Problem statement:

• Earlier while the conveyor is moving, if the operator tries to cross the
conveyor unknowingly which is unsafe and may lead to the major incident.

2.2 Proposed Solution

• With the help of Lift & Carrey operator unloads the Assy body from the last
station and load it on a fixture and then starts to work.
• After completing the work, both side operators press the authorization button
provided on the control panels and the Assy body is ready to shift to the next
station.
• While the conveyor is moving, if the operator tries to cross the conveyor
unknowingly which is unsafe and may lead to the major incident.
• To eliminate this problem and to increase the safety Photo sensors are
provided on L&C conveyor at both sides of station.

Fig 2.1. Photo sensor provided on L&C conveyor

• So when operator tries to cross the conveyor after authorization light of

photo sensors brakes & conveyor will stop immediately.

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 • When the conveyor stops it indicates red light on the board.
(image)
• To restart the conveyor, an operator has to repress the button provided on a
control panel.

2.3 Advantages:
• Safety Ensured
• Unsafe condition eliminated

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 Assignment No.03

Automotive Applications of Welding Technology – A Study

Introduction:

A wide variety of automobile body components are joined together using welding
techniques. The necessity for development of new welding techniques for
automotive applications is ever growing to meet the new material combinations for
auto body parts. The requirement for innovative welding processes is felt strongly in
the recent days with automotive manufactures focusing on lighter yet strong and fuel
efficient vehicles employing lightweight alternative materials.

The most commonly used welding methods for automotive applications include

1) Resistance Spot Welding (RSW)

2) Resistance Seam Welding (RSEW)
3) Metal Inert Gas (MIG) Welding
4) Tungsten Inert Gas (TIG) Welding
5) Laser Beam Welding (LBW)
6) Friction Welding (FW)

3.1 Resistance spot welding

The conventional steel body of a cab, on an average, contains 4500 spot weld
joints. Resistance spot welding is the principle joining method used in automotive
industries & has been for many years. In this method, the joint is produced by the
heat generated due to the resistance of work pieces to the flow of current and
application of pressure. The weld is limited to the spots on overlapped work pieces
and hence not continuous. The pointed copper electrodes conduct the welding
current to the work spot and also serve to apply pressure to form the strong joint.

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RSW is automated and used in the form of robotic spot welding in automotive
industries to weld the sheet metals to form cab body.

• Structural integrity of the Vehicle depends on the Spot Weld Quality

• The spot weld has to with stand the impacts during a crash

• Resistance welding consists of the joining of two or more pieces of metal by

the application of heat and pressure. The heat is generated by the ‘resistance’
offered by these parts to the passage of current.

Fig 3.1. Resistance spot welding

• A spot welding is made by pressing two or more overlapping piece together

while an electrical current is passed through a localized contact area. The
heat in the welding zone should be generated rapidly so that only minimum
heat is dissipated by conduction to cooler area.

Fig3.2.RSW Process

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 • Squeeze time : time set to ensure predetermined welding force before current
flow

• Weld time : time for which welding current is switched on

• Hold time : time electrodes are held together under pressure after weld time

• Cool time : current off time between successive current pulses in pulsation or
seam welding

Fig3.3: spot welding gun and types of electrodes.

Weld Defects:

• Good weld

• Small nugget

• Stick weld

• No weld

• Thin weld

• Flaws (porosity) in nugget

• Burnt spot

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Nugget Testing:

Non Destructive Chisel Testing Destructive Testing

Chisel

Hammer

Fig 3.5: Non Destructive testing Fig 3.6: Destructive testing

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3.2 Resistance seam welding
Seam welding is a resistance welding process in which the overlapping Workpieces
held under pressure are joined together by a series of spot welds made
progressively along the joint utilizing the heat generated by the electrical resistance
of the workpieces.
Seam welding is similar to spot welding process, but, instead of pointed electrodes,
mechanically driven wheel shaped electrodes are used to produce a continuous
weld.

Fig 3.7. Principle of resistance seam welding Fig 3.8. RSEW producing continuous joint

3.3 Metal Inert Gas Welding (MIG):

Metal Inert Gas Welding (Gas Metal Arc Welding) is the arc welding process, in
which the weld is shielded by an external gas (argon, helium, CO2, argon + oxygen
or other gas mixtures). Consumable electrode wire, having chemical composition
similar to that of the parent material, is continuously fed from a spool to the arc zone.
The arc heats and melts both the work pieces edges and the electrode wire. The
fused electrode material is supplied to the surfaces of the work pieces, fills the weld
pool and forms joint. Due to automatic feeding of the filling wire (electrode) the
process is referred to as a semi-automatic. The operator controls only the torch
positioning and speed.

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 Fig 3.9: setup of MIG welding

The MIG Welding in Tata Motors uses a mixture of C02 and Argon with a Copper
coated Mild Steel wire:

Fig 3.10: MIG welding & MIG welded joint

3.4 Friction welding

In solid state welding the joint is produced by the application of pressure without
significant melting any of the work parts. Friction welding is a form of solid state
welding where the heat is obtained from the mechanically induced sliding motion
between the parts to be welded. The weld parts are held together under pressure.
Generally, the frictional heat is generated by rotating one part against the other.
When certain temperature is reached, the rotational motion is seized and the
pressure applied welds the parts together. The two shafts joined by FW process is
depicted in Fig. This welding process can be controlled by regulating the time,
rotational speed and pressure.

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 Fig 3.11 Shafts joined by friction welding process

The metallic materials possessing certain degrees of plasticity at high temperature

and thermal stability can easily be friction welded. Although all common engineering
alloys can be friction welded, cast iron is an exception. In automotive industries, the
FW is used to fabricate a wide range of components including half shafts, axle
cases, steering columns, hydraulic cylinders, pistons rods and engine valves etc.
The Fig. shows few friction welded automotive components.

Fig3.12 Friction welded automotive component (Engine valves)

3.5 Projection Welding

Projection Welding is a type of resistance welding in which only the projected portion
of the metal is melted and joined to the base metal. Projection welding is a
modification of spot welding. In this process, the weld is localized by means of raised
section, or projections, on one or both of the workpieces to be joined.

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 Fig3.13: Projection welding

In Tata Motors, Pune projection welding is used for welding of nut in a hole on frame
LH side. Nut is kept on the tower fork of the projection welding machine manually.
The alignment of the nut and the hole on the frame must be proper. Pushing the foot
lever forces the 2 forks of the projection welding machine to come together and do
the welding.

Fig 3.14. Projection welding machine

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