A Report On Summer Training

Carried Out At

BAJAJ AUTO LIMITED

WALUJ
Submitted in Partial Fulfillment of the Requirements for the Award of Degree of

Bachelor of Technology
In
Mechanical Engineering

CORPORATE MENTOR- SUBMITTED BY-

MR.D.B.GHODSE PRABAL AGRAWAL

SR. MANAGER ID- 2014UME1418

BAL, WALUJ (VII SEMESTER)

CERTIFICATE

ii
 DEPARTMENT OF MECHANICAL ENGINEERING
MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY

JAIPUR RAJASTHAN -302017

DECLARATION

I hereby declare that the project work entitled “To Minimize The Surplus Amount Of Material Fed
To The Assembly Line By Using Auto-guided Vehicles”& “To Find Out The Possible Reasons For
Flaring Of Spring/Split Washer During Nut Tightening Of Wheel Assembly” are authentic record of
my own work carried out at Bajaj Auto Limited as per requirements of internship for the award of degree of
B.Tech. In Mechanical Engineering, Malaviya National Institute of Technology, Jaipur, under the guidance
of Mr.D.B.Ghodse during 01 June to 15 July, 2017.

Certified that the above statement made is correct to the best of my knowledge and belief.

PRABAL AGRAWAL
Date:
ID-2014UME1418

iii
 ACKNOWLEDGEMENT

Industrial training is an indispensable part of any engineering curriculum. It provides the students
an opportunity to gain experience about the practical applications of their knowledge.

My Training at BAL provided me experience in not only the technical and practical aspects of
the industry but also in human relations, teamwork and also provided great insights into the
actual working of an industry. I am sure that the hands on experience I have gained here will go a
long way towards making me a competent engineer.

I express sincere thanks to my industrial mentor Mr. D.B.Ghodse, for his diligent attention,
constant encouragement and valuable guidance throughout all stages of work in this training.
Without his efforts this training would not have been as great a learning experience as it has
been.

I would like to thank Mr. S.S.Kshirsager and Mr. Vikram Salunke for giving me the opportunity
to work in their department.

At the end I want to thank my college, Malaviya National Institute of Technology, Jaipur for
providing me such a wonderful opportunity, which turned out to be an amazing experience for
me and will be fruitful to me throughout my life.

iv
ABSTRACT

A pre-requisite of B. Tech study is to undergo a summer internship. I got the opportunity to join
one of the most reputed companies BAJAJ Auto limited at their plant in Waluj, Aurangabad for
the said purpose for a period of 45 days.

It has been a journey of great experience when I got chance to visit and see the technologies
used in the factory. Practical experience is the thing which cannot be matched up with the books
information and view. It has helped me in acquiring different approach for any problem set and
had provided me the ability to come up with the solution of a problem. Interaction with people
having position, different skill set, management position has inculcated a sense of responsibility
and tremendous hard work through which success is achieved.

Bajaj Auto has adopted TPM as its production philosophy. The primary objective is to reduce or
eliminate waste. The 7 waste which are hidden along each step of production process as
identified by Mr. Taiichi Ohno are:

 Wastes arising from overproduction.

 Wastes arising from waiting.

 Wastes arising from transporting.

 Wastes arising from production itself.

 Wastes arising from unnecessary inventory.

 Wastes arising from unnecessary motion.

 Wastes arising from producing defective goods.

The main aim of this project is to reduce wastage due to waiting, transporting and unnecessary
motion and to ensure smooth flow of material and quick response to customer demand.

v
 CONTENTS

Certificate ii

Declaration iii

Acknowledgement iv
Abstract v

Table of content vi

List of figures viii

List of tables x

Abbreviation xi

CHAPTER 1: Introduction

1.1 About the company ...................................................................................................... 1

1.1.1 Advantages to India ............................................................................................ 1

1.2 Manufacturing facilities……………………………………………………………….2

CHAPTER 2:THREE WHEELER DEPARTMENT

2.1 Introduction to Three wheeler division Exports Division. ............................................5

2.2 Introduction to Three wheeler assembly ...................................................................... 8

2.2.1 Material flow … ................................................................................................. 8

2.3 CVD 3-Wh ASSEMBLY LAYOUT… ...................................................................... 10

2.4 Steps involved in assembly of three wheeler ............................................................. 11

CHAPTER 3: Minimize The Surplus Amount Of Material Fed To The Assembly Line By Using

Auto-guided Vehicles

3.1 Introduction ................................................................................................................. 18

3.2 Current scenario .......................................................................................................... 18

 3.3 Constraints ................................................................................................................... 19

3.4 Observations ............................................................................................................... 20

3.5 Procedure Followed .................................................................................................... 23

3.5.1 Measurement of weights and capacities Picking ............................................. 23

3.5.2 One AGV on RH side and two on LH side ................................................... 24

3.5.3 Workforce Management… ............................................................................... 24

3.6 Benefits…………………………………………………………………………………..28

3.7 Conclusion… ..................................................................................................................... 28

CHAPTER 4: Reasons For Flaring Of Spring/Split Washer

4.1 Introduction ................................................................................................................. 29

4.1.1 spring washer ....................................................................................................... 29

4.2 Observations ................................................................................................................. 31

4.3 Probable reasons for failure .......................................................................................... 31

4.3.1 Torque requirements ........................................................................................... 31

4.3.2 Presence of burrs: ............................................................................................... 32

4.3.3 Thickness of washer ............................................................................................ 33

4.3.4 Dimensional analysis… ...................................................................................... 35

4.4 Conclusion… ................................................................................................................ 36

CHAPTER 5: Conclusion............................................................................ …….38

References ........................................................................................................... 40
LIST OF FIGURES:

Figure Figure Caption Page No.

Figure 1.1 Layout of Waluj plant 2

Figure 1.2 Bajaj policies 3
Figure 2.1 Product Portfolio of 3WH 5
Figure 2.2 Compact Model 6
Figure 2.3 Optima Model 6
Figure 2.4 Maxima Diesel Passenger model 7
Figure 2.5 Maxima Diesel cargo model 7
Figure 2.6 3WH assembly 8
Figure 2.7 Material Flow 8
Figure 2.8 3WH final assembly layout 10
Figure 2.9 Chassis unloading 11
Figure 2.10 Master cylinder fitment 11
Figure 2.11 Brake pipe fitment 11
Figure 2.12 Steering column fitment 12
Figure 2.13 Cross member fitment 12
Figure 2.14 Shock Absorber fitment 12
Figure 2.15 Steering plate fitment 12
Figure 2.16 Front brake hose fitment 13
Figure 2.17 Side hand brake lever fitment 13
Figure 2.18 ECU mounting 14
Figure 2.19 Front wheel fitment 15
Figure 2.20 Electric plate cover fitment 15
Figure 2.21 Dashboard fitment 15
Figure 2.22 Body bolt insertion 16
Figure 2.23 Driver seat fitment 16
Figure 3.1 D-Conveyor of Assembly line 18
Figure 3.2 BOPT 19
Figure 3.3 AGV 19
Figure 3.4 Delivery modes of Assembly parts 20
viii
Figure 3.5 Trolley with front tire assembly 20
Figure 3.6 Trolley with LH tire assembly 20
Figure 3.7 Bins 21
Figure 3.8 Position of assembly parts 22
Figure 3.9 New position of assembly parts 25
Figure 3.10 Benefits 28
Figure 4.1 Wheel Assembly 29
Figure 4.2 Spring washer 29
Figure 4.3 Flared spring washer 32
Figure 4.4 Damaged nuts 32
Figure 4.5 Damaged wheel rims 30
Figure 4.6 Sample analysis 31
Figure 4.7 Auto shut off gun 31
Figure 4.8 Washer having burr 32
Figure 4.9 Dimensions of washer 33
Figure 4.10 Combined effect of all reasons 37

ix
 LIST OF TABLES:

Table No. Title Page No.

1.1 Plant division 4
2.1 Comparison of assembly line 9
3.1 Comparison of delivery mode of assembly parts 21
3.2 Minimum surplus 23
3.3 Final sequence of LH side 26
3.4 Final sequence of RH SIDE 27
4.1 End thickness of washer 34
4.2 Other dimension of washer 35
4.3 Suggestions and benefits 36

x
 LIST OF ABBREVIATIONS

BAL BAJAJ Auto Limited

BOPT Battery Operated Pickup Truck
CVD Commercial Vehicle Division
AGV Auto-Guided Vehicle
TMC Tandem Master Cylinder
ECU Electronic Control Unit
PC Personal Computer
OPC Operation and process control

xi
 CHAPTER 1
INTRODUCTION

1.1 ABOUT THE COMPANY: BAJAJ AUTO LTD.

The Bajaj Group is amongst the top 10 business houses in India. Its footprint stretches over a
wide range of industries, spanning automobiles (Two Wheelers Manufacturer And Three
Wheelers Manufacturer), home appliances, lighting, iron and steel, insurance, travel and
finance. The group's flagship company, Bajaj Auto, is ranked as the world's fourth largest three
and two wheeler manufacturer and the Bajaj brand is well-known across several countries in
Latin America, Africa, Middle East, South and South East Asia. Founded in 1926, at the height
of India's movement for independence from the British, the group has an illustrious history. The
integrity, dedication, resourcefulness and determination to succeed which are characteristic of
the group today, are often traced back to its birth during those days of relentless devotion to a
common cause.

 TYPE OF INDUSTRY: Automotive: The Company designs and manufactures motor cars.

 KEY REPRESENTATIVE: Mr. Rahul Bajaj, Chairman and Mr. Rajiv Bajaj, CEO

 REVENUE: US$3.5 billion (2016)

 EMPLOYEES: 9000(2014)

1.1.1 ADVANTAGES TO INDIA

India holds huge potential in the automobile sector including the automobile component sector owing
to its technological, cost and man-power advantage. Further, India has a well-developed, globally
competitive Auto Ancillary Industry and established automobile testing and R&D centers. The country
enjoys natural advantage and is among the lowest cost producers of steel in the world.

1
1.2 MANUFACTURING FACILITIES
BAL has three manufacturing facilities in India, two at Waluj and Chakan in Maharashtra and
one in Pant Nagar, Uttaranchal. Bajaj Auto has sold over 2 million motorcycles in India. Every
12 seconds a vehicle rolls out of the Bajaj plant, it is therefore imperative that the transfer of
contemporary technology is a smooth process. Great stress is laid on training and motivating the
people who man and maintain the equipment, since the best equipment alone cannot guarantee
high quality and productivity.

Figure: 1.1 Layout of Waluj Plant

2
The plant at Waluj is spread over an area of 900 acres. It is the only manufacturing plant of Bajaj
that produces three wheelers.
Bajaj Auto specifically follows two main policies- “TPM policy” and “SHE policy”.

Figure: 1.2 Bajaj Policies

3
The plant is mainly divided into three parts- Motorcycle Division, Commercial Vehicle Division
and Four wheeler Division.
Table: 1.1 Plant division

PLANT

COMMERCIAL VEHICLE
MOTOR CYCLE DIVISION FOUR WHEELER DIVISION
DIVISION

CHASIS SHOP CHASIS SHOP BIW SHOW

PAINT SHOP PAINT SHOP PAINT SHOP

MACHINING SHOP MACHINING SHOP MACHINING SHOP

ENGINE ASSEMBLY ENGINE ASSEMBLY ENGINE ASSEMBLY

VEHICLE FINAL ASSEMBLY VEHICLE FINAL ASSEMBLY PAINT SHOP

EXPORT EXPORT VEHICLE FINAL ASSEMBLY

4
 CHAPTER 2
THREE WHEELER ASSEMBLY
2.1 INTRODUCTION TO THREE-WHEELER DIVISION
Bajaj Auto Limited started producing three wheelers at AKURDI, pune in 1961. In 1987 it was
transferred to Waluj. Currently Bajaj Auto is the largest manufacturer of three-wheelers in India.
Bajaj Auto has an extensive network of distribution, with the company supplying its three-
wheelers/commercial vehicles all over India as well as to over 27 countries. Export volume is
60% of total production with its major presence in south East Asia. South Asia, east & North
Africa and Latin America.

The three wheeler department is termed as COMMERCIAL VEHICLE DEPARTMENT or

CVD. Commercial vehicle division of BAL caters to “passenger carriers” and „goods carrier‟
segments of BAL‟s 3 wheelers.

Following is the product portfolio of 3Wh. Total as many as 22 different models are being
produced at commercial vehicle division of Bajaj Auto.

THREE
WHEELERS

PASSENGER CARGO

MAXIMA
COMAPCT OPTIMA MAXIMA DIESEL
ENGINE

DIESEL DIESEL DIESEL

4S ENGINE 2S ENGINE 4S ENGINE
ENGINE ENGINE ENGINE

Figure: 2.1 Product Portfolio Of 3Wh

5
A) COMPACT
PETROL
COMPACT-4S , 205CC CNG
LPG
PETROL
COMPACT-2S, 145CC CNG
LPG
COMPACT DIESEL,445CC DIESEL

Figure: 2.2 Compact

B) OPTIMA/COMPACT PLUS/MAXIMA-Z
PETROL
OPTIMA-4S , 205CC CNG
LPG

OPTIMA-4S , 236CC PETROL (UPCOMING)

OPTIMA DIESEL,445CC DIESEL

Figure: 2.3 Optima

C) MAXMA DIESEL

PASSENGER MODEL DIESEL

CNG
GOODS CARRIER(CARGO) LPG

6
Figure: 2.4 Maxima Diesel - Passenger Model Figure: 2.5 Maxima Diesel - Cargo Model

D) UPCOMING
ELECTRIC BATTERY

FUEL INJECTION PETROL

MAXIMA WIDER BODY PETROL

7
2.2 INTRODUCTION TO THREE -WHEELER ASSEMBLY
The three wheeler assembly occupies an area of 3.5 acres. The three wheeler department
produces around 2300 vehicles per day.

Figure: 2.6 Three-Wheeler Assembly

2.2.1 MATERIAL FLOW

The following is the material flow that occurs before and after the product reaches the Three
wheeler assembly department.

CHASSIS AND BODY

FROM FABRICATION

PAINT SHOP

ENGINE VEHICLE FINAL

ASSEMBLY ASSEMBLY

DOMESTIC AND
EXPORT DISPATCH

Figure: 2.7 Material Flow

8
As seen above the final assembly department forms the heart of the Commercial Vehicle
Division. The final assembly department consists of three assembly lines A,D and E lines.
Three wheelers for domestic market are produced on D line and those for export markets are
produced on E line. Cargo models or Carrier goods model are produced on A line.

Table: 2.1Comparison Of Assembly Line

CELL D LINE E LINE

PRODUCTION For domestic market For export market
NO: OF STAGES 95 80
CONVEYOR SPEED 3.9m/min 3.9m/min
PRODUCTION CAPACITY 1188(594 per shift) 1024(512 per shift)
OPERATION SHIFT 2 (16 hrs) 2 (16 hrs)
CYCLE TIME (sec) 48.48 56.25
M/Cs/EQUIPMENTS 16 17
NO: OF MODELS 14 12

9
2.3 CVD 3WH VEHICLE FINAL ASSEMBLY LAYOUT

Figure 2.8 "3Wh Final Assembly Layout"

10
2.4 STEPS INVOLVED IN THE ASSEMBLY OF THREE-WHEELER
1.Chassis unloading from I beam Conveyor & Loading on track with grommet fitment being
done

Figure 2.9 Chassis Unloading

2.Front and rear harness fitment

3.Reverse lever fitment and front electric plate connections
4.Master cylinder fitment ,single piece brake pipe fitment and chassis number punching.

TMC

5. SUPPORT FITMENT

Figure 2.10 Master Cylinder Fitment Figure 2.11 Brake Pipe Fitment

11
 5. Speedometer wire , Control cables & Reverse cable insertion.
6. Steering Column And Cross Member Fitment.

Figure 2.12 Steering Column Fitment Figure 2.13 Cross Member Fitment

7.. Shock absorber and steering plate fitment.

Figure 2.14 L.H. Shock Absorber Fitment Figure 2.15 Steering Plate Fitment

8. .Headlamp screw fitment

9. Foundation block and horn fitment

12
10. LHS & RHS blinker and steering cover fitment connection

11. Front Break Hose Fitment And Engine Loading

Figure 2.16 Front Brake Hose Fitment

12. Engine bolts fitment and engine tightening

13. Starter motor connection

14. Short connecting tube fitment ,Shock absorber fitment (RHS) and Clutch connection.

16. Side hand brake Lever and Fix end Reverse cable fitment

Figure 2.17 Side Hand Brake Lever

13
16. Handle bar fitment & tightening ,Clutch and gear cables fitment in handle bar.

17. Electric plate fitment with ECU Mounting and coupling

Figure 2.18 Electric plate fitment with ECU Mounting

19. Connection of ECU with throttle body by rear harness

20. Battery base fitment and Traling arm fitment

21. Battery fitment & connection and connecting tube fitment

22. Dash board dome nuts (for twin head lamp vehs), Gear connection (Fix end) and Accelerator
connection.

23.Trailing arm LHS & benjo tightening (after prefitting ), L' bkt fitment

24.Propellar shaft fitment

14
25.Front wheel, Bellow clip LHS and Bellow clip RHS

Figure 2.19 Front Wheel Fitment

26.Wheel fitment and Wheel tightening (LHS and RHS)

27.Hand brake (LHS ), RHS hand brake connection

28.Starting tube fitment & greasing

29.Gear shifter cover fitment and Hazard switch connection

30.Silencer fitment
31.Break bleeding machine
32.Electrical plate cover fitment and Dash board fitment.

Figure 2.20 Electrical Plate Cover Fitment Figure 2.21 Dash Board Fitment

15
33. Handle bar Coupler connections and scanning

34. Fuel tank mounting inside body and HT coil assembly fitment and body harness routing.

35. Body bolt insertion and tightening (LHS) and RHS

Figure 2.22 Body Bolt Insertion And Tightening

36. AC Box duct connection an connection of it to throttle body.

37. Driver seat fitment.

Figure 2.23 Driver seat fitment

16
38. Petrol filling

39. Spare wheel fitment (Alternate stage) and Side filling door lock

40. Cabin lamp fitment and Battery lock

41. Inspection of vehicle

17
 CHAPTER 3
PROJECT-1
To Minimize The Surplus Amount Of Material Fed To The Assembly Line By
Using Auto-guided Vehicles.

3.1 INTRODUCTION:
The Three-Wheeler Assembly Department is very challenging as it maintains a large number of
final assembly parts or vehicle components, hence a great deal of accuracy and efficiency is
required .This makes management of their availability on the assembly line, better utilization of
storage space and manpower very critical. In this project, effort is made to minimize the surplus
which is fed on the D-conveyor of assembly line by using auto-guided trolleys.

Figure:3.1 D-Conveyor Of Assembly Line

3.2 CURRENT SCENARIO

The current scenario at D-conveyor consists of BOPTs (battery operated pallet trucks) which are
used for loading and unloading of the components brought from assembly stores to the required
positions on the assembly line. Five workers are involved in this process(one in assembly stores
and rest four using BOPTs) with only one trolley being carried by a particular BOPT.

18
 It was observed that there was improper utilization of storage space near the assembly line
resulting in a chaos. Also since there is a requirement of high volumes of repetitive movements
of material which involves very little human decision making skill to perform the movement, it
was decided to replace the BOPTs by AUTO-GUIDED VEHICLES to ensure efficient
manpower and space utilization along with improved technology benefits.

Figure: 3.2 Battery Operated Pallet Truck(earlier) Figure: 3.3 Auto-Guided Vehicle(proposed)

The project, therefore, aims to achieve the above mentioned targets through minimization of the surplus
material feeding the assembly line .

3.3 CONSTRAINTS

The D-conveyor assembly line can be divided in three sections-Body Mounting Section, Engine
Mounting Section And Preparation Line Section .

1) It was needed that the auto-guided trolleys deliver the required components within
9.6minutes for farthest components on assembly line (ahead of body mounting section -spare
wheels ,driver seats etc),7.6minutes (for components near engine mounting section) and 5.6
minutes (for components near preparation line).

2) The bots or auto-guided vehicles can make 50trips per shift and can tow a weight of 500kg
per trip.

3) Moreover the approximate daily production on D-line could reach upto 600 vehicles per
shift(8 hours) .

19
Henceforth our main aim was to channelize the total number of trips in the given time
considering all the given constraints so as to ensure minimum surplus and efficient management
of workforce.

3.4 OBSERVATIONS
a) Observations were made to ensure the proper distribution of assembly parts(reducing
surplus) within the given time periods(shifts) .
b) It was observed that components used to arrive on the assembly line through three means
trolleys, bins and I-conveyors.

ASSEMBLY
PARTS DELIVERY
MODES

WITH BOPT WITHOUT BOPT

BINS TROLLEYS I-CONVEYOR

Figure: 3.4 Delivery Modes Of Assembly Parts

20
 The following table shows the differences between the above mentioned modes to deliver
assembly parts
Table: 3.1Comparison Of The Delivery Modes Of Assembly Parts

PARTS IN TROLLEYS PARTS IN BINS PARTS ON I-CONVEYOR

Heavy parts -wheel assembly, Medium weight-cabin lamps, Light weight- benzo nuts, long
trailing arms battery cutouts etc bolts etc

Lesser quantity (bigger parts) Huge quantity (smaller parts) Least quantity (one I-conveyor
carries parts only for one
vehicle)
Single station on assembly Single station on assembly Multiple stations on assembly
line line line

Figure: 3.5 Trolleys With Front Tyre Assembly Figure: 3.6 Trolleys With L.H. Tyre Assembly

A collection of bins were stored in a particular trolley and sent along with the direct components
placed on trolleys. Hence, a large number of components could be sent in one go in case of bins.

Figure: 3.7 Bins 21

 c) Proper positioning on the assembly line of all the required assembly parts was noted so as
to ensure proper delivery within the given time periods of auto-guided vehicle. The given
figure mentions all the assembly components to be delivered in their proper order.

SPARE WHEEL

DRIVER SEAT

SILENCER

L.H. WHEEL
R.H. WHEEL
TRAILING ARM(L.H.)
BATTERY
BODY
CONNECTING TUBE MOUNTING TRAILING
SPM CABLE ARM(L.H.)

CONTROL CABLE
SET
HANDBRAKE
SPM CABLE ENGINE CABLE
MOUNTING
REVERSE CABLE ENGINE
MOUNTING CROSS
CONTROL CABLE MEMEBER
SET

REVERSE LEVER PREPARATION BRAKE PIPE

LINE
KNOB MOUNTING TMC
ASSEMBLY
REAR HARNESS
FRONT HARNESS
AC BOX

PETROL TANK

Figure: 3.8 Positioning Of Assembly Parts 22

3.5 PROCEDURE FOLLOWED
3.5.1 MEASUREMENT OF WEIGHTS AND CAPACITIES
Weights of the components carried via trolleys and bins were calculated and their quantity
required per vehicle was calculated (for both LH and RH side)
Capacities of trolleys/bins were measured as well as calculations were done for the number of
trolleys/bins required for the given line setting.

Table: 3.2 Minimum Surplus

23
3.5.2 ONE AGV ON R.H. SIDE AND TWO ON L.H. SIDE

Considering all the above parameters calculations were done using hit and trial as well as various
optimization techniques and it was observed that for the production of 100 vehicles minimum
surplus was supplied and minimum number of trips occurred.

Since lesser components were required on the RH side it was further decided to engage one auto-
guided vehicle on RH side and the remaining two on the LH side of the assembly line.

Henceforth a proper layout was prepared(both for LH and RH side of assembly line) for the
delivery of components on the assembly line for a cycle of 80mins i.e. production of 100
vehicles.

3.5.3 WORKFORCE MANAGEMENT

To ensure efficient management of workforce the layout was prepared ensuring that only three
workers are required in this process(one in the assembly stores for hooking the trolleys to be
towed, one on the RH and LH side respectively).

Moreover since components delivered on the LH side are more ,efficiency of one worker was
ensured by simultaneous arrival of the two auto-guided trolleys thus minimum movement of
workers was ensured.

The layout even ensured that repetition of cycle 6times would result in production of 600
vehicles .These bots on the first day if made to start an hour earlier than the shift timings ,would
ensure the inventory to be kept for next day first cycle during its last 80mins of usage.

24
The given layout was made for the three auto-guided trolleys (i.e. for the LH and RH side).

Figure: 3.9 Positioning Of Assembly Parts

25
Final sequence for L.H. bots:

Table: 3.3 Final Sequence Of L.H. Bots

STOPPING POINTS
S4 - STOPPED NEAR DRIVER SEAT -9.6 MIN S1,S2,S3,S4 LOCATED IN LAYOUT
S3 - STOPPED NEAR DRIVER WHEEL-7.6 MIN
S2 - STOPPED NEAR ENGINE-5.6 MIN
LH S1 - STOPPED NEAR PETROL TANK

26
Final sequence for R.H. bot:

Table: 3.3 Final Sequence Of L.H. Bots

STOPPING POINTS
S2 LOCATED NEAR RH WHEEL 7.6
RH S1 LOCATED NEAR CROSS MEMBER 5.6
GOES EM EMPTY/SURPLUS
27
3.6 BENEFITS

Optimum Space
Workforce Reduction
Utilisation On
From 5(earlier) To
Assembly Line By
3(now)
Reducing The Surplus.

Multiple Trolleys Can Minimum Movement

Be Sent Of Workers

Figure: 3.10 Benefits

3.7 CONCLUSION
The above sequence of assembly components resulted in the minimum surplus being sent i.e.
optimum space utilization on assembly line by reducing surplus. The use of auto guided vehicles
even resulted in multiple trolleys being delivered in one go.
Workforce involved for this process reduced from 5(earlier) to 3(now) workers. Moreover the
arrangement of assembly parts is done in such a way that it resulted in minimum movement of
workers on the assembly line, thus enhancing efficiency.

Henceforth, proper layout for material feeding with minimum surplus on the assembly line of the
three-wheeler assembly is done with the aforementioned benefits.

28
 CHAPTER 4
PROJECT 2
To Find Out The Possible Reasons For Flaring Of Spring/Split Washer During Nut
Tightening Of Wheel Assembly
4.1 INTRODUCTION:
Spring washers are used in nut tightening of wheel assembly. Every vehicle is fitted with 12 spring
washers (4 on each tyre).Since the three-wheeler plant consists of three assembly lines (A,D and E
assembly lines),wheel assembly occurs on all three of these lines and majorly on the D and E lines.
Depending upon the model washers were used i.e. different models were fitted with different
washers.
Spring washers(Spring Steel-7080C6) were used majorly in two models i.e OPTIMA and
COMPACT

Figure: 4.1 Wheel Assembly

4.1.1 SPRING WASHER:A spring/split washer generally functions as a spring and is designed to stop
threaded fasteners from loosening. They utilise teeth to prevent rotation by penetrating the mating surface
that the washer is in contact with i.e. the sharp edges of the washer are supposed to dig into the nut and
mounting surface to prevent counter-clockwise rotation.

29
Fig 4.2 Spring Washers
It was observed that the spring washers flared during the nut tightening of wheel assembly. Out of
250 washers used, on an average 30-40 washers used to flare per shift. This also resulted in
damaging of nut as well as rim surface of the wheel.

Figure: 4.3 Flared Spring Washers

Figure: 4.4 Damaged Nuts Figure:4.5 Damaged Wheel Rim

DAMAGED
PORTION

Henceforth the project aimed at studying and finding out the possible reasons for the flaring of
spring washers .

30
4.2 OBSERVATIONS
Upon observation it was seen that the spring washers flaring in optima model were more in
comparison to compact model.

NUMBER OF WASHERS FLARED OUT OF 250

45
40
35
30
25
NUMBER OF WASHERS FLARED
20 OUT OF 250
15
10
5
0
Optima Compact
Model Model

Figure: 4.5 Sample Analysis

4.3 PROBABLE REASONS FOR FAILURE OF SPRING WASHERS

4.3.1 TORQUE REQUIREMENTS: The automatic shut off guns are preset for a
particular value of torque that is used for tightening of nuts and spring washers. The best
suited specified torque range in the case of using spring washers was between 4.5 to 5.5
kgm .

Figure: 4.6 Auto Shut Off Gun 31

But it was observed that when the torque value exceeded 5kgm, a greater number of spring washers
flared. Setting of torque values greater than 5kgm was useful in case of uneven or rough nut and
bolt surfaces and since, generally the nuts and bolts available were of good surface finish ,a higher
value of torque was unnecessary .

Moreover very large torques resulted in complete deformation of the spring washer ,making it go
flat and resulting in a loss of its spring action. Henceforth when the torque limit was set to 5kgm a
lesser number of spring washers flared.

4.3.2 PRESENCE OF BURRS:

Presence of sharp burrs on the spring washer even resulted in flaring. Generally after tightening of
the spring washer it gets flattened and one end due to the presence of burrs at the edges of spring
washer can get engaged in rim and the other end gets engaged in nut (since nut hardness and rim
hardness is less than washer hardness ) .The clockwise torque further provided results the flaring of
washers as both the ends of washer are fixed now .

BURR

Figure: 4.7 Washer Having Burr

32
 4.3.3 THICKNESS OF WASHER:
Generally after tightening of the spring washer it gets flattened .Now in such a situation if the
thickness on both the ends of the spring washer varies then it may result in one end getting engaged
in the nut .Any further clockwise torque would result in flaring of the washers.
Dimensional analysis was done for 200 washers and those having maximum variations in length as
well those not matching the standard dimensions were checked for any possibility of flare.

Standard Thickness Of Spring Washer = 2.2+/-0.15

Figure: 4.8 Dimensions Of Washer

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 Measured thickness of a few washers has been mentioned below.The ones highlighted in red are
showing extreme variations from standard dimensions.
It was further observed that on an average 7 out of 20 such washers flared.

Table:4.1 End Thickness Of Washers

(Units are in mm)


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4.3.4 DIMENSION ANALYSIS
Dimensional analysis was performed to ensure that the dimensions of the spring washers delivered
by the supplier matched the required specifications.
It was observed that the dimensions i.e. inner diameter ,outer diameter and width were within the
specified limits (tolerances) . W

STANDARD SPECIFICATIONS:
A=Inner diameter D =10.2+/- 0.5 mm
B=Outer diameter D1=18.1+/-0.4mm
W=Width= 3.5+/-0.2mm
Figure: 4.9 Dimensions Of Washer

Table:4.2 Other Dimensions Of Washers

(Units are in mm)

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4.4 CONCLUSIONS
The following suggestions were made and results for the same are as follows:

Table:4.3 Suggestions And Benefits

Issue/Loss Suggestion Benefit/Result

More flaring was observed Torque value of auto shut off Lesser number of washers
in Optima Model gun was reduced to less than flared.(5-7 on an average
5kgm from 5.2kgm reduced)
Presence of burrs resulted in Pre-lot checking so as to Reduction in surface
flaring remove the rough or burred damaging of rim and nut
surfaced spring washers

Efficiency of spring washers Replacing spring washers Very less number of

is a problem when there is a with nyloc nuts or serrated washers flare.
loss of its spring effect. washers. (4-5 only in one shift)

It was observed that one of the reasons behind using spring washers is their cheap cost. It was also
realised that flaring of washers cannot be assigned just one particular reason i.e. it was occurring
due to a number of factors and every factor contributed in some percentage that eventually led to
the flaring.

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 Torque
applied
Variations
Presence
in end
of burrs
thickness
FLARING
OF
WASHERS

Figure: 4.10 Combined Effect Of All Reasons

It was also studied that the usefulness of these type of washers have been under scrutiny due to the
idea that these washers when tightened flat against a substrate, the edge will not bite. Therefore
there will not be any difference in resistance when an unthreading torque is applied compared to a
regular washer.
The only time a split washer might prove useful would be for fastening onto soft easily deformed
surfaces such as wood, where the washer‟s springiness & sharp edges could actually work.
Practically the torque values in the range of 4.5 to 5 kgm resulted in making the washers go flat,
therefore no benefit of its springiness & sharp edges was observed.

Henceforth, the major challenge in this project was to identify suitable reasons for flaring of split
washer. Once the reasons were observed and highlighted, necessary actions were taken and
improvements (as mentioned above) were observed.

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 CHAPTER 5
CONCLUSION

Training at one of the top automobile manufacturers in India was an insightful one. The learning
period at BAJAJ AUTO was for 45 days. Bajaj is a leading manufacturer in mainly three
wheeler market and in motorcycle division. It follows the TPM way of working, the following
are the pillars of TPM :-

 Autonomous maintenance

 Kobetsu Kaizen

 Planned Maintenance

 Quality management

 Education and Training

 Office TPM

 Safety, Health and Environment

 Early management and Initial flow control

Each of these pillars contributes to the successful running of the organization and in achieving
targets.
Through the projects assigned to me, entitled, “To Minimize The Surplus Amount Of Material
Fed To The Assembly Line By Using Auto-guided Vehicles” and “To Find Out The Possible
Reasons For Flaring Of Spring/Split Washer During Nut Tightening Of Wheel Assembly ”, I have
been able to widen my scope of knowledge and skills. I also have successfully completed these projects by
reducing the surplus fed on the assembly line as well as minimizing the number of trips made by AGV.
Moreover workforce was reduced from 5 (earlier) to 3(now) and the prepared sequence resulted in minimum
movement by the workers, thus increasing efficiency. In the second project possible reasons for flaring of
spring washers along with suggestions were highlighted and number of washers flaring reduced by 12-15 in
number per shift. Through this, productivity of the process is improved and there is proper flow of work. It
also improves the performance of the worker as well as the company.

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I gained insights of the various departments in the company and was also able to observe how an
automobile is being manufactured. From my training, I could understand the working culture of
an organization, different technologies used and role of different members.

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 CHAPTER 6
REFERENCES

1. http://multichannelmerchant.com/blog/10-ways-improve-
warehouse-efficiency-reduce- costs/
2. http://www.cisco-eagle.com/blog/2011/03/17/best-practices-for-
warehousing-13-tips-for- productivity/
3. http://www.yourarticlelibrary.com/industries/plant-layout/four-
main-types-of-plant- layout/34604/

4. http://cerasis.com/2015/03/05/warehouse-operations/
5. http://www.inventoryops.com/dictionary.htm

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