ACKNOWLEDGEMENT

This project carried out by me has been only possible because of the exception help, support and guidance from TOOL ENGINEERING DEPARTMENT, TATA MOTORS, Pantnagar. I express my sincere gratitude to Mr. Ashihs Bora who gave me the project and provide all the information and explanation required throughout the project. I would like to thank Shivank Bajpai of TOOL ENGINEERING DEPARTMENT, for the constant support and help in the successful completion of my project.

PRATEEK SATI

CERTIFICATE
This is to certify that Mr. Prateek Sati, a student of College Of Engineering Roorkee , has successfully completed his training in the Tata Motors Ltd. Pantnagar under the able guidance and supervision of Mr. Rajeev Bhardwaj (Div. Manager, Tata Motors Pantnagar). The period for which he was on training for 4 week, starting from 6 june 2011 to 5 july 2011.

Mr. N.B. TILAK D.G.M (U&M)

Mr. RAJEEV BHARDWAJ (Div. Manager Maintenance Deptt.)

CERTIFICATE
This is to certify that Mr. Varun Phartiyal, a student of Amrapali Institute Of Science & Technology, has successfully completed his training in the Tata Motors Ltd. Pantnagar under the able guidance and supervision of Mr. Rajeev Bhardwaj (Div.Manager, Tata Motors Pantnagar). The period for which he was on training for 4 week, starting from 6 june 2011 to 5 july 2011.

Mr. N.B. TILAK D.G.M (U&M)

Mr. RAJEEV BHARDWAJ (Div. Manager Maintenance Deptt.)

SUMMER TRAINING PROJECT

Manufacturing
Tata Motors owes its leading position in the Indian automobile industry to its strong focus on indigenisation. This focus has driven the Company to set up world-class manufacturing units with state-of-the-art technology. Every stage of product evolutiondesign, development, manufacturing, assembly and quality control, is carried out meticulously. Our manufacturing plants are situated at Jamshedpur in the East,Pune and Sanand in the West and Lucknow and Pantnagar in the North.

Jamshedpur
Established in 1945, the Jamshedpur unit was the Company's first unit and is spread over an area of 822 acres. It consists of four major divisions - Truck Factory, Engine Factory, Cab & Cowl Factories. The divestments in March 2000 hived off the Axle and Engine plants into independent subsidiaries viz. HVAL & HVTL, respectively. The Truck Division boasts of two assembly lines. The main assembly line, measuring 180 m in length has 20 work stations with a vehicle rolling out every 8 minutes. The other line is dedicated to special purpose vehicles and for meeting the requirements of the Indian Army. The uniqueness of the Factory lies in its possession of

Advanced facilities for manufacturing long members comprising of a set-up of 5000 Tones Hydraulic press line,

cut-to-length line for strip preparation purchased from M/s Kohler of Germany and a Camber Correction line. Facility for hot forming of axle halves with a 3000 tone press and heating furnace. Flexibility in manufacturing frames with an off line Prototyping facility.

The Cab & Cowl Factory is equipped with state-of-art facilities like Centralized Paint Shop and Automated painting set up, Robot painting, BIW Fabrication of day & sleeper cabs for trucks, Articulates (Tractor/ Trailer), BIW Fabrication of Cowls for buses, and other miscellaneous applications. The fully equipped Foundry, that the unit is supported by, supplies high-grade SG Iron castings for automobile components and excavators, and is rated as one of the cleaner, better and highly automated foundries in the world. It has an annual capacity of 42,000 MT of Good castings and makes, both, Gey and SG cast Iron casting. It manufactures all critical automobile castings e.g. Cylinder Block, Cylinder Head etc. It has a sophisticated Kunkel Wagner High Pressure Moulding line of a rated production capacity of 90 moulds/ hour. This is supported by a sand cooler and sand mixer from Kunkel Wagner. Its melting shop has Medium Frequency Induction Furnaces for melting and Channel Furnaces for holding. The pouring is done by a Channel Press Pour coupled with a Steam Inoculation Dispenser. The core shop has a state-ofthe-art Cold Box Machine, making four cores per minute. It has elaborate sand and metallurgical laboratories. In 1993 the foundry was ISO 9002 certified by the Bureau Veritas Quality International, which was later followed by the more stringent QS 9000 certification from the BVQI in the year 2000. Currently it is certified as TS: 16949 by BVC.

The 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. As one of the most modern forging set-ups in the Country, the Forge Division is equipped with a semi-automated forging line with 40,000 mkg Beche Hammer and state-of-the-art presses from Kurimoto of Japan. It produces critical forgings like crankshafts, front axle beams and steering parts for the automobile plant. The new forging line, installed in April 1984, has the capacity to forge front axle beams at 90 sec per piece and crankshafts at 120 sec per piece. Mechanical presses help produce a variety of heavy forgings. The sophisticated FIDIA digit 165 CC Graphite Milling Machine links shop floor machines to the design workstation. The Forge has been certified as ISO 9002 and QS 9000 by the BVQI. HV Axles Ltd., a wholly owned subsidiary of Tata Motors, is currently the market leader in medium and heavy commercial vehicles axles in India with an installed capacity of over two lakh axles per annum. The Company's product range includes Front Steer axles- both live and normal, Rear Drive axles and dummy/ trailer axles. It is currently the sole suppliers of M&HCV axles to the Jamshedpur and Lucknow plants of Tata Motors. HVAL has state-of-the-art manufacturing facilities for making all major Axles components such as Front Axle Beam, Stub Axles, Front & Rear Wheel Hubs, Differential, Axle Gears (Crown Wheel, Pinion, Bevel Gear & Shaft Gear), Banjo Axle Beam, Swivel Heads, Constant Velocity Shafts etc. For being in the forefront of cutting edge technology, HVAL has proven skills in manufacturing axles from component level to assembly & testing. As a TS 16949 company, HVAL encourages and continuously supports its vendor base to upgrade their Quality Management System to TS 16949.

HVTL was established on 13th March 2000 as a major subsidiary of Tata Motors by taking over operations of Tata Motors' erstwhile Gearbox Division. It is a leading manufacturer of automotive transmissions, components and engineering applications for a wide range of medium and heavy commercial vehicles. The Company has a capacity of producing 94,000 gearboxes per year which is being enhanced to a capacity of 120,000 Gearboxes per year. It provides products and services of superior quality, matching with the current economic and business trends in medium and heavy commercial vehicle markets. The Quality System of HVTL is certified under ISO/ TS-16949. In the environmental and safety front, it was ISO 14001 certified in 2004 and OHSAAS-18001 certified in 1999. While making technological advancements, the social responsibilities are also taken up seriously. Tata Motors, Jamshedpur, plays an active role in serving rural communities surrounding its Works through various community centres. While striving to create a culture for self-help amongst the local populace, it has made significant progress in community and social forestry, sustainable development of wastelands, road construction, rural health and education, development of rural industries, water supply and family planning. A signatory to the UN Global Pact, it also takes various initiatives in human rights protection, labour standards, environmental issues, modern effluent treatment facilities, sanitation drives, soil and water conservation programmes, tree plantation drives, etc.

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, which has one of the most versatile tool making facilities in the Indian subcontinent. It houses a Vehicle manufacturing complex which is one of the most integrated automotive manufacturing centres in the Country producing a large variety of individual items and aggregates. It is engaged in the design and manufacture of sophisticated press tools, jigs, fixtures, gauges, metal pattern and special tools, as well as models for the development of new ranges of automobile products. Its capabilities have enabled Tata Motors to introduce new products and improve existing ones without resorting to imports of dies or fixtures. Over the years, this division has developed expertise in design and manufacture of automated dies, fixtures and welding equipment. Its large design group is fully conversant with state-of-the-art CAD facilities and manufacturing facilities comprising of light and heavy CNC machine shops, jigs boring room, plastic template shop, wood pattern and model pattern shop, five axis precision machine tools and laser control machines. To cope with such a diverse range, four assembly lines have been established, one each for MCVs and HCVs, LCVs, Utility vehicles and one for Passenger Cars (Indica and Indigo). The Passenger Car Division in 'K' block executes the entire process of car manufacture over five shops - the engine shop, the

transmission shop, press and body shops, paint shop and the trim and final assembly shop. The shops are fully automated ensuring that there is minimal chance for error in the manufacturing processes. After the car is completely assembled, it goes through several checks like wheel alignment, sideslip test, brake test, shower test, and a short test run before it is ready for dispatch. All systems such as materials management, maintenance and other activities are computerized, enabling smooth operations and minimum inventory needs. The Electronics Division is engaged in the production of a wide variety of Machine Tool Controllers, PLCs, Test rig instrumentation, Servomotors, Proximity Switches. In addition, it has developed a number of components such as flashers, horns, timers that are used in Tata Motors' vehicles. Industry experts rate the fully automated Foundries at Chinchwad and Maval among the best, worldwide. The Iron Foundry at Chinchwad produced 37,000 Tons of high precision castings in 2006-07 while the Iron Foundry at Maval produced 14000 Tons of spheroidal Iron castings in 2006-07. These include Cylinder Blocks, Cylinder Heads, Gear Box Housing, etc. To dispense with the need for outsourcing, an Aluminium Foundry with an annual capacity of 3,300 tonnes has been established.

Lucknow
Tata Motors Lucknow is one of the youngest production facilities among all the Tata Motors locations and was established in 1992 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 set-up to support with latest technology and cater to the complexities of automobile manufacturing. Fully Built Vehicle business, which is one of the fast growing areas of our business, is also established in Lucknow. Our plant, rolls out commercial vehicles and is specialised in the designing and manufacturing of a range of modern buses which includes Low-floor, Ultra Low-floor, CNG & RE Buses. The Lucknow facility also specialises in manufacturing HCBS (High capacity Bus System) buses. In light of Companys aggressive growth plans, we are currently in expansion phase and production at Lucknow would grow manyfold in near future. The expansion shall be in the areas of painting, welding, vehicle assembly & testing and utility services, driven by latest technology. To achieve these plans we invite people who have good Technical Knowledge, seek Challenging Opportunities and have a Drive for Engineering Excellence to come and partner us in our journey.

Pantnagar
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 953 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. The Company has invested over Rs.1000 crores in the plant. Vendors for the vehicle have made additional investments to set up their plants in the vendor park adjoining the plant. The operation has generated about 7500 direct and indirect jobs in the plant, among vendors and service providers in the area.

Sanand
Tata Motors plant for the Tata Nano at Sanand, in Ahmedabad district of Gujarat, marks the culmination of the Companys goal of making the Tata Nano available to hundreds of thousands of families, desirous of the car a safe, affordable and environmental friendly mode of transport. The capacity of the plant, to begin with, will be 250,000 cars per year to be achieved in phases, and with some balancing is expandable up to 350,000 cars per year. Provision for further capacity expansion has also been incorporated in this location. Built in a record time of 14 months starting November 2008, the integrated facility comprises Tata Motors own plant, spread over 725 acres, and an adjacent vendor park, spread over 375 acres, to house key component manufacturers for the Tata Nano. In line with latest world-class manufacturing practices, the Tata Nano plant has been equipped with state-of-the-art equipment. They include sophisticated robotics and high speed production lines. Conscious of the critical need of environment protection, the plant has energy-efficient motors, variable frequency drives, and systems to measure and monitor carbon levels. These are supplemented with extensive tree plantation, sustainable water sourcing through water harvesting and ground water recharging and harnessing solar energy for illumination.

Company Profile
Tata Motors Limited is Indias largest automobile company, with consolidated revenues of Rs.1,23,133 crores (USD 27 billion) in 2010-11. It is the leader in commercial vehicles in each segment, and among the top three in passenger vehicles with winning products in the compact, midsize car and utility vehicle segments. The Company is the world's fourth largest truck manufacturer, and the world's third largest bus manufacturer. The Company's over 25,000 employees are guided by the vision to be "best in the manner in which we operate, best in the products we deliver, and best in our value system and ethics." Established in 1945, Tata Motors' presence indeed cuts across the length and breadth of India. Over 5.9 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The Company's manufacturing base in India is spread across Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set up an industrial joint venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce both Fiat and Tata cars and Fiat powertrains. The Company's dealership, sales, services and spare parts network comprises over 3500 touch points; Tata Motors also distributes and markets Fiat branded cars in India. Tata Motors, the first Company from India's engineering sector to be listed in the New York Stock Exchange (September 2004), has

also emerged as an international automobile company. Through subsidiaries and associate companies, Tata Motors has operations in the UK, South Korea, Thailand and Spain. Among them is Jaguar Land Rover, a business comprising the two iconic British brands that was acquired in 2008. In 2004, it acquired the Daewoo Commercial Vehicles Company, South Korea's second largest truck maker. The rechristened Tata Daewoo Commercial Vehicles Company has launched several new products in the Korean market, while also exporting these products to several international markets. Today two-thirds of heavy commercial vehicle exports out of South Korea are from Tata Daewoo. In 2005, Tata Motors acquired a 21% stake in Hispano Carrocera, a reputed Spanish bus and coach manufacturer, and subsequently the remaining stake in 2009. Hispano's presence is being expanded in other markets. In 2006, Tata Motors formed a joint venture with the Brazil-based Marcopolo, a global leader in bodybuilding for buses and coaches to manufacture fully-built buses and coaches for India and select international markets. In 2006, Tata Motors entered into joint venture with Thonburi Automotive Assembly Plant Company of Thailand to manufacture and market the Company's pickup vehicles in Thailand. The new plant of Tata Motors (Thailand) has begun production of the Xenon pickup truck, with the Xenon having been launched in Thailand in 2008. Tata sons has two divisions:Tata Quality Management Services: Helps Tata companies achieve business excellence through the Tata Business Excellence Model. Tata Financial Services: In- house financial consultancy which carries out long and short term financial planning for Tata companies.

TATA MOTORS
Tata Motors is Indias largest automobile company, with consolidated revenues of USD 20 billion in 2009-10. It is the leader in commercial vehicles and among the top three in passenger vehicles. Tata Motors has products in the compact, midsize car and utility vehicle segments. The company is the world's fourth largest truck manufacturer, the world's second largest bus manufacturer, and employs 24,000 workers. Since first rolled out in 1954, Tata Motors has produced and sold over 4 million vehicles in India.[3] Established in 1945, when the company began manufacturing locomotives, the company manufactured its first commercial vehicle in 1954 in a collaboration with Daimler-Benz AG, which ended in 1969.[4] Tata Motors is a dual-listed company traded on both the Bombay Stock Exchange, as well as on the New York Stock Exchange. Tata Motors in 2005, was ranked among the top 10 corporations in India with an annual revenue exceeding INR 320 billion. In 2010, Tata Motors surpassed Reliance to win the coveted title of 'India's most valuable brand' in an annual survey conducted by Brand Finance and The Economic Times.[5] Tata Motors has auto manufacturing and assembly plants in Jamshedpur, Pantnagar, Lucknow, Ahmedabad, Sanand, Dharwad and Pune in India, as well as in Argentina, South Africa and Thailand

MILESTONES
The Tata group is one of India's oldest, largest and most respected business conglomerates. The group's businesses are spread over seven business sectors. 1868 Jamsetji Nusserwanji Tata starts a private trading firm, laying the foundation of the Tata group. 1874 The Central India Spinning, Weaving and Manufacturing Company is set up, marking the group's entry into textiles and its first large-scale industrial venture. 1902 The Indian Hotels Company is incorporated to set up the Taj Mahal Palace and Tower, India's first luxury hotel, which opened in 1903. 1907 The Tata Iron and Steel Company (now Tata Steel) is established to set up India's first iron and steel plant in Jamshedpur. The plant started production in 1912. Sets up its first office overseas, Tata Limited in London.

1910 The first of the three Tata Electric Companies, The Tata HydroElectric Power Supply Company is set up. The second, Andhra Valley Power Supply Company was established in 1917 and Tata Power in 1919. The first two companies were merged with Tata Power in 2000 to form a single entity. 1911 The Indian Institute of Science is established in Bangalore to serve as a centre for advanced learning. 1912 Tata Steel introduces eight-hour working days, well before such a system was implemented by law in much of the West. 1917 The Tatas enter the consumer goods industry, with the Tata Oil Mills Company being established to make soaps, detergents and cooking oils. The company was sold to Hindustan Lever (now Unilever) in 1984.

1932 Tata Airlines, a division of Tata Sons, is established, opening up the aviation sector in India. Air India was nationalised in 1953. 1939 Tata Chemicals, now the largest producer of soda ash in the country, is established. 1945

Tata Engineering and Locomotive Company (renamed Tata Motors in 2003) is established to manufacture locomotive and engineering products. Tata Industries is created for the promotion and development of hi-tech industries. 1952 Jawaharlal Nehru, India's first Prime Minister, requests the group to manufacture cosmetics in India, leading to the setting up of Lakme. The company was sold to Hindustan Lever (now Unilever) in 1997. 1954 India's major marketing, engineering and manufacturing organisation, Voltas, is established. 1962 Tata Finlay (now Tata Tea), one of the largest tea producers, is established. Tata Exports is established. Today the company, renamed Tata International, is one of the leading export houses in India. 1968 Tata Consultancy Services (TCS), India's first software services company, is established as a division of Tata Sons. 1971 Tata Precision Industries, the first Tata company in Singapore, is founded to design and manufacture precision engineering products.

1984 The first 500 MW thermal power unit at the Trombay station of the Tata Electric Companies is commissioned.

1995 Tata Quality Management Services institutes the JRD QV Award, modelled on the Malcolm Baldrige National Quality Value Award of the United States, laying the foundation of the Tata Business Excellence Model. 1996 Tata Teleservices (TTSL) is established to spearhead the group's foray into the telecom sector. 1998 Tata Indica India's first indigenously designed and manufactured car is launched by Tata Motors, spearheading the group's entry into the passenger car segment.

1999 The new Tata group corporate mark and logo are launched. 2000 Tata Tea (now Tata Global Beverages) )acquires the Tetley group, UK. This is the first major acquisition of an international brand by an Indian business group. 2001 Tata AIG a joint venture between the Tata group and American International Group Inc (AIG) marks the Tata re-

entry into insurance. (The group's insurance company, New India Assurance, set up in 1919, was nationalised in 1956). 2002 Tata Sons acquires a controlling stake in VSNL (renamed Tata Communications in 2008), India's leading international telecommunications service provider. Tata Consultancy Services (TCS) becomes the first Indian software company to cross one billion dollars in revenues. Titan launches Edge, the slimmest watch in the world. 2004 Tata Motors is listed on the world's largest bourse, the New York Stock Exchange, the second group company to do so after VSNL. Tata Motors acquires the heavy vehicles unit of Daewoo Motors, South Korea. TCS goes public in July 2004 in the largest private sector initial public offering (IPO) in the Indian market, raising nearly $1.2 billlion. 2005 Tata Steel acquires Singapore-based steel company NatSteel by subscribing to 100 per cent equity of its subsidiary, NatSteel Asia. VSNL (now Tata Communications) acquired Tyco Global Network, making it one of the world's largest providers of submarine cable bandwidth. Tata Sons completes 60 years of Tata operations in the US. The Taj acquires a hotel run by Starwood, Sydney (renamed Blue) and takes over management of The Pierre, NY.

2006 Tata Sky satellite television service launched across the country. Foundation stone for the Tata Medical Centre unveiled in Kolkata. 2007 Tata Steel acquires the Ango-Dutch company Corus, making it the world's fifth-largest steel producer. TCS inaugurates TCS China a joint venture with the Chinese government and other partners. Computational Research Laboratories, a division of Tata Sons, develops Eka, one of the fastest supercomputers in the world and the fastest in Asia. The Taj acquires Campton Place Hotel in San Francisco. Tata Steel celebrates its centenary on August 26, 2007. 2008 Tata Motors unveils Tata Nano, the Peoples Car, at the 9th Auto Expo in Delhi on January 10, 2008. Tata Motors acquires the Jaguar and Land Rover brands from the Ford Motor Company. Tata Chemicals acquires General Chemical Industrial Products Inc. 2009 Tata Motors announces commercial launch of the Tata Nano; Tata Nano draws over 2.03 lakh bookings; first 100,000 owners of the Tata Nano chosen; delivers first Tata Nano in the country in Mumbai. Tata Teleservices announces pan-India GSM service with NTT DOCOMO.

TRF acquires Dutch Lanka Trailer Manufacturers (DLT), Sri Lanka, a world-class trailer manufacturing company. Jaguar Land Rover introduces its premium range of vehicles in India. Tata Motors acquires remaining 79 per cent shares in Hispano Carrocera, one of the largest manufacturers of bus and coach cabins in Europe. Tata Chemicals launches Tata Swach the worlds most costeffective water purifier. Tata Housing makes waves with its launch of low cost housing in Mumbai. 2010 TRF acquires UK-based Hewitt Robins International. New plant for Tata Nano at Sanand inaugurated. Advinus Therapeutics announces the discovery of a novel molecule GKM-001 for the treatment of type II diabetes. Tata Tea announces joint venture with PepsiCo for health drinks. Tata Tea group rebrands itself as Tata Global Beverages, headquartered in London. Tata DOCOMO launches its 3G services in Maharashtra and Gujarat. Brunner Mond acquires 100-per-cent stake in leading vacuum salt producer British Salt, UK. Tata Chemicals launches i-Shakti dals, a range of branded pulses.

2011 Tata Coffee and Starbucks sign MoU for strategic alliance in India. Tata Chemicals rebrands its global subsidiaries in the UK, the

US and Kenya under the Tata Chemicals corporate brand. The Tata brand soars into the top 50 club of global brands. Tata Medical Center, a comprehensive cancer care and treatment facility established in Kolkata, was inaugurated by Chairman Ratan Tata.