327323 190200102036

A PROJECT REPORT

Submitted by

NISHANT GADHVI

190200102036

In partial fulfilment for the award of the degree of

BACHELOR OF ENGINEERING

in

AUTOMOBILE ENGINEERING

GOVERNMENT ENGINEERING COLLEGE, RAJKOT

Gujarat Technological University, Ahmedabad

[May, 2023]

Gujrat Technological University Government Engineering College, Rajkot

327323 190200102036

12 WEEKS INTERNSHIP AT TMPVL, SANAND &

B.MANGATRAM, MUNDRA

A PROJECT REPORT

Submitted by

NISHANT GADHVI

190200102036

In partial fulfilment for the award of the degree of

BACHELOR OF ENGINEERING

in

AUTOMOBILE ENGINEERING

GOVERNMENT ENGINEERING COLLEGE, RAJKOT

Gujarat Technological University, Ahmedabad

[May, 2023]

Gujrat Technological University Government Engineering College, Rajkot

327323 190200102036

Government Engineering College

Rajkot -360005

CERTIFICATE

This is to certify that the project report submitted along with the project

entitled 12 weeks internship at Tata Motors Passenger Vehicles Ltd.,

Sanand has been carried out by Nishant Gadhvi under the guidance in the

partial fulfilment for the degree of Bachelor of Engineering in Automobile

Engineering, 8th Semester of Gujarat Technological University, Ahmedabad

during the academic year 2022-2023.

Prof. U.R. Bhuva Prof. B.J. Makwana

Internal Guide Head of the Department

Gujrat Technological University Government Engineering College, Rajkot

327323 190200102036

Gujrat Technological University Government Engineering College, Rajkot

327323 190200102036

TMPVL CERTIFICATE

Gujrat Technological University Government Engineering College, Rajkot

327323 190200102036

B. MANAGATRAM & CO. CERTIFICATE

Gujrat Technological University Government Engineering College, Rajkot

327323 190200102036

Government Engineering College

Rajkot -360005

DECLARATION

We hereby declare that the Internship report submitted along with the

Internship Project entitled 12 weeks internship at Tata Motors Passenger

Vehicles Pvt., Sanand submitted in partial fulfilment for the degree of

Bachelor of Engineering in Automobile Engineering to Gujarat technological

University, Ahmedabad, is a bonafide record of original work carried out by

me at TMPVL, Sanand under the supervision Prof. U.R. Bhuva of and that no

part of this report has been directly copied from any students report or taken

from any other source, without providing due reference.

Name of the student Sign of Student

1. Nishant Gadhvi

Gujrat Technological University Government Engineering College, Rajkot

327323 190200102036

ACKNOWLEDGEMENT

One should always acknowledge the fine peoples who helps one in his or her journey. And

during in this 12-week long internship period I got chance to upgrade my theoretical

knowledge and upskill my practical knowledge under there guidance.

Firstly, I would like to thank Prof. U.R. Bhuva head of Automobile Department and other

faculty member of GEC, Rajkot for helping and guiding me during this training.

I express my deep sense of gratitude and heartfelt thanks to my supervisor and mentor Mr.

Radha Raman Sharma (head of Press shop), Tata motors Passenger Vehicles Ltd. For his

valuable guidance and vital help throughout this internship period.

I would specially thank Mr. Samat Gelva (line operator), Mr. Dixit Rathod (press

production), Mr. Nanda(quality), Mr. Dipanjan (press production), Mr. Pradip De (press

production), Mr. Kamil (press production) and all the Press Shop team of their valuable

guidance and perfect practical training, which will help to discharge my duties to the best

of my abilities in the industry.

I express my sincere thanks to Miss. Pragati Kadiya of HR department, T.M.P.V.L for

their kind co-operation in scheduling my training.

I would like to express my deepest thanks to Mr. Kanji Gadhvi Manager and Mr. Hemant

Goswami service Manager at B. Mangatram &Co. Mahindra for taking part in the useful

decision and giving necessary guidance and I show my gratitude to the B. Mangatram &Co.

team.

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ABSTRACT

During this industrial training of 12-week at Tata Motors Passenger Vehicles

Ltd. Sanand and B. Mangatram &Co. Mahindra, Mundra-Kutch I have gained
a vast practical and theoretical knowledge of the production of passenger
vehicle and the service in the automobile industry.

This report covers the overall work experience and learning outcomes during
the training program. It consists the entire press process, which takes place in
Press Shop of the automobile industry and the general service of a car
dealership.

I have included different parts of the plant and their key feature and functions.
It also contains the possible upgrades in the current system.

In this training report also contain company overview of Tata Motors and
Mahindra and Mahindra and various departments of press shop and the tools
used in the work shop respectively.

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List of Figures

Fig. No. Figure Name Page No.

1.1 Tata Logo 1
1.2 Indic 2
1.3 Tata Motors Plants Location in India 4
1.4 Tiago 5
1.5 Altroz 5
1.6 Tigor 5
1.7 Safari 5
1.8 Punch 5
1.9 Nexon 5
1.10 Harrier 5
1.11 Mahindra Logo 6
1.12 Mahindra Product Portfolio 7
2.1 Plant Layout 9
2.2 Shop Process Flow 11
2.3 Flow Process of Press Shop 11
2.4 Layout of EV Shop 13
2.5 Flowchart of Powertrain 13
2.6 Workshop Layout 15
3.1 Press Shop Layout 16
3.2 KOMATUS Press Layout 17
3.3 Die’s Preventive Maintenance Schedule 22
3.4 Fixture Table 23
3.5 Panel Checker Inspection Report 23
4.1 OM Forklift 26
4.2 Overhead Crane 26
4.3 DSP 27

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Fig. No. Figure Name Page No.

4.4 Tools Used at Fixture Area 28
4.5 Fix Spanner 29
4.6 Ring Spanner 29
4.7 Combination Spanner 29
4.8 Allen Key 30
4.9 Screwdrivers 30
4.10 Ratchet Wrench 30
4.11 Stand 31
4.12 Hammers 31
4.13 Scissor Jack 31
4.14 Filler Gauge 32
4.15 Pliers 32
4.16 Torque Wrench 32
4.17 Two-Post Hydraulic Lift 33
4.18 Oil-Filter Wrench 33
4.19 Wheel Balancer 33
5.1 PLC 34
5.2 Fix 1S PLC 35
5.3 FX 1 n PLC 35
5.4 FX 3U PLC 35
5.5 Q Series PLC 35
5.6 Block Diagram of PLC 36
5.7 Photo of End of Line 39
5.8 Line Operation Panel 42
5.9 Hourly Production Check List 42
5.10 Die Maintenance 42
5.11 General Service 43
6.1 Safety PPE 44

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List of Table

Table No. Table Name Page No.

1.1 Mahindra Cars Engine and Transmission Option 8
2.1 Product of TMPVL, Sanand 14
3.1 Opening Stock Report 20
3.2 Press Production and Downtime Report 21
5.1 Types of PLC 35
5.2 I/O devices in PLC 36
5.3 Blank Rejection Data 38
5.4 Blank Panel Weight and Gauge Size 40
5.5 Press Shop Panel Data 41

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List of Abbreviations

FY Financial year
SCV Small Commercial Vehicles
LCV Light Commercial Vehicles
M&HCVs Medium and Heavy Commercial Vehicles
EV Electric Vehicle
ILCV Intermediate Light Commercial Vehicle
GIDC Gujarat Industrial development Corporation
M&M Mahindra and Mahindra
TMPVL Tata Motors Passenger Vehicle Limited
TCF Trim Chassis Final
BIW Body In White
ED Electrophoretic Deposited
LH Left Hand
RH Right Hand
PDI Pre-Delivery Inspection
DSP Die Spotting Press
PLC Programmable Logic Controller
PPE Personal Protection Equipment
BSO Body Side Outer
RDO Rear Door Outer
RDI Rear Door Inner
FDO Front Door Outer
FDI Front Door Inner
TGI/O Tail Gate Inner/Outer
TLI Trunk Lid Inner
TLO U/L Trunk Lid Outer Upper/Lower

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List of Content

Content Page No.

Acknowledgement i
Abstract ii
List of Figure iii
List of Table v
List of Abbreviations vi
List of contents vii
Chapter: 1 Introduction 1
1.1. Tata Group 1
1.1.1. Tata Group Overview 1
1.1.2. Tata Motors 2
1.1.3. Tata Motors Plants in India 3
1.1.4. Products from Tata Motors Passengers vehicles 4
1.2. Mahindra and Mahindra Ltd. 6
1.2.1. Overview of M & M 6
1.2.2. Overview of B. Mangatram 6
1.2.3. Product Portfolio of B. Mangatram 7
1.2.4. Engine and Transmission Options 8
Chapter: 2 Organization Structure and Layouts 9
2.1.TMPVL, Sanand 9
2.1.1. Plant Layout 9
2.1.2. Different Departments at TMPVL 10
2.1.3. Different Shops at TMPVL 11

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Content Page No.

2.1.4 Production Manufacturing at TMPVL 14
2.2. B.Mangatram Workshop Layout 15
Chapter: 3 Overview of Assigned Shop 16
3.1. Press Shop 16
3.1.1. Press Shop Basic 16
3.1.2. Press Production Department 20
3.1.3. Press Maintenance Department 22
3.1.4. Die Maintenance Department 22
3.1.5 Quality Department 23
3.1. B. Mangatram Workshop 25
Chapter: 4 Tools, Equipment and Machinery 26
4.1. Tools, Equipment and Machinery used in Press Shop 26
4.1.1. Machinery used in Press Shop 26
4.1.2 Tools and Equipment used in Press Shop 27
4.1.3. Tools Used by Quality Department 28
4.2. Common Tools used at Press Shop and B. Mangatram 29
4.3. Tools used at B. Mangatram 33
Chapter: 5 Project works and In Hand Experience 34
5.1. Projects at TMPVL 34
5.1.1. PLC Training 34
5.1.2. Blank Rejection 37
5.1.3. Loss Report of End of Line 39
5.1.4. Assistance in Project of Supply Chain 40
5.1.5. In Hand Experience at Press Shop 41
5.2. In Hand Experience at B. Mangatram, Mahindra 43
5.2.1. General Service 43

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Content Page No.

5.2.2. PDI 43
Chapter: 6 Safety Precautions 44
6.1. Safety Precaution at Press Shop, TMPVL 44
6.2. Safety Precaution at B. Mangatram, Mahindra 45
Chapter: 7 Suggestion on the Current System 46
7.1. Material Quality Check at end of Line 46
7.2. Supermarket 46
7.3. Blank Storage Area 46
7.4. Addition of New equipment’s/Tools and Manpower at 46
B. Mangatram, Mundra
Chapter: 8 Conclusion and Learning Outcomes 48
8.1. Conclusion and Learning Outcomes at TMPVL, Sanand 48
8.2. Conclusion and Learning Outcomes at B. Mangatram, 48
Mundra
References 49

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311419 Company Overview

CHAPTER: 1

COMPANY OVERVIEW

1.1. TATA GROUP

1.1.1. Tata Group Overview

Fig.1.1 Tata logo
The Tata Group was founded as private trading firm in 1869 by Mr.
Jamshedji Nusserwanji Tata, the group privately owned conglomerate 100
companies encompassing several sectors (Chemicals, Consumer products,
Energy, Engineering, Info. Systems, Materials and Services). The group’s
headquarters are in Mumbai. The group operates in more than 100 countries
across six continents, with a mission ‘To improve the quality of life of the
communities we serve globally, through long-term stakeholder value creation
based on Leadership with Trust’.

Each company under the Tata Group operates independently under the
guidance and supervision of its own board of directors and shareholders. Tata
Sons is the principal shareholder and promoter of Tata companies. 66% of the
equity share capital of Tata Sons is held by philanthropic trusts, which support
education, health, livelihood generation and art and culture. The group employs
over 695000 people with a revenue of $100.39 billon (2106-17 data)

Many Tata companies have achieved global leadership in their businesses.

For instance, Communications is no.1 international wholesale voice provider and
Tata Motors is among the top ten commercial vehicle manufacturers in the world.
Tata steel is among the top fifteen best steelmakers.

There are 29 publicly listed Tata enterprise with a combined market

capitalization of about $130.13 billion (as on March 31,2017). For instance, Tata
Motors, Tata Steel, TCS, Tata Power, etc. As of 2020 the Tata Group had 7
chairmen.

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1.1.2. Tata Motors

Tata Motors group is a $37 billion organisation. It is a leading global automobile

manufacturing company, with a diverse portfolio includes an extensive range of cars,
sports utility vehicles, trucks, buses and defence vehicles.
The company was founded in 1945 known as Tata Engineering and Locomotive
Company as a manufacturer of locomotives. The first commercial vehicle was
manufactured by the company in 1945 in a collaboration with Daimler-Benz AG till
1969. Tata Motors entered the passenger vehicle market in year 1988 with launch of
Tata Mobile followed by the iconic Tata Sierra in
1991. In the year 1998 Tata launched the first Indica,
first fully indigenous Indian passenger car and in
2008 the promise was fulfilled with the launch of
Tata Nano. Fig.1.2 Indic

Tata Motors acquired the South Korean commercial truck manufacture Daewoo
Commercial Vehicle Company in 2004. The group has been the parent company of
Jaguar Land Rover from Ford in 2008. It also has a joint venture with Hitachi
(construction-equipment) and Stellantis which manufactures automobile components
and Fiat Chrysler and Tata branded vehicles.
Tata Motors has auto manufacturing and vehicles plants in Jamshedpur, Pantnagar,
Lucknow, Sanand, Dharwad and Pune in India, as well as in Argentina, South Africa,
United Kingdom and Thailand. It has research and development centres in Pune,
Jamshedpur, Lucknow, Dharwad in India and South Korea, United Kingdom and
Spain.
Tata Group Mission: We innovate mobility solution with passion to enhance the
quality of life.
And the vision: by FY 2024, we will become the most aspirational Indian auto brand,
consistently winning, by
 Delivering superior financial returns
 Exceeding customer expectations, and
 Creating a highly engaged work force.

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1.1.3. Tata Motors Plants in India

I. Karnataka Plant: The Karnataka plant is located in the Belur Industrial Area of
Dharwad. It manufactures SCV, LCV, M&HCVs and also EV buses on the ILCV
and M&HCV lines. It is sprawls over an area of 405 acres. It has a cumulative
manufacturing capacity of 410 Vehicles per day working in two shift facilities.
II. Pune Plant: The Pune plant is located in the Pimpri-Chinchwad industrial belt of
Maharashtra. It is the most versatile Manufacturing plant of the company. The
supplies both commercial and passenger vehicle with a daily capacity of producing
730 commercial and 1000 passenger vehicles in two shifts. The range of defence
vehicles is also produced here. The plant spans over an area of 930 acres. The plant
is one of the most technologically advanced Tata Motors Manufacturing plants.
III. Uttarakhand Plant: The Pantnagar plant of Tata Motors is where the bestselling
Tata Ace minitruck and its variants are manufactured. The project spreads across
1000 areas in the State Industrial Development corporation of Uttarakhand. This
plant can produce 1440 vehicles per day.
IV. Uttar Pradesh Plant: The U.P plant was established in 1992 to meet the growing
demand of the commercial vehicles demand in the Indian market. It specializes in
designing and manufacturing a range of Morden buses. The plant has also
commissioned a JV company, Tata Macropolo Motors Ltd. on the premises. It is set
on land of 600 acres in the Chinhut Industrial Area. It manufactures 300 vehicles
per day.
V. Jamshedpur Plant: This plant is the first manufacturing facility of Tata Motors.
Its state-of-the-art manufacturing and assembly lines can roll out a medium or
heavy-duty truck every five minutes. Its world-class engineering and research
centre can carry out complex vehicle designing through 3D visualization. Its area
spans 603 acres with a separate township of 1200 acres. It is the only plant to have
its own hospital as well as township.
VI. Gujrat Plants: The Gujrat Facility is the youngest of the Tata Motors
manufacturing plants. It is located in GIDC Sanand, 35 Km from Ahmedabad city.
It has been producing various models of passenger vehicles like the Tigor and
Tiago. The first electric vehicle of the company was produced in this plant, the Tigor
EV. The plant spans over an area of 1100 acres the plant can produce around 800
vehicles at full capacity in three shifts. The new acquired manufacturing plant of
Ford will help to scale up the production capacity.

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Location of Tata Motors plants in Indian

Fig.1.3 Tata Motors plants Location in India

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1.1.4. Products From Tata Motors Passengers Vehicles

i. Hatchback

Tiago Altroz

Fig.1.4 Tiago Fig.1.5 Altroz

ii. Sedan

Tigor

Fig.1.6 Tigor

iii. SUVs

Safari Punch Nexon Harrier

Fig.1.7 Safari Fig.1.8 Punch Fig.1.9 Nexon Fig.1.10 Harrier

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1.2. MAHINDRA AND MAHINDRA Ltd.

1.2.1. Overview of M&M Fig.1.11 Mahindra logo

M&M was founded on 2nd of October 1945 as a steel trading company in

Ludhiana as Mahindra and Muhammed. The company was named Mahindra and
Mahindra in the year 1948 after the independence.
The company saw business opportunity in the manufacturing and selling MUVs,
and stared the assembly under the licence of the Willys Jeep in India. The company
soon was established as the Jeep manufacture in India and later commenced
manufacturing Light Commercial Vehicles and Agricultural tractors. Later M&M
also purchased Gujrat Tractor in 1999 and in year 2007 Punjab Tractor Ltd.
Later on, the group entered the 2-wheeler industry by taking over Kinetic
Motors in 2008.
In year 2010 it took 55% stake in Reva Electric Car company and later acquired
100% stake and renamed it Mahindra Electric Mobility Ltd. M&M acquired
majority of stake in South Korea’s Ssang Yong motors and later sold it in 2022. A
100% stake in Peugeot Motorcycle was acquired on October 2019.
Mahindra and Tech Mahindra buy 76.06% stake in the Italian car designer
Pininfarina in December, 2015. M&M has also equity stakes in MITRA Agro
Equipment’s Pvt. In Jan,2018. In April 2020, Mahindra and Renault ended their
joint venture which operation from 2005 onwards.

1.2.2. Overview Of B. Mangatram

B. Mangatram & Co. are authorised channel partners for Mahindra & Mahindra
Ltd. for Kutch district since 1981. B. Mangatram have 3 steps at Bhuj,
Gandhidham and Mundra.
At B. Mangatram & Co. one will discover a 360-degree range of Mahindra’s
cars, SUVs and LCV’s at very conveniently located State of the Art Showrooms.

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1.2.3. Product Portfolio of B. Mangatram

XUV700 THAR XUV 300

Bolero Neo Marazzo Bolero

Scorpio Classic Scorpio N XUV 400 EV

Fig.1.12 Mahindra Product Portfolio

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1.2.4. Engine And Transmission Options

Model Engine Transmission

XUV 700 Petrol:2.0L mStallion I4 turbo 6-speed manual
Diesel: 2.2L mHawk I4 turbo 6-speed automatic
THAR Petrol: 2.0L mStallion I4 turbo 6-speed manual
Diesel: 2.2L mHawk I4 turbo 6-speed automatic
1.5L D117 I4 turbo
XUV 300 Petrol:1.2L I4 T-GDI 6-speed manual
Diesel:1.5L I3 6-speed automatic
BOLERP NEO Petrol: nil 5-speed manual
Diesel:1.5L mHawk I3 5-speed automatic
2.2L DW12 mHawk I4
BOLERO Petrol: nil 5- speed manual
Diesel:1493cc mHawk D70
turbo I3
2498cc XD3P I4
2523cc MDI turbo I4
2523cc M2DiCR turbo I4
SCORPIO N Petrol: 2.0L mStallion I4 turbo 6-speed manual
Diesel:2.2L mHawk I4 turbo 6-speed automatic
SCORPIO CLASSIC Petrol: nil 6-speed manual
Diesel:2.2L mHawk
Marazzo Petrol: nil 6-speed manual
Diesel:1.5L I4
XUV 300 EV 147.51 kW permanent magnet Automatic
synchronous motor
Table 1.1 Mahindra Cars Engine and Transmission Options

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311419 Organization Structure & Layouts

CHAPTER: 2

ORGANIZATION STRUCTURE AND LAYOUTS

2.1. TMPVL, SANAND

2.1.1. Plant Layout

Fig.2.1 Plant Layout

1. Administrative Budling
2. Press Shop
3. Weld Shop
4. Paint Shop
5. TCF shop
6. Powertrain
7. Warranty Office
8. TMLD Yard
9. TML Storage area
10. EV Shop

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2.1.2. Different Departments at TMPVL

There are different departments at TMPVL which are listed below

1. Manufacturing Department:
 Production Department
 Maintenance department
 Manufacturing Quality Department
2. Manufacturing Engineering
 Vehicle Planning Department
 Productivity Service Department
 Engineering Change Management
 Infrastructure Planning
 Tool Room Engineering
 Powertrain Planning
3. Purchase and Supply Chain Department
 Purchase
 Logistics
 SQIG
4. Production Planning and Control Department
5. Human Resource (H.R)
6. Fire, Safety and Security Department
7. I.T
8. Central Quality
9. Engineering Research Centre (ERC)

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2.1.3. Different Shop at TMPVL

The TMPVL plants operates in different stages, these different stages have
predefined functions and these functions are achieved by various shops and this
shops work in line.

Fig.2.2 Shop Pross flow

1. Press Shop

The function of the Press Shop pressing the Blank sheet into car Body Panels. The
Press shop has a different set of dies of different vehicle body panels. These dies are
installed in the High Tandem Press Line of KOMATSU Press. The panels are checked at
the press end of line by the quality department.

Fig.2.3 Flow Process of Press Shop

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2. Weld Shop

The Weld shop is also known as Body in White (BIW) shop in the plant. The
Weld Shop welds different body panels and child panels (outsourced by different
vendors) together and builds the monocoque chassis of the vehicle by Mig, Spot and
Stud welding.
i. UBF (Under Body Frame): The UBF is weld both with manually and robotic
machines.
ii. UBC (Under Body Complete): in this line under part of the body is completed,
which further goes to drop lift by quality checking department. The spots are
applied at the required places in spot welding, and re-spot are done on already
applied spots to provide required strength in welding by spot. MIG welding
is also carried out at required places.
iii. MF (Main Framing): in Main framing line there is fitting of a door and
connecting of main frame by robotic machine. Body Side Complete LH & RH
are joined to Formed assembly and then spot welded Manually as well by
Robots, after its Underbody Fitment & spot welding at required places.
iv. MR Line (Main Re-Spot): In this line the full body of a car is completed by a
manually spot welding and fitting required parts. In BC line the required parts
like Front & Rear Door, Fenders, Hood Complete, Tail Gate are adjusted,
settled and tighten bolts and placed Hinges by Men as well Robots. Quality
check, Gap setting, etc. is carried out.
v. Closer Line: In Closer Line there are different parts of a car like door, fender,
hood, BSO, Tailgate, Trunk Lid are welded in closer line with the help of
robots and manual spot welding.

3. Paint Shop:

This area is restricted as even a single dust particle can damage the complete paint
work. ED coating, Sealer application for water proofing parts and joints, Base coat
and finish coat on the robotic line and quality inspection by skilled operators.

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4. EV Shop:

In this shop, the EV’s after leaving the assembly shop are brought here for fitment
of battery and other sub-assemblies. EV shop mainly consists of different stations,
where assembly of all the parts are done. Here the EV’s are charged for testing after
the connections of the battery.

Fig.2.4 Layout of EV shop

5. Powertrain:

In the Powertrain machining of the crank shaft, cylinder head and engine block are

done.

Fig.2.5 Flowchart of Powertrain

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6. Trim Chassis & Final (TCF):

The painted body for Paint shop and engine from the Powertrain arrives at TCF,
complete car assembly is done here. The TCF shop consists of different lines.

i. Under Body Line

ii. Door Line
iii. Trim Line
iv. Mechanical Line
v. Shower Line
vi. Cradle Line
vii. Cockpit Line

A series of test are done before dispatching the vehicle at TCF

 A/C Leak Test,

 ECOS Test,
 Brake, Static Test,
 Vibration Test,
 Wheel Alignment,
 Head Lamp Aiming,
 Rolls and Brake Test,
 Shower Test,
 Drive Test.

2.1.4. Products Manufactured at TMPVL

Model IC ICNG EV
Tiago Petrol  
Tigor Petrol  
Table2.1 Product of TMPVL

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311419 Organization Structure & Layouts

2.2 B. Mangatram Workshop Layout

Fig.2.6 Workshop Layout

1) Spare parts room,

2) Two post lift
3) Blank space for cars
4) Blank space for cars
5) Two post lift
6) Tool table
7) Headlight adjustment aiming
8) Tool room
9) Engine room
10) Lunch room
11) Washing bay.

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311419 Overview of Assigned Shop

CHAPTER: 3

OVERVIEW OF ASSIGNED SHOP

3.1 PRESS SHOP

3.1.1 Press Shop Basic

The Press Shop is the shop which brings the blank into shape of the body panels
required for building car body. The press shop has a High-Speed Tandem Press Line
from KOMATSU.
The Press Shop is the one which provides the TMPVL plant with the body panels,
which are used in making of the Monocoque chassis of the car build at the plant.

Fig.3.1 Press Shop Layout

In total 24 panels are pressed at the press shop, with the help of a 120 Dies (including
dummy dies), there are also the old 55 Dies of the Tata Neno for its 11 panels.
This Dies are installed in the on a High-Tandem Press line in a set of 5 Dies set in
on 5 presses installed in the KOMATSU Press.

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311419 Overview of Assigned Shop

Given below is the Layout of the Press used in the press shop:

Fig.3.2 KOMATSU Press Layout

1) Blank lifter Crane
2) Blank Washing Unit
3) Blank Centring area
4) Loder
5) Press 1 (2000 T)
6) Feeder 1
7) Press 2 (1000 T)
8) Feeder 2
9) Press 3(1000 T)
10) Feeder 3
11) Press 4 (1000 T)
12) Feeder 4
13) Press 5 (1000 T)
14) Unloader
15) Exist conveyor
16) Press Crown

The Press line has 3 parts

1) Front line: This area includes the

 The Blank Lifter Crane: The blank from the Blank Area is staked in the
help of forklift.
 Blank Washer unit: This unit is at the centre of the front line; the panel
are washed by oil (the oil used is for washing is mixture of Lubrication
oil and Cleaning oil)
 The Blank Centring Area: The washed panel are then centred at this
conveyer with help of clamps

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Gujrat Technological University Government Engineering College, Rajkot
311419 Overview of Assigned Shop

2) Press Line: The Press line includes the area from the Loader to the Unloader.
 The Loader grabs the washed panel from the front-line conveyer and drop it in
place at the Press 1.
 The Press 1 (OP 10) is a drawing press with 2000T capacity, it draws the basic
shape of the body panel.
 The Press 2 (OP 20) is Sheering and Pershing press with a capacity of 1000 T.
 The Press 3 (OP 30) is Sheering and Pershing press with a1000 T load capacity.
 The press 4 (OP 40) is flanging press of 1000 T, this press gives bends and
shape
 The Press 5 (OP 50) is restamping and Perishing and Flanging press of 1000 T.
 The panels in the press line are shifted from one press to other press with the
help of 4 feeders installed between the presses.
 The types of motion of Loader and Unloader are
 Slider motion
 Swing axis motion
 Tilt axis motion
 The type of motion in a Feeder are
 Linear axis motion
 Slider motion
 Swing axis motion
 Tilt axis motion
3) End of the Line: The end of line of the press is the line where the press panels exist
from the press after the operation is completed.
The end line has 3 conveyers:
 Exit conveyer: The panel from OP 50 is drop here by the Unloader
 The other conveyers are the RH & LH conveyer where the Material Quality is
checked by skilled workers.
 The panels are then staked in their respected pallets and then these pallets are
then stocked in the Super Market.
The press also has a Scrap Conveyer which collects the scrap from the sheering and
perishing operation in the presses and take the scrap to the dumping arear, where the scrap
is dumped in the trucks.

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311419 Overview of Assigned Shop

Type of panels press in the Press Shop are:

 Body Side Outer LH & RH (for Tiago and Tigor)
 Roof (for Tiago and Tigor)
 Hood (Inner and Outer)
 Front Door Outer LH & RH (same in Tigor and Tiago)
 Rear Door Outer LH & RH (for Tiago and Tigor)
 Tail Gate Inner (for Tiago and Nexon)
 Tail Gate Outer (for Tiago and Nexon)
 Fender LH & RH (same for Tiago and Tigor)
 Fender LH & RH (for Nexon and Altroz)
 Front Floor (same for Tiago and Tigor)
 Trunk Lid Outer Upper/Lower (for Tigor)
 Trunk Lid Inner (for Tigor)
The Nexon and Altroz panel are made as per the order from Pune Plant.
The name the panels are also written in the form of the abbreviations:
 Body Side Outer - BSO
 Front Door Outer - FDO
 Rear Door Outer - RDO
 Tail Gate Inner -TGI
 Tail Gate Outer - TGO
 Trunk Lid Outer Upper/Lower – TLOU/TLOL
 Trunk Lid Inner - TLI

The blank panels come from number of venders Tata Steel, JSW Steels, BASO Steel,
POSCO India centre Pvt. Ltd. Different panels have different set of Dies. Various
departments work in harmony in the Press Shop and delivery the upmost performance,
with best quality of the panels

The Press Shop consists of four department:

i. Press Production
ii. Press Maintenance
iii. Die Maintenance
iv. Quality

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311419 Overview of Assigned Shop

3.1.2 Press Production Department

The Press Production department is meant to make production plan and manage
production data. The High-Tandem Press Line is operated by the Press Production.
The department has manpower for different areas, one operator sits at the front of
line, one operator operates the line operation Panel and a team of manpower in at the
end of line in which skilled workers checks the quality of the panel and stack it in the
pallet, this filled pallet are then are staked in the Supermarket in their respective areas.
Press Production makes an Opening Stock report every day in A shift, this report
consists data of the blank panel data in the blank storage area, the pressed panels in
the Supermarket and data of vehicles in and out in BIW.

Panel Total Panel

Production Panel
Panel Name Model Opening Press Tiago Out Tigor Out Part Number Model Opening
21.04.23 Name
21.04.23 Panel 21.04.24

FDO LH K4/K5 0 0 0 0 0 0 0 0

FDO RH K4/K5 0 0 0 0 0 0 0 0

FDI LH K4/K5 0 0 0 0 0 0 0 0

FDI RH K4/K5 0 0 0 0 0 0 0 0

FF K4/K5 0 0 0 0 0 0 0 0

FDR LH
(W.O.H.) K4/K5 0 0 0 0 0 0 0
XZ,,NRG,XT
0
FDR LH
(W.H.) K4/K5 0 0 0 0 0 0 0
XM, ,XE

FDR RH
K4/K5 0 0 0 0 0 0 0
(W.O.H.)
0
FDR RH
(W.H.)
K4/K5 0
Table 3.1 Opening Stock Report
0 0 0 0 0 0

HDO K4/K5 0 0 0 0 0 0 0 0

This Opening stock report needs the data of the blank and the press panels, the blank
HDI K4/K5 0 0 0 0 0 0 0 0

panels data is collected from the Blanks storage area and for the pressed panels data
RDO LH K4 0 0 0 0 0 0 0 0

one member of the production department visits the Super Market and fill the panel
RDO RH K4 0 0 0 0 0 0 0 0

data and then feeds the data in the Opening stock report.
RDI LH K4 0 0 0 0 0 0 0 0
The management of the manpower at end of the line of the High-Tandem Press is
RDI RH K4 0 0 0 0 0 0 0 0
also done by the Press Production and the Material Quality of the panels pressed.
BSO LH K4 0 0 0 0 0
The Press Production department also make the0 list and
0
sequence of 0the Die which
need toBSObe
RH
installed
K4 0
in the0 press
0
machine
0 0
and 0the number
0
of the panel
0
produced
according
ROOF the K4
blank available
0 0 in 0the Blank
0 Storage
0 0 area0 and the blank pallet
0 available
in the Super
TGO Market.
K4 0 0 0 0 0 0 0 0

TGI
(W.H.) K4 0 0 0 0 0 0 0
XZ,NRG
0
TGI
(W.O.H.) K4 0 0 0 0 0 0 0
XT,XM,XE
20
Gujrat Technological
BSO LH
University
K5 0 0 0 0 0
Government
0 0
Engineering 0College, Rajkot
BSO RH K5 0 0 0 0 0 0 0 0
311419 Overview of Assigned Shop

Press Production also maintenance the data of the run time of the press machine and
makes a Daily down time report of the press machine, this report includes the cause of
down time and also the variation from the plane.

Press Production and Down Time Summary Remark

A Shift
Production Day Loss Time summary DT minutes
Press Shop Capacity 5170 SPM Loss 65
Strokes per minute 11 Quality 14
Actual Production Nos. 2520 BD/Maintenance 60
Strokes lost 2650 Other/ Material 0
Loss Time in Min 226 Process / Others 25
Online Die repair 38
Setup change 24
TOTAL 161
Hourly Production Chart
6:30 to 7:30 to 8:30 to 9:30to 11:30 to 12:00 to 1:10 to 2:10 to
Hours Total
7:30 8:30 9:30 11:00 12:00 1:00 2:10 3:00
Plan 660 660 660 990 330 660 660 550 5170
Actual 190 349 384 457 220 113 400 407 2520
Loss Time Summary
Loss Time Summary in Min Day Major Reasons Today
Shortages

Materials Problem

Quality
mq inspection
Quality 14

BD/Maintenance
sheet hung down
Breakdown / Maint 60 1P pre acc pump closed forl unit change line not ready
dbd miss judge
Process/ Others
eol stop
Process ( In-House) 25

Online Die Repair

scrapmark in rdo tiago
Online Die Repair 38 op 20 scrapjam

Set up change

No of ADC = 3 24

Model
=
Change

Other

Total 161

Table.3.2 Press Production and Downtime Report

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3.1.3 Press Maintenance Department

All the maintenance work done in the Press Shop is done and managed by the
Press Maintenance department. This department is the in charge of all the maintains
required in the press machine, the forklifts, the cranes, pellets in the Super Market,
the Scrape conveyer, the racks of the Blank storage area, Ac system in the Press
Shop, the electric wiring and also the door/windows.

3.1.4 Die Maintenance Department

The maintenance of the Dies is done by the Die Maintenance. There are four type
of maintenance performed by the Die Maintenance department, this four type of
maintenance are listed below:
1) Predictive Maintenance: The Predictive Maintenance is the maintenance in
which the Die Maintenance department make a predictive time when the die
will require maintenance, the time is predicted according the data of the cycle
completed by die (by the production data).
2) Preventive Maintenance: Preventive Maintenance is done to prevent any shot
of permeant damage to the die or prevent die breakdown and also preventive
maintenance help to maintenance the good condition of the die. This
maintenance is done according to Die Preventive Maintenance Schedule and
the maintenance done according the check list.

Fig.3.3 Die’s Preventive Maintenance Schedule

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311419 Overview of Assigned Shop

3) Online Maintenance: The Maintenance while the die is online is called Online Die
maintenance. This maintenance is done according to the damage detected by the
workers at the end of line. One representee from the Die Maintenance is always
present at the press line for online maintenance.
4) Regular Die Maintenance: The Regular Maintenance includes the regular
maintenance done on the die after on production (it includes the cleaning of the
die, polishing of the surface and checking different parts). Regular Maintenance
also includes the maintenance suggestion from the Press Production department.
3.1.5 Quality Department

The Quality Department ensures the quality of the panels produced in the Press
Shop, it also makes sure that the panels are as per the pre-set dimensions and the
quality. This department has different departments under it which help the Press
Shop to maintain the quality of the panel produced.
The departments of Quality department are:
1) Fixture department: The Fixture department checks the panel by placing the
panels on a fixture of that panel. A skilled and experienced person, known as
the panel checker, checks the panel according to the checkpoints and fill the
Panel Checker Inspection report.

Fig.3.4 Fixture Table Fig.3.5 Panel Checker Inspection

Report

The Panel Checker Inspection report has different points according to which
the checker measures and tally the data with the ideal data, if there is a major
difference then the lot of panels are sent to rework or rejected, also feedback
to the Die Maintenance is sent and required work is done on the die. The
checker uses different tools for measurements.

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311419 Overview of Assigned Shop

The checkpoint of the Fixture:

 Matching Gap
 Matching Flush
 Trim Gap
 Trim Flush
 Holes Size
 Flange Length
2) Quality Gate: The quality gate checks the pressed panel in the Green Room under lights
and checks for damages on the panel. It also checks the panels dimensions with the
Limit Sample of the panel.
Type of damages on a panel are:
 Dent/Rain mark
 Chip/Scrap mark
 Rust/Pitting
 Scratches
 Scoring
 Tool/Pad/Punch/Cup mark
 Bump/Cavity
 Wavy Wrinkle/Material folding
 Black mark
 Oil marks/patterns
 Thinning/Crack
 Shock line
 Shinning/Line marks
 Burr
 Deformation/Damaged
3) Rework Department: Number of damages of the panel can be corrected by rework, this
rework is done in the rework area, where skilled and trained worker do the work.
4) PDI department: The PDI (Pre-Delivery Inspection) department inspects the quality of
the panel which are manufactured for the Pune Plant (Fender of Altroz /Nexon and
Nexon TGI & TGO).

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3.2. B. MANGATRAM WORKSHOP

The B. Mangatram workshop at Mundra provides the general services for the
Mahindra vehicles, for the passenger vehicles and also small commercial vehicles. Pre-
Delivery check of the brand-new model is also done in the workshop.
The workshop is located just behind the B. Mangatram showroom and has all the
tool which are required for General service of the vehicles and the PDI of the cars.
Most of the Pre-Delivery Inspections are done by the B. Mangatram’s Bhuj
dealership, as all the car delivery from the company are delivered there and from there
the cars are brought at the Mundra showroom. Still there are a number of check-ups
done at Mundra showroom, which includes the outer-body check, interior check, the
electronic check, under body check, fluid check and at last the car goes for washing.
The general service is of two types free service and paid service. The free services
are given to the new cars which are bought buy the costumer and there are generally 3
free services per car.
The general services include:
 Oil and oil filter change
 Break-pad and disc check
 Break bleeding
 Coolant top-up
 Air filter cleaning/change
 A.C filter change
 Washer fluid top-up
 Battery check
 Door greasing
 Washing

The service is done according to the kilometres covered by the car or the time period
between the last service.

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311419 Tools, Equipment & Machinery

CHAPTER: 4

TOOLS, EQUIPMENT AND MACHINERY

4.1. TOOLS, EQUIPMENTS AND MACHINERY USED IN PRESS

SHOP

4.1.1 Machinery used in Press Shop

1) Forklifts: Forklifts are industrial vehicles, having a powered operated

forked platform attached at the front that can be raised and lowered for
insertion under a cargo to lift or move it.
The Press Shop has total of 7 forklifts.
 4 forklifts of 3 ton are used at the end of life, supermarket and the
PDI area.
 3 forklifts of 8 ton are used at the Blank storage area and the front
of line.

Fig.4.1 OM Forklift Fig.4.2 Overhead Crane

2) Cranes: Overhead cranes are used in the press shop. The overhead cranes
are commonly called a bridge crane
There are 3 overhead cranes operated in the Press Shop:
 Overhead crane of 15/50 ton capacity with 2 hoists
 Overhead crane of 50ton capacity with 1 hoist
 Overhead crane of 5/15 ton capacity with 2 hoists

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3) Die Spotting Press: The DSP are machines typically used in the maintenance and
repair of die. A DSP is used to verify contact surface of the upper and lower
portions of the die and ensure dimensional accuracy and precision.
The Press Shop has a 500 T Die Spotting Press from Simpac.

Fig. 4.3 DSP

4.1.2. Tools and Equipment used in Press Shop

The Press Shop has a sperate room for all the tools called the Tools Room:
 Lathe Machine
 Surface Grinder
 Universal Cylinder Grinding Machine
 Vertical Milling Machine
 Plasma Cutting Machine
 Between Centre
 Band Saw
 Hydraulic Shearing Machine
 Power Master Bench Grinder
 Belt Grinder
 Electrode Baking Oven
 Radial Drill

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4.1.3. Tools Used by Quality Department

Tools used by the checker in the fixture area:

 Vernier Calliper
 Plunger Type Dial
 Taper Scale
 Micrometre
 Dimond fill

Fig. 4.4 Tool used at Fixture Area

Tools used in Rework:

 File
 Dolly
 Hammer
 Dent puller
 Sander
 Wheel
 Pneumatic Gun

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4.2. COMMON TOOLS USED AT PRESS SHOP AND B.Mangatram

1)Fix Spanner: These spanners have a U-shaped opening that grips the face of the
bolt of the nut. This spanner is often doubled ended, with a different sixed
opening.

Fig. 4.5 Fix Spanner

2)Ring Spanner: A Ring spanner often are double ended and usually with offset
handles to improve access to the nut or bolt head.

Fig. 4.6 Ring Spanner

3)Combination Spanner: It is a double ended tool with one ending being an open-
end spanner and the other end with a ring ended spanner.

Fig. 4.7 Combination Spanner

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311419 Tools, Equipment & Machinery

4) Allen Key: Allen key is a L-shaped tool that’s used for the installation and removal
of fasteners with a hexagonal head, also known as hex key.

Fig. 4.8 Allen Key

5) Screw Drivers: A typical simple screwdriver has a handle and a shaft, ending in a tip
the user puts the screw head before turning the handle.

Fig. 4.9 Screwdrivers

6) Ratchet Wrench: It has a one-way mechanism that allows the socket to be turned
without removing it from the nut of bolt simply by cycling the handle backward and
forward.

Fig. 4.10 Ratchet Wrench

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311419 Tools, Equipment & Machinery

7) Stand: A stand is used to give support of any object from underneath, it is designed
in such a way that it could with stand load with any deformation.

Fig. 4.11 Stand

8) Hammers: A hammer is a tool, most often a hand tool consisting of a weighted head
fixed to a long handle that is swung to deliver an impact to small area of an object.

Fig. 4.12 Hammers

9) Mechanical Scissor Jacks: Scissor jacks usually use mechanical advantage to allow
a human to lift a load by manual force alone.

Fig.4.13 Scissor Jack

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311419 Tools, Equipment & Machinery

10) Filler Gauge: Feeler Gauge are mechanical measurement instruments that are used
to provide a precise reading of the gap that exists between two parallel surfaces.

Fig.4.14 Filler Gauge

11) Pliers: This are hand tools for holding and gripping small articles or for bending and
cutting wire. A slip-joint plier has grooved jaws and the pivot hole in the one
member is elongated so that the member can pivot in either of the two positions in
order to grasp object of different size in most effective way.

Fig.4.15 Pliers
12) Torque Wrench: A Torque Wrench is a tool used to apply a specific Torque to a
fastener such as a nut, bolt of lag screw. It is usually in the form of a socket wrench
with an indicating scale or an internal mechanism which will indicate when a
specific torque vale has been reached during application.

Fig.4.16 Torque Wrench

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311419 Tools, Equipment & Machinery

4.3. TOOLS USED AT B. MANGATRAM

1)Two-post Hydraulic Lift: A two-post Hydraulic lift consist of two upright

columns with four adjustment arms attached to a carriage assembly and two
hydraulic cylinders. The arms are attached under the hooks in the under body
of the car and then the car is lifted-up for further work by technician.

Fig.4.17 Two-post Hydraulic Lift

2)Oil-Filter Wrench: A Oil-Filter Wrench is a tool for removing spin-on type oil
filter.

Fig.4.18 Oil-Filter Wrench

3)Wheel Balancer: This are used to balance wheels and ensure smooth and safe
operation.

Fig.4.19 Wheel Balancer

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311419 Project Works & In Hand Experience

CHAPTER:5

PROJECT WORKS AND IN HAND EXPERIENCE

5.1. PROJECT AT TMPVL

5.1.1. PLC Training

During my internship period at TMPVL I got an opportunity of getting PLC

tanning from MR. Radha Raman Sharma. PLC stands for Programmable Logic
Controllers.
Definition: A digitally operating electronic apparatus which uses a
programmable memory for the internal storage of instructions by implementing
specific functions such as logic sequencing, timing, counting, and arithmetic to
control various types of machine or processes through digital or analog input/output
modules.
Basically, PLC are industrial computers, with
various inputs and outputs, used to control and monitor
industrial equipment bade on custom programming,
PLC were designed to replace Relay Logic, they can
perform the sequential operations that were previously
implemented with relays, timers, etc. Fig.5.1 PLC

PLCs come in many different sizes and form factors. Some are small enough
to fit in your pocket, while others are large enough to require their own heavy-duty
racks to mount. Some PLCs are more modular, with only basic I/O (input and
Outputs), but can be customized with additional back planes and function modules
to fit different types of industrial applications.
PLCs are widely used in a variety of industries because they are fast, easy to
operate, and considered easy to program. There are five standard PLC programming
language. The most commonly used language is Ladder Logic, but it is also possible
to use function Block Diagrams, Sequential Function /charts, Structured Text or
Instruction Lists to achieve the same functionality.

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311419 Project Works & In Hand Experience

The types of PLCs are given in the table below:

Type of Key Features Sample Photo

PLC
Micro PLC  I/O range typically less
than 32
 Alpha PLC
 FX 1S

Fig.5.2 FX 1S PLC
Small PLC  I/O range typically less
than 128
 FX 1N

Fig.5.3 FX 1N PLC
Medium  I/O range less than 1024
PLC  Expansion possible
 FX 3U

Fig.5.4 FX 3U PLC
Modular  I/O range is more than
PLC 1024
 Functionality is
modularized
 Expansion of racks also Fig.5.5 Q Series PLC
 Q series PLC
Table 5.1 Tpyes of PLC

Basic components of PLC are:

 Central Processing unit: Processor and Memory
 Input Interface
 Output Interface
 Power supply

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311419 Project Works & In Hand Experience

 Programming device
 Operator interface

Fig.5.6 Block Diagram of PLC

The list of some input and output devices which connect in a PLC are listed below:

INPUT Devices OUTPUT Devices

Pushbuttons Valve
Selector Switch Motor Starters
Limit Switch Solenoids
Level Switch Control Relays
Photoelectric Switch Alarms
Motor Starter Contacts Lights
Relay Contacts Fans
Thumbwheel Switch’s Horns
Sourcing Inputs
Sinking Inputs
Table 5.2 I/O Devices in PLC

The software’s used at Press Shop for PLC are GX Developer, GX Worx 2 and HMI
PROFACE is used for the display.

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311419 Project Works & In Hand Experience

5.1.2. Blank Rejection

Blank panel of different size and shape come from different vendor for different
body panels, these blanks are unloaded from the commercial vehicle with the help
of the OM’s 8T forklift and then these blanks are stored in the Blank Storage area
and then loaded in the Blank Lifter Crane at the Front of the Line of the High-
Tandem Press Machine.
Some blank panels get damage during:
 At the time of loading form the vender,
 During the time of transportation,
 At the time of unloading from the trailer,
 At the time of stacking the blanks in the racks of the Blank Storage area,
 During the time of loading the blanks in the Blank Lifter Crane at the Front
Line.

The most common damages in the blank panel are:

 Burr
 Rusting/
 Deformation/Damage
 Scratches
 Wrinkles/Material Folding
 Cracks

All the blank panel are checked before taking the delivery by a skilled worker
and the worker keeps the data of this rejected blank panels in a book, this rejected
blank panels are sent to the scrap.

My project was to collect the data of this rejected blank panels of the past 6
months and make a excel sheet of the data and suggest solution for the problem.

Some of the suggested solution to this problem are:

 To add a dummy panel at the bottom and top of the blank stake,
 To install rubber cover to the forks of the forklift
 To used cam to keep the panels in place at the time of transportation.

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Given below is the excel sheet of the blank rejection of past 6 months

BLANK REJECTION DATA

Part DB 60 TB 22 DB 61 DB 62 DB 63 TB 23 DB 64 DB 65 DB 66 TB 24 DB 67 DB 68 DB 69 TB 25 DB 70 DB 71 DB 72 DB 73 DB 74 TB 26 DB 75 DB 76 DB 77 TB 27 DB 78 DB 79 DB 80 TB 28 DB DB 81
DATE 02-09-2022 04-09-2022 04-09-2022 09-09-2022 17-09-2022 16-09-2022 23-09-2022 30-09-2022 11-10-2022 17-10-2022 18-10-2022 27-10-2022 02-11-2022 02-11-2022 07-11-2022 15-11-2022 23-11-2022 29-11-2022 08-12-2022 03-12-2022 to 30-12-22 16-12-2022 23-12-2022 01-01-2023 01-01-2023 to 29-1-23 12-01-2023 24-02-2023 31-01-2023 29-01-2022 to 28-02-2023 31-2-2023 04-02-202
B. S. O. LH 3 3 3 7 7 7 5 6 7 2 6 4 2 4 2 5 5 5 5 3 4 3 3 3 4 4 4 6 5 4
B. S. O. RH 4 3 4 6 6 6 6 5 6 2 5 3 3 4 2 6 6 4 4 3 3 4 4 3 4 4 4 6 1 5
R. D. O.LH 8 5 0 4 10 9 7 8 7 3 4 6 5 7 4 5 8 6 8 6 5 5 5 8 6 8 7 9 12 8
R. D. O RH 8 5 0 3 10 9 9 8 8 3 4 6 5 7 4 5 8 6 8 6 5 5 4 8 7 8 8 9 0 7
R. D. I. LH 6 5 4 6 8 10 8 6 6 33 3 5 8 6 2 10 7 10 9 6 6 10 6 8 8 9 9 7 0 9
R. D. I. RH 6 5 4 6 7 10 8 7 6 33 4 5 8 6 2 10 7 10 9 5 6 10 6 8 8 9 8 7 0 8
T T. G. O. 7 3 4 5 5 8 6 5 4 2 3 4 3 4 4 3 4 3 4 4 5 4 2 6 5 6 6 6 4 5
T. G. I. 5 3 3 4 6 8 6 4 5 3 2 3 4 3 5 9 5 2 5 5 9 6 3 8 4 7 5 5 16 6
I
F. D. O LH 9 6 6 5 9 11 8 9 7 4 5 8 6 7 4 4 8 7 7 6 6 5 5 9 9 10 7 9 10 7
A
F. D. O RH 10 6 6 5 9 11 8 9 7 4 5 8 3 7 4 4 9 7 7 6 5 6 4 9 9 10 7 9 0 7
G
F. D. I. LH 8 5 5 5 10 10 9 10 9 4 6 9 5 8 5 10 10 15 8 4 11 7 6 11 8 9 8 10 16 8
O F. D. I. RH 9 5 6 7 10 10 9 11 8 4 7 9 5 8 5 10 9 15 8 5 10 6 7 11 8 8 8 10 3 8
Panel Roof 5 3 3 7 4 6 5 6 4 3 8 4 3 9 3 6 4 10 6 5 6 3 4 4 5 5 5 7 6 5
Front Floor 13 3 7 7 12 9 12 13 11 7 10 9 3 6 5 0 6 8 13 8 13 10 8 7 13 14 10 8 8 13
Fender LH 11 5 8 7 8 13 7 8 8 7 6 8 2 8 5 6 8 9 7 9 6 6 7 10 8 10 7 10 2 9
Fender RH 12 5 8 6 8 13 9 9 9 7 6 9 2 8 5 6 7 9 8 9 6 7 7 10 9 11 7 10 0 8
Hood Outer MCE 9 7 6 2 68 10 10 7 15 7 15 4 10 4 11 9 6 7 25 8 8 9 19 10 9 9 14 5 10
Hood Inner MCE 11 6 7 2 57 9 9 8 16 6 15 4 10 4 10 9 5 9 25 8 8 8 18 9 10 9 14 9 9
Hood Outer 0 0 0 0 0 4 2 11 0 0 0 1 0 1 0 1 1 0 0 2 0 1 1 2 0 2 0 2 0 0
Hood Inner 0 0 0 0 0 4 2 11 0 0 0 1 0 1 0 1 1 0 0 2 0 1 1 2 0 2 0 2 0 0

B.S.O LH. 3 3 2 3 4 5 4 4 5 3 5 2 4 2 4 5 4 8 3 2 5 3 2 4 3 5 3 5 8 3
T B. S. O. RH. 5 2 1 3 3 5 5 5 5 2 5 3 4 2 4 4 5 8 4 2 5 4 3 4 4 5 4 6 3 2
I R. D. O. LH. 3 3 7 5 0 7 3 5 6 4 4 7 3 5 3 6 6 5 6 4 2 5 4 7 6 7 8 7 5 5
G R. D. O. RH. 3 3 7 5 0 7 3 5 5 4 3 7 3 5 3 6 6 5 6 4 2 4 6 7 6 7 8 7 0 6
O R. D. I. LH. 4 5 5 7 4 6 6 6 7 3 3 3 1 5 4 5 5 7 5 4 5 3 5 8 7 8 7 8 10 7
R R. D. I. RH. 4 5 5 7 4 6 6 6 6 3 3 3 1 5 4 5 5 7 7 5 6 4 4 8 5 8 7 8 4 6
TLO U 5 23 2 4 7 37 7 10 5 4 4 6 3 15 3 6 7 3 6 14 4 4 6 15 8 9 6 18 2 6
TLO Lower 4 4 2 3 4 7 5 6 5 4 5 4 2 5 2 4 5 2 4 5 3 5 5 6 6 8 4 20 1 5
Trunk Lid Inner 7 14 2 2 5 18 6 7 6 14 5 5 3 14 3 3 3 8 5 4 4 4 4 14 5 7 5 15 0 7
Panel Roof 4 2 2 3 3 7 4 4 3 2 3 3 0 5 0 8 3 5 4 3 2 3 7 4 4 4 3 17 0 3

TGI 7 6 5 9 8 12 9 8 10 12 10 8 6 8 7 7 8 9 8 9 8 8 6 12 10 10 7 11 5 9
NEXON FENDER LH 10 7 6 7 11 12 12 9 9 13 8 9 5 10 7 8 9 20 10 10 8 10 7 13 12 12 9 13 1 10
FENDER RH 10 7 6 7 11 11 12 9 9 13 8 9 5 9 7 8 9 20 10 10 8 10 7 13 12 12 9 13 6 10

FENDER RH 2 3 2 2 2 4 2 4 2 5 2 2 2 5 2 3 3 3 3 4 8 3 4 4 5 5 5 5 6 4
ALTROZ
FENDER LH 2 3 2 2 2 4 2 4 2 5 2 2 2 5 2 3 3 3 3 4 8 3 4 4 5 5 5 5 8 4
total 217 160 140 172 201 431 231 257 212 243 167 205 119 224 124 203 212 250 216 228 200 188 174 287 232 267 218 318 156 2

Table 5.3 Blank Rejection Data

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311419 Project Works & In Hand Experience

5.1.3. Loss Report of End of Line

There are a number of reason due to which the Press line stopes, it could be due to
sensor fault in the die or due to any defect on the pressed panel of dur to some pressure
problem in the press or the feeders’ cups or due to restacking of the blanks or due to
the blank pallet. My project was to make a report on the loss report on the end of line
and the reason due to which the line stopped by the end of line.
On an average the loss time due to the end of line is about 70-75 minutes (if any
major defect or problem does not show’s up) in A shift, this also includes the lunch
and tea break of the workers.
Some of the reasons due to which the line was stopped are:
 Quality check of the first panel (Quality department checks for any defect and
counts the number of holes on the panel).
 The line also stop’s due to the shortage of blank pallet or the forklift operator
delays to bring the blank pallet.
 If any defect is detected then the line is stopped and the required correction is
done by the respected department.
 The line is also stopped due to the panel stacking up at the end line conveyer.

Fig. 5.7 Photo of End of Line

Solution for the loss of time at the end of line:

 The roller needs to be changed of the conveyer for pallet.
 The blank pallet should be available on time.
 Ideal number of man power should be there and with proper coordination.

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311419 Project Works & In Hand Experience

5.1.4. Assistance in Project of Supply Chain

An intern from the Supply chain department had a project on the weight of the blank
panels and the number of blanks inserted in and the number of panels pressed. Different
blank panels have different weight and gauge. This wight and gauge depends of the
panel’s uses and the amount of stress and load it going to experience by the press.
The weight of Tiago panels and their gauge are listed below:
Panel name Panel Weight(kg) Panel Gauge(mm)
Fender LH & RH 5.0 0.63
BSO LH & RH 18.5 0.7
FDO LH & RH 8.2 0.63
RDO LH & RH 7.0 0.63
RDI LH & RH 8.1 0.7
HOOD Inner 6.5 0.6
TGI 9.1 0.7
FDI LH & RH 9.0 0.7
HOOD Outer 8.0 0.63
Front Foor 14.7 0.7
ROOF 12.7 0.7
TGO 9.4 0.7
Table 5.4 Blank Panel Weight and Gauge size

The number of the blank inserted in the press at the front of line and the number of
pressed panels from the end of line conveyer are not always same, because some time
there are faults in the press due to which the panel get stuck in the line and get damage
in such case the line is stopped and the panel are manually removed from the line.

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311419 Project Works & In Hand Experience

5.1.5. In Hand Experience at Press Shop

There were a number of in hand experiences I had at the Press Shop

1. The counting of panels in the Super market for the Daily Opening Stock
report, to make the counting easy there were a fix number of panel in a pallet
was set. The format of daily panel count of the super market is show below:
PRESS SHOP PANEL DATA
PRESS SHOP WELD SHOP

SUB ASSEMBLY
LOOSE PANEL
M. REWORK
OK PANNEL

ASSEMBLY
REWORK
Model Part Name TOTAL

1 LH
FDO (35)
2 RH
3 LH
FDI(150)
4 RH
5 FRONT FLOOR(50)
6 TIAGO + TIGOR LH
FENDER (W.O.H)(40)
7 RH
8 LH
FENDER (W.H)(40)
9 RH
10 HOOD OUTER(35)
11 HOOD INNER(80)
12 LH
BSO(10)
13 RH
14 LH
RDI(150)
15 RH
16 LH
Tiago + Tigor RDO(35)
17 RH
18 ROOF(19)
19 TGO(30)
20 TGI (W.O.H)(150)
21 TGI (W.H)(150)
22 LH
BSO(10)
23 RH
24 LH
RDI(150)
25 RH
26 LH
RDO(35)
27 TIGOR RH
28 ROOF(19)
29 TLU (46)
30 TLL (W.O.H)(102)
31 TLL (W.H)(102)
32 TLI (100)

Table 5.5 Press Shop Panel Data

2. End of Line: During the internship apart from the projects I also got an
opportunity to get in-hand experience to operate the KUMATSU press from
the end of the line, observe Material Quality of the pressed panels and
manage the workers. At the end of line there is a Line Operation Panel
through were all the operation of the line from the press 1 (OP 10) to the end
of the line conveyer all are controlled.
On the Line Operation Panel their sit’s an operator who operates all the
operation for the press 1 to the end of line conveyer belt, the operator also
keeps a record of the hourly production control chat book.

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311419 Project Works & In Hand Experience

The hourly production control chart bool includes all the data related to the panel
produced, faults that came during the production and loss of time data with reason of
every hour of production. The Line Operation Panel has a screen which shows all the
data of the press line (including the production count of the current panel, total panel
produced, line speed, it shows where the fault is and which type of fault it is), we can
also reset the cycle, stop the press and re-set the operation.

Fig.5.8 Line Operation Panel Fig.5.9 Hourly Production Check List

3. Blank Storage area: All the Blank coming from the venders are unloaded and
checked, the data of the vehicle is written with the total number of panels in the pallet.
I was assigned to assist the supervisor in keeping a track of the data and to guide the
worker.
4. Die Maintenance: Observed the regular maintenance of the dies, also the online die
maintenance and also got to observe the matching of the updated OP 30 die of the
Tiago RDI from Pune plant.

Fig.5.10 Die Maintenance

5. Press Maintenance: In the slider of the left arm of the Feeder 1 two screw were broke
and needed to be replace, due to which the press was shut in the A shift. Firstly, the
Feeders slider part was secure and then detached, then all the helical screws were
fastened and the 2 screws were replaced.

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311419 Project Works & In Hand Experience

5.2. IN HAND EXPERIENCE AT B. MANGATRAM, MAHINDRA

5.2.1. General Service

The General Service includes:

 Oil and oil filter change
 Break-pad and disc check
 Break bleeding
 Coolant top-up
 Air filter cleaning/change
 A.C filter change
 Washer fluid top-up
 Battery check
 Door greasing
 Washing

There were vehicles which used to come for only

oil -change. As the Mundra workshop is equipped
only for general services, the major services were
done at the Bhuj dealership’s workshop

Fig.5.11 General service

5.2.2. PDI

The Pre-Delivery Inspection (PDI) is done to ensure that the vehicle is in perfect
condition and there is no damage or defect before delivering the car to the
customer. As the new cars are delivered at the Bhuj dealership so a PDI is done
there and then the car is brought to the Mundra Showroom by road (with the
customer concern), then at the Mundra showroom the cars is washed and the outer
body is checked, the electronic are checked, the under body of the car is checked
by lifting it on the 2-post hydraulic lift for any leakage of damage/defect and also
the fluid are checked of the car (engine oil, brake oil, coolant and washer fluid).
Once the car’s PDI is done the car is ready for delivery.

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311419 Safety Precautions

CHAPTER: 6

SAFETY PRECAUTIONS

6.1. SAFETY PRECAUTION AT PRESS SHOP, TMPVL

Safety is given number one priority at the TMPVL, Sanand, all the shops follow
all the required safety measures and in addition of these poster are displaced with
the safety guidelines, importance of safety and all the safety equipment require in
that zone, in addition to that in every department of every shop has a safety marshal
who ensure that all the worker follow the safety guidelines.
At the Press shop there are two types of measures taken for ensuring all over
shop safety: the first is the safety equipment’s which the employees need to care on
them and the other are the safety equipment’s used for machine. Safety measures
take at the Press shop:
 Safety helmet
 Gloves and Sleeves
 Safety Glasses
 Ear Plugs
 Safety masks
 Safety shoes
 Safety railing
 Photon sensor
 Alarms
 Safety light Fig. 6.1 Safety PPE
 Safety marking on the floor for forklift
 Marked Walking Zone
 Ventilation system for the shop
 First -aid box available at different zones of the Press Shop

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311419 Safety Precautions

6.2. SAFETY PRECAUTIONS AT B. MANGATRAM,

MAHINDRA

The work shop follows majorly to types of safety precautions:

1. Vehicle safety: The vehicle safety includes the safety precautions that the
employs follow to keep the vehicle safe from damages, such safety
precautions are:
 Proper body covers should be used during work of the vehicles to
protect it from scratches.
 The vehicle should be checked that it safely secured before lifting
the lift.
 The vehicles in the workshop are derived at the waking speed.
 Special tools are used for specific tasks.
2. Employs safety:
 The workers should be wearing a proper PPE (Personal Protective
Equipment’s) such as safety shoes, safety glasses, Gloves, sleeves,
and portative clothing.
 Follow proper lifting techniques for the lift.
 Proper disposal of hazardous material
 The battery should be disconnected before working on the vehicle
 The workshop is a no smoking zone.
 Proper fire safety measure

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311419 Suggestions on The Current System

CHAPTER: 7

SUGGESTIONS ON THE CURRENT SYSTEM

7.1. MATERIAL QUALITY CHECK AT END OF LINE

The Material Quality of panels is done by skilled workers, this works check
for the defects/damage in the panels with their naked eye under light and with
the touch of their skilled hands. They are able to detect majority of the
defect/damages but the implementation of Morden technology can be done.
The use of smart inspection techniques can be implemented such as the 3D
scanning and infra-red camera inspection to ensure supreme levels of build
quality.
7.2. SUPER MARKET

The current system of the supermarket follows a marking of the area for the
panel at the top of the shade with the help of boards but marking of the floor
for each panel would be more convent for the forklift drivers. In addition to
that magnetic badges with proper iron slots could be used in place of stickers
on the pallet (rework, ok and rejection indication).
7.3. BLANK STORAGE AREA

The racks used for the storage of stake of blank panel in the Blank storage
area causes damage to the blanks at the bottom, so thick sheet of rubber could
be used to reduce the damage.
Also, the used of rubber cover for the forklift could be done to decrease the
chance of damage of the panel during operation.
7.4. ADDITION OF NEW EQUIPMENTS/TOOLS AND

MANPOWER AT B. MANGATRAM, MUNDRA

The workshop requires a list of new equipment’s, tools and manpower for
doing major service with the on-going general service. Various special tools
and equipment’s can be introduced in the workshop (as the workshop has ample
space for the new equipment’s).

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311419 Suggestions on The Current System

List of tool and Equipment’s required:

 Wheel Alignment Machine,
 Battery charger and Tester
 Washed oil drainer
 Engine crane
 Special tools for engine overhauling

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Gujrat Technological University Government Engineering College, Rajkot
311419 Conclusion & Learning Outcomes

Chapter: 8

CONCLUSION AND LEARNING OUTCOMES

8.1. CONCLUSION AND LEARNING OUTCOME AT TMPVL,

SANAND

The internship at TMPVL has been an excellent opportunity for me. During the
course of this internship, I got to connect the bridge between my theoretical
knowledge and practical work. The internship served me best with the best
knowledge of working in manufacturing plant under the banner of such prestigious
company.
I feel enrich in more than one way, it gave me the experience of how to manage
manpower, how to do planning according to the resources available. my allotment
to the Press Shop gave me the experience on how are the body panels are made from
a blank sheet of sheet. I believe that I have been trained not only in the project
activates given to me, but also trained in time management, industrial management,
communication and soft skills, safety and also maintenance related work. It also
helped me to get in touch with the industrial environment and the value of time and
professionalism.

8.2. CONCLUSION AND LEARNING OUTCOME AT B.

MANGATRAM, MUNDRA

The period of internship at B. Mangatram, Mundra was short but it gave me a lot
of experience of a workshop and the enhanced my skills both theoretical and
practical. The internship helped me to apply my theoretical knowledge in the
practical, while working with the skilled workers. This internship also taught me
various tricks that the mechanics use will performing service to save effort and time.
The primary objective of this 12-weeks of internship was to gather real-life
working experience and put the theoretical knowledge in practice and I consider
that the objective was achieved. Over-all, it has been such a great experience and I
think the knowledge I got here will completely help me in my career.

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311419 References

REFERENCES

Websites:

 Autobizz website: https://autobizz.in/tata-motors-manufacturing-

plants-in-india/
 Britannica website - https://www.britannica.com/topic/Tata-
Group
 B. Mamantram website:http://www.bmangatram.com/
 E Scholarly Community Encyclopedia -
https://encyclopedia.pub/entry/36019
 Tata Motors- https://www.tatamotors.com/about-us/company-
profile/
 Wikipedia - https://en.wikipedia.org/wiki/Tata_Group
https://en.wikipedia.org/wiki/Tata_Motors
https://en.wikipedia.org/wiki/Mahindra_%26_Mahindra

PPT’s

 MESSUNG automation people ppt on Mitsubishi PLC

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