MEDICAPS INSTITUTE OF SCIENCE & TECHNOLOGY

INDUSTRIAL TRAINING REPORT

Pithampur Industrial Area, District Dhar, Pithampur, Madhya Pradesh, Pin code-
454775
Training duration -30 Days (5th June 2018 to 4th July 2018)

Project topic
To eliminate the problem come into the A.C. ventilation (nozzle) or
the R.P.M. meter fouling in Trax vehicle.
Submitted by: Submitted to Guide:

Sandeep Raghuvanshi Mr. O.P Gorkhe /

B.E.(Automobile Engineering) Mr. Pankaj Bairagi
Medicaps ,Indore (M.P.)

Submitted to HOD: Submitted to Plant Head:

Mr. R. Sinnarkar Mr. Y. Mathur

Sr. Manager, R&D V.P. Operation
 CONTENTS
S.NO TOPIC PAGE
NO.
1. Declaration 1

2. Acknowledgement 2

3. Certificate 3

4. Company profile 4

5. History and 5
heritage
6. Overseas presence 6

7. Vehicles 7-8

8. Pithampur plant 9

9. Vehicle assembly 10-14

10. Project description 15-32

11. Conclusion 33
 DECLARATION

I hereby declare that this Project on “To eliminate the problem come into
the A.C. ventilation (nozzle) or the R.P.M. meter fouling in Trax
vehicle’’ has been prepared by me, under the guidance & supervision of
Mr.O.P. Gorkhe / Mr.Pankaj Bairagi, FORCE MOTORS LIMITED. As a
part of my course B.E and all the work submitted by me is my original work.

It was great experiences working in esteem organization of FORCE

MOTORS Ltd. I learnt a lot and consider lucky to get an opportunity and
look forward to such an opportunity again.

Through the suggestion our mind creation there was a lot of sources that
helped me in understanding the working system and theoretical aspects of
the industry.

SANDEEP RAGHUVANSHI
B.E (Automobile Engineering)
Medicaps, Indore (M.P)
 ACKNOWLEDGEMENT

I would like to thank the organization and respected Dr. Abhay

Firodia (Chairman), Mr. Prasan A. Firodia (Managing Director),Mr. Sudhir
Mehta (Director), Mr.Abhay Patil (Senior General Manager) for providing
me the opportunity of training at Force Motors Limited .

I would like to extend my thanks and regards to Mr. R. Sinnarkar , Mr. O.P.
Gorkhe for assigning me with valuable projects that helped to gain a lot
during my training and for being such an inspirational guide.

My sincere thanks to Mr. Pankaj Bairagi for guiding us throughout the

project and being a supportive mentor.

I would also like to thank all the acquaintances of Force Motors Limited who
supported us directly or indirectly and solved queries and made us stay
pleasant.

I perceive this opportunity as a big milestone in our career development. I

will strive to use gained skills and knowledge in the best possible way, and
will continue to work on their improvement, in order to attain desired career
objectives. Hope to continue cooperation with you all in the future.

Sincerely,
SANDEEP RAGHUVANSHI
 CERTIFICATE

This is to certify that SANDEEP RAGHUVANSHI of Medicaps, Indore

has prepared his report on the Project entitled “To eliminate the problem
come into the A.C. ventilation (nozzle) or the R.P.M. meter fouling in
Trax vehicle.” and is submitted to the R & D department of Force Motors
Limited . To the best of my knowledge the work has not been submitted to
any other department. This work is an authentic work carried out by him
under my supervision and guidance.

Guide: Mr.O.P. Ghorke / Mr. Pankaj Bairagi

FORCE MOTORS LIMITED

 Company profile

Force Motors was established in 1958 by Shri. N. K. Firodia, with the vision
to provide affordable commercial transport for the masses by harnessing the
best available technology and offering economical, reliable and efficient
products.
Today, its range includes Small Commercial Vehicles (SCV), Multi-Utility
Vehicles (MUV), Light Commercial Vehicles (LCV), Special Utility
Vehicles (SUV) and Agricultural Tractors. So no matter what the need be,
Force has a solution to offer.

FULLY VERTICALLY
INTEGRATED

Force Motors is fully vertically integrated, making its own engines, chassis,
gear boxes, axles, bodies etc. for the entire product range.
Force provides appropriate solutions for transport –both goods, as well as
passenger - rugged, reliable and efficient transport solutions for every need -
rural or urban, long distance or local, over good roads or bad tracks.

The company continues in the founder's vision of providing

efficient,utilitarian vehicles that empower the individual entrepreneur to
meet his and the country's ever changing needs.
 HISTORY

The foundation of the Group was laid by Late Shri. N. K. Firodia freedom
fighter and pioneering industrialist.

He gave India two paradigms - the concept of 'low cost public transport' - the
Autorikshaw (a word he coined that now finds a place in the Oxford
Dictionary).The Tempo Matador was the first diesel light commercial
vehicle in India. The word Tempo (a registered trade mark of Daimler) is
now generic for any small goods carrier in India

Over the last five decades it has partnered with leading global automotive
names like Daimler, ZF, Ricardo, Bosch and MAN etc. Through these
associations it has developed necessary expertise in-house to harness the
latest advances in technology and developing relevant mobility solutions.
 OVERSEAS PRESENCE

Force Motors is a highly flexible automotive company that has the capability
to cater to different types of markets, by providing customized 'country
specific' solutions.

Force Motors has a formidable product range in all segments, be it small

commercial vehicles, light commercial vehicles, multi utility vehicles and
agricultural tractors. The company exports its range of world class products
to various countries in Middle East, Asia, Latin America and Africa.

Over the last five decades it has partnered with leading global automotive
names like Daimler, ZF, Ricardo, Bosch and MAN etc. Through these
associations it has developed necessary expertise in-house to harness the
latest advances in technology and developing relevant mobility solutions.

The company exports its complete range of world class products to various
countries Middle east , Asia, Latin America,and Africa.
 BRANDS

TRAVELLER(LIGHT COMMERCIAL VEHICLES

PASSENGER CARRIER)

TRAX(MULTI UTILITY VEHICLES

PASSENGER CARRIER)
 GURKHA (OFF-ROADER)

BALWAN(AGRICULTURAL VEHICLE)

KARGO KING (MUV GOODS CARRIER)

 PITHAMPUR PLANT
Pithampur plant is having 5 shops:

PRODUCTION FLOW
RAW MATERIAL
(METAL SHEETS ETC. )

PRESS SHOP

PRESSED PARTS INPUTS

TO THE BODY SHOP

BODY SHOP

WELDED BODY INPUTS

TO THE PAINT SHOP

PAINT SHOP

REAR AXLE SHOP

PAINTED BODY INPUTS
TO THE ASSEMBLY SHOP

AGGREGATE ASSEMBLY SHOP

SHOP

ENGINE SHOP
POWERTRAIN
GEAR BOX SHOP SHOP
DISPATCH

REAR AXLE SHOP

 VEHICLE
ASSEMBLY SHOP
 ASSEMBLY SHOP LAYOUT

TRAX TRIM LINE

Rectification

TRAX CHASSIS LINE

TRAX

GANG WAY

TRAXFINAL LINE

STORES
TRIM-1 TRIM-2

TRAVELLER FINAL LINE

Office

TRAVELLER RECTIFICATION AREA

RBT WHEEL
ALIGNMENT
 OPERATION WISE LINE STRATIFICATION

Trax Trim line Trax chassis line Trax final line

Masking of body chassis loading on Station Station1 Bundy tube fitment
Station1 Foam fitment Station1 chassis number punching
Wheel box NVH fitment rear buffer fitment Station2 Autoelectric fitment

Bonnet NVH fitment rear axle assembly HVAC fitment

engine compartment NVH
Station2 Station2 rear suspension Station3 Wheel arch fitment
fitment
EGR modular fitment oil filling Bellow fitment

Autoelectric front axle assembly Station4 Air cleaner assembly

Station3
Station3 wiper motor fitment front suspension
A post covering fitment Station5 Wheel arch fitment
Rack &pinion assembly
Station4 and fitment
AC cooling Unit Transfers case fitment Station6 Radiator S/A &intercooler
Station4
Hanging pedal S/A fitment
Station5 Engine assembly &fitment Station7 Steering system
Gear shifting assembly
propeller shaft assembly
Hand brake fitment Station6 Seat belt Assembly
Station5 and fitment
Station8
Rear door seat assembly
Door lock fitment Station7 Fuel tank assembly protection cover fitment

Door winding Station8 Bundy tube fitment Foot step assembly

Hot and cold pipe fitment wheel arch
Station6
Exhaust system assembly & Station9
head lamp fitment Station9 side moulding
fitment
Bumper fitment
Roof fitment Tyre fitment
Station10
Station7 Spoiler lamp fitment Front antiroll bar fitment Seat assembly
Door stopper fitment Station10 protection
Station11 chassis verification cover fitment
Door panel and side
Station8
covering fitment

sunshield mirror fitment

center mirror fitment
Station9
window S/A ( subassembly)

Rubber seal and window

Station10
fitment

matting fitment
Station11
speaker covering

Station12 sticker pasting

Station13 Body locking and shifting

  TECHNICAL SPECIFICATIONS OF TRAX
TOOFAN

ENGINE
Model FM 2.0 CR

Emission BS – IV

Type 3 Cylinder, Common Rail

Displacement 1947 CC

Max Output 67 HP @ 3200 R.P.M

Max Torque 175 Nm @ 1600-2400 R.P.M

TRANSMISSION
Type Synchromesh

No. of Gears 5 Forward &1 Reverse

AXLES
Front Independent

Rear Live Rigid

SUSPENSION
Front Independent with solid torsion bar, hydraulic telescopic shock ab

Rear Semi Elliptical Two Stage Leaf Springs with Hydraulic telescopic

STEERING
Type Mechanical / Power Steering (Optional)

Turning Radius 7.0 Meters

BRAKES
Service Brakes Hydraulic, Dual Circuit, Vacuum Assisted, (ABS with EBD) optio
Front Disc Brakes

Rear Drum Brakes with LSV

Parking Mechanical on Rear Wheels

WHEELS & TYRES

Size 7.00 R 15

DIMENSIONS
Wheel Base (mm) 3050

Overall Length (mm) 4832

Overall Width (mm) 1790

Overall Height (mm) 2055

Overhang Front (mm) 707

Overhang Rear (mm) 1075

Ground Clearance (mm) 210

WEIGHTS
( KG )

Max. Permissible FAW 1090

Max. Permissible RAW 1785

Max. Permissible GVW 2875

CAPACITY
Fuel Tank 63.5 Litres

SEATING CAPACITY
Seating Capacity 11+D
  TECHNICAL SPECIFICATIONSOF TRAX
TOOFAN DELUXE

ENGINE
Model FM 2.6 CR

Emission BS IV

Type 4 Cylinder, Common Rail

Displacement 2596 CC

Max Output 85 hp @ 3200 R.P.M

Max Torque 230 Nm @ 1400-2400 R.P.M

TRANSMISSION
Type Synchromesh

No. of Gears 5 Forward and 1 Reverse

AXLES
Front Independent

Rear Live Rigid

SUSPENSION
Front Independent with solid torsion bar, Hydraulic Telescopic Shock

Rear Semi Elliptical two stage leaf springs with Hydraulic Telescopic

STEERING
Type Power Steering

Turning Radius 7.0 meters

BRAKES
Service Brakes Hydraulic- Dual Circuit, Vacuum assisted, (ABS with EBD) optio

Front Disc Brakes

Rear Drum Brakes with LCRV

Parking Mechanical on rear wheels

WHEELS & TYRES

Size 7.00 R15

DIMENSIONS
Wheel Base (mm) 3050

Overall Length (mm) 4832

Overall Width (mm) 1790

Overall Height (mm) 2055

Overhang Front (mm) 707

Overhang Rear (mm) 1075

Ground Clearance (mm) 210

WEIGHTS
( KG )

Max. Permissible FAW 1090

Max. Permissible RAW 2010

Max. Permissible GVW 3100

SEATING CAPACITY
Seating Capacity 11+D
  PROJECT TOPIC-
To eliminate the problem come into the A.C. ventilation (nozzle) or
the R.P.M. meter fouling in Trax vehicle.

 DESCRIPTION OF PROBLEM
4W1H

A. What is problem To eliminate the problem come into the

A.C. ventilation (nozzle) or the R.P.M
meter fouling.

B. When it is started It is five months existing problem.

C. Where is the problem At Trax trim line.

D.
Who is complaining Internal costumer.

E. How much 60% of the vehicle

 Research and development (R&D)
Our Research & Development centre at Akurdi, Pune is considered
among the most advanced in the automotive research and development
facilities in the country.

Force Motors encourages innovation and motivates its 500 strong

design team to create path breaking automotive designs. Huge
investments in equipment, facilities and manpower are already in place
to complete the development of BSVI compliant engines before 2020
deadline.
The R&D facility includes hardware, software, verification and
validation, and test facilities which are utilized during the complete
product development cycle from Concept to Start of Production (SOP).
The process includes creative vehicles styling and design by our CAE
team, well-equipped with the most advanced software.
 Every new vehicle is run though durability test lab, engine test lab and
driveline test setups before it hits the road. Apart from test labs Force
Motors has in-house torture track (Pave Track) for complete vehicle
durability testing.

How Air Conditioning Works

Air conditioning like it says 'conditions' the air. It not

only cools it down, but also reduces the moisture
content, or humidity. All air conditioners work the
same way whether they are installed in a building, or
in a car. The fridge or freezer is in a way an air
conditioner as well. Air conditioning is a field in it's
own right, but we'll stick to the main points or a car's
air conditioning and the main parts used and a few
hints to keep the air-con system running properly.
Air conditioning's main principles are Evaporation and Condensation,
then Compression and Expansion.

Evaporation: You may have noticed that if you rub a little surgical spirits
on the back of your hand, then your hand will feel cold. Why is that? It's
evaporation. It is because the spirits on the back of your hand start to
evaporate. As the spirit evaporates, it takes away heat from the surface of
your skin.

Condensation: Have you ever noticed when somebody walks in from the
cold into a take-away wearing glasses, their glasses steam up? Why is that?
It's condensation. The moist air of the take-away cools as it contacts the cold
surface of the glasses and the air has less capacity to hold moisture, so it
condenses into water on the glasses.

Heat of Compression: Have you ever noticed when you pump up a bicycle
tyre with a hand pump, that the end of the pump gets hot? This is because the
energy that you have put into the air by pumping it has not only compressed
it, but has also caused the air molecules to push closer together so giving off
heat with the friction.

Compression: At some point all gases will eventually become liquid. An

example of that would be a can of deodorant - it's liquid inside the can
(because you can hear it when you shake it) but is a gas when it comes out
and hits your underarm. The pressure inside the can is higher, so the
propellant inside is liquid.

Cooling by Expansion: Going back to the deodorant, you will notice also
how cold it feels that's because the propellant has just expanded in volume
quickly.

Hard tubing and flexible hoses connect all the actual components of the air
conditioning in your car. Evaporation and condensation, expansion and
compression are the physics of why it works. There are five main
components to the whole system, namely the Compressor, Condenser,
Receiver-dryer, Expansion valve, and the Evaporator.
 The fluid that passes around the
whole system is the refrigerant.
The refrigerant can evaporate at a
low temperature, and then
condense again at a higher
pressure. In the bad old days, R-12
was the refrigerant used in almost
all cars. It was widely available,
however it was found to be a
contributor to the hole in the
earth's ozone layer as it was a
chlorofluorocarbon (CFC). These
refrigerants were discontinued,
and all cars after 1996 use a non-
CFC fluid called R-134A which is
kinder to the environment.

So, here is how all the various parts of a car's air conditioning works:

Compressor: The compressor is the work horse of the air conditioning

system, powered by a drive belt connected to the crankshaft of the engine.
When the aircon system is turned on, the compressor pumps refrigerant
vapour under high pressure to the condenser.

Condenser: The condenser is a device used to change the high-pressure

refrigerant vapor to a liquid. It is mounted in front of the engine's radiator,
and it looks very similar to a radiator. The vapour is condensed to a liquid
because of the high pressure that is driving it in, and this generates a great
deal of heat. The heat is then in turn removed from the condenser by air
flowing through the condenser on the outside.

Receiver: The now liquid refrigerant moves to the receiver-dryer. This is a

small reservoir vessel for the liquid refrigerant, and removes any moisture
that may have leaked into the refrigerant. Moisture in the system causes
havoc, with ice crystals causing blockages and mechanical damage.

Expansion Valve: The pressurised refrigerant flows from the receiver-drier

to the expansion valve. The valve removes pressure from the liquid
refrigerant so that it can expand and become refrigerant vapour in the
evaporator.

Evaporator: The evaporator is another device that looks similar to a car

radiator. It has tubes and fins and is usually mounted inside the passenger
compartment behind the fascia above the footwell. As the cold low-pressure
refrigerant is passed into the evaporator, it vaporises and absorbs heat from
the air in the passenger compartment. The blower fan inside the passenger
compartment pushes air over the outside of the evaporator, so cold air is
circulated inside the car. On the 'air-side' of the evaporator, the moisture in
the air is reduced, and the 'condensate' is collected and drained away.

Compressor: The compressor then draws in the low-pressure refrigerant

vapour to start another refrigeration cycle. The refrigeration cycle then runs
continuously, and is regulated by the setting of the expansion valve.

 GRILLE
A grille is a device for supplying or extracting air vertically without
any deflection.Grilles and diffusers may be mounted in ceilings, floors, walls, doors and
in ducts. Some are suitable for horizontal or vertical mounting while floors grilles tend
to be especially strong to withstand foot traffic.

 Types of Grille

Egg grate grille Bar grille

Transfer grille Louvre bladed diffuser
Straight bladed diffuser Linear slot diffuser

 Egg Crate Grille

The Egg Crate Grille is probably one of the simplest and cheapest grilles.
In some cases the plenum box above the grille is visible from the room below.
If air is to be removed by an extract ventilation system then a diffuser with profiled
blades to direct the air is not necessary and an egg grate grille can be used.

 Bar Grille

The blades of this type of grille are shaped as a bar compared to a narrow blade.
The bar profile may be ‘T’ shaped to reduce ‘see through’ visibility.

Some linear bar grilles have adjustable blades or angled blades to reduce ‘see through’.
  Transfer Grille

These are often used in doors and walls to provide ventilation but stop the spread of
smoke and fire should it occur. An intumescent fire damper is incorporated in some
Transfer grilles as a means of isolation in the event of a fire.

 PROBLEM IN THE A.C GRILLE (NOZZLE)

 The old fitment of the grille will create the problem. The nozzle will stuck into
the duct of the A.C.

 SUGGESTION
 The left side of A.C grille will fit on to the right side.
 The right side of A.C grille will fit on the lift side.
 The nozzle will stuck into the duct of the A.C we will change the design of the
A.C duct.
  To change the shape of the nozzle of the A.C grille.

R.P.M METER
A tachometer (revolution-counter, tach, rev-counter, R.P.M gauge) is an instrument
measuring the rotation speed of a shaft or disk, as in a motor or other machine. The
device usually displays the revolutions per minute (R.P.M) on a calibrated analogue
dial, but digital displays are increasingly common. The word comes
from Greek ταχος (tachos"speed") and metron ("measure"). Essentially the words
tachometer and speedometer have identical meaning: a device that measures speed. It is
by arbitrary convention that in the automotive world one is used for engine and the
other for vehicle speed. In formal engineering nomenclature, more precise terms are
used to distinguish the two.

 PROBLEM IN THE R.P.M METER(FOULING)

 The R.P.M meter will fouling on to the A.C duct.

 Therefore the connection of the R.P.M meter will disconnect and to connect them
the whole assembly of the dash board will be disassembly. It will be very time
consuming process to disassembly or assembly the dash board.

 SUGGESTION
 The position of the R.P.M meter will be change. The old position of the meter is
in the lift side of the driver. It’s to be change on the right side of the driver on the
just beside the cluster.

 The connection of the terminal of the R.P.M meter will not so tight. So we can
provide a connecter to extend the connection wire or a locking arrangement on to
the terminal of the R.P.M meter
 OLD POSITION OF THE R.P.M METER
 The R.P.M meter is located at the bottom panel of the dash board. And the switch
of the A.C is located at the center of the A.C grille.

 NEW POSITION OF THE R.P.M METER

 The R.P.M meter is located at the center of the A.C grille into the bazzel of the
dash board. And the switch of the A.C is located at the bottom side of the dash
board.
 LEARNINGS

1) Poka Yoke –
 Poka-yoke is a Japanese term that means "mistake-proofing" or "inadvertent error
prevention".

2) Kaizen -
Kaizen, also known as continuous improvement, is a long-term approach to work
that systematically seeks to achieve small, incremental changes in processes in
order to improve efficiency and quality.

3) Cycle time –
Cycle time is the total time from the beginning to the end of your process, as
defined by you and your customer. Cycle time includes process time, during
which a unit is acted upon to bring it closer to an output, and delay time, during
which a unit of work is spent waiting to take the next action.

4) Take time –
Takt time may be thought of as a measurable “beat time,” “rate time” or “heartbeat.”
In Lean, takt time is the rate at which a finished product needs to be completed in
order to meet customer demand.

5) Lead time –
the time between the initiation and completion of a production process.

6) Throughput time –
throughput time is the amount of time required for a product to pass through a
manufacturing process, thereby being converted from raw materials into finished
goods. The concept also applies to the processing of raw materials into a component
or sub-assembly.

7) 5S
Removing all unnecessary items
Sort (Seiri)
from the workplace
Set In Creating a specific location for
(Seiton)
Order everything
Shine (Seiso) Clean the work area
Standardise the best practice
Standardise (Seiketsu)
within the workplace
Never slip back into the old
Sustain (Shitsuke)
ways

8) 4M
Man
 a. Skill
b. Technology
c. Organization
d. Resources
e. Communications
Machine
f. Design
g. Installation
h. Supplier
Methods
i. Schedule
j. Procedure
Material
k. Design
l. Quality

9) 3M
Muda (waste), Muri(overburden) and Mura(unevenness)

10) PDCA
The plan–do–check–act cycle (Figure 1) is a four–step model for carrying out
change. Just as a circle has no end, the PDCA cycle should be repeated again and
again for continuous improvement.

11) 7 QC Tools

Histograms
Cause and Effect Diagram
Check Sheets
Pareto Diagrams
Graphs
Control Charts
Scatter Diagrams

12) QC STORY (QUALITY CONTROL )

QC story is a systematic methodology commonly used in practical procedures and

practical methods of problem solving in team.

The Quality Control Story (QC Story) method represents, for the automotive
industry companies, a problem-solving method based on considering the facts and
data, without speculation, for a problem caused by several factors. QC Story method
is applicable not only to quality problems, but also to problems of productivity,
costs, logistics, and energy. This paper presents the improvement in the customer
complaints process achieved by an effective use of the QC Story methodology. It is
presented the QC Story methodology and its performance in influencing the
customer complaints management process throughout a case study in the automotive
industry

TEAM FORMATION

SELECT THE THEME

JUSTIFY THE CHOICE

UNDERSTAND THE CURRENT SITUATION

SELECT THE TARGET

ANALYSIS

IMPLEMENT CORRECTIVE MEASURES

CONFIRM THE EFFECTS

STANDARISE

SUMMARISE AND PLAN FUTURE

 CONCLUSION

The whole experience of working in this environment of Force Motors was

great .The organization has good culture , best minds of industry , cutting
edge technology and high quality of work which has yielded great results .
Throughout my internship I could learn more about the definition of
mechanical engineer and prepare myself to more responsible and
innovative engineer in future.

Throughout my project I got deep knowledge of working with Vehicle

Assembly department.

The work I accomplished is satisfactory and I tried my best to grasp as

much as I can learn various aspects of how Vehicle assembly department
works and how defect analysis is done.

It is really great learning experience at Force Motors Ltd.

Thank you all for your support and guidance.