International Cars & Motors Ltd.(ICML) Sonalika Training Report

Department of Mechanical Engineering
SubmittedBy:-
Shubham Thakur
13BME8149
5MEL3
B.E. MechanicalEngineering
6 WEEKS INDUSTRIAL TRAINING REPORT

Shubham Thakur – 13BME8149 Page 2

CONTENT:- Page No.:-
Acknowledgement 4
Company Profile 5
Introduction 9
Plant Area Detail 10
Strength 13
Term and Definition 14
Welding Shop 15
Weld shop Flow Chart 18
Section of Weld Shop 19
Types of Welding Process 24
Term used in Spot Welding 26
Spot Welding Parameter 28
MIG Welding 31
Paint Shop 32
Paint Shop Flow Chart and Processes 33
Assembly Shop 39
Process Flow of Assembly Shop 41
Objective and Product Specification 43
Lubrication and Fluids Specifications 47
Machines and Equipment 48
Quality Checking Point in Various Stations 50
Road Testing of Product 52
Quality Control Shop 53
Importance of 5S 59
Conclusion 64
Bibliography 65

ACKNOWLEDGEMENT
Apart from the efforts of me, the success of this training depends largely on the encouragement and
guidelines of many others. I take this opportunity to express my gratitude to the people who have
been instrumental in the successful completion of this training report.
I would like to show my greatest appreciation to my teachers. I can’t say thank you enough for his
tremendous support and help. I feel motivated and encouraged every time I attend his meeting.
Without his encouragement and guidance this training
The guidance and support received from Ambrish Kumar Sharma was vital for the success of the
dissertation. Without the wise counsel and able guidance, it would have been impossible to complete
the dissertation in this manner I am grateful for his/ her constant support and help.
I express gratitude to other faculty members of Department of Mechanical Engineering,
University Institute of Engineering, Chandigarh University for their intellectual support
throughout the training. Finally, I am indebted to all whosoever have contributed in this training
work and friendly stay at International Cars & Motors Ltd. Sonalika (ICML).

COMPANY PROFILE :-
Chairman: - Sh. L. D. Mittal
Vice-Chairman:- Sh. A. S. Mittal
Managing Director: - Sh. D.K. Mittal
Sonalika Group started its journey of success during 1976 with the foundation of small scale unit to
fabricate & assemble Wheat harvesting machines was laid. With passage of time this small initiative
taken by Mittals in 1976 turned into great success due to the undulated efforts of promoters &
thousands of employees who worked unfiltered throughout.
The great success provided further motivation ultimately resulting in setting up a new plant in the
name of International Tractors Limited for the production of tractors, the demand & requirement of
which was steadily growing at that time. Now Sonalika group consists of 4-companies:-
1. International Tractors Limited.
2. Agriculture Division.
3. Three-Wheeler Division.
4. Automobile Division.
5. International Cars and Motors Limited.

MISSION: -
The Sonalika Group offers quality product with distinctive features at reasonable price the
company ensure better than best after sale service for satisfaction of the customer. Company is
exporting its tractors, MUVs and agri machinery to different Asian as well as African countries.
TRAINING & LEARNING: -
All classes of employees are trained. Non-skilled are trained to become skilled worker & skilled
are trained to acquire multiple skills. Diploma & graduates are trained for 1 year.
WORK CULTURE: -
The ICML seeks to create a culture where each employee, vendor, & dealer feels himself as a part
of enterprises. Every member respects 5F formula.
1. Fast
2. Focused
3. Fair
4. Friendly
5. Fun

FUTURE PLANS:-
To provide superior quality products all over the world, with new technology at reasonable rates &
to become No.1 automobile industry. The newly launched MUV Rhino and the proposed SUV are
leaps towards that goal. There's good news for whoever thought that British cars came in price tags
of crore plus, in India.
If the British Bentley is the dream car for the rich and famous, the Indian middle class could soon
be zipping around in British Sports Utility Vehicle (SUV) at affordable prices.
The eighteen hundred croreSonalika group that makes tractors with French collaboration at
Hoshiarpur has launched a Multi Utility Vehicle in collaboration with MG Rover Group of the
UK. Having broken into the league of top five tractor manufacturers in the last four years, the
company wants break new ground in the MUV market.
The MUV named RHINO has hit the Indian road in the late 2005. Amrit Sagar Mittal Vice-
Chairman of International Cars and Motors Limited (ICML) who signed an MOU with MG
Rover said, "Our research has indicated that there is a large market for MUV in India.
He said that competitive pricing coupled with high technology would create an entirely new market
for car users who want to upgrade to SUV's as well as new consumers.

ICML has also signed a MOU with Power train LTD of the UK to manufacture a new common
rail diesel engine and six speed gearbox that would be used in the SUV. The SUV that was
previously designed indigenously will now have the technical backing of the famous UK’s largest
car manufacturing Company that is part of the USD 3.5 billion Phoenix Venture holdings Limited.
For the project, ICML has put in an investment of over Rs 200 crores and the plant is being set up at
Amb in Himachal Pradesh. Mr. Mittal said that a state of the art assembly line is being set and the
plant would have an annual capacity to manufacture over twenty-four thousand MUVs and SUVs per
year.
British Sports Utility Vehicles (SUVs) will soon hit the Indian market at a price that the Indian
middle class can now afford.

International Cars & Motors Limited:-
International Cars And Motors Ltd. (ICML) is a subsidiary of Sonalika Group.
ICML is the manufacturer of passenger vehicles, Multi Utility Vehicles (MUVs), and Sports
Utility Vehicles (SUV) in the country. It was established in 2003 by L. D. Mittal with its
headquarters in Delhi. Its parent company Sonalika Group is one of the speedily growing tractor
companies that has registered a growth of over 1.80 Lakh in 10 years.
It’s headquarters are located in Himachal Pradesh, India. It’s headed by Mr. A.S Mittal, Mr.
Deepak Mittal and Mr. L.D. Mittal. The company produces tractors, farm machines and
automobiles.
ICML manufactures multi-utility vehicles and sports utility vehicles from Amb in Himachal
Pradesh. The company is a “Mother Unit”
Company History
International Cars & Motors Limited (ICML), is a Group Company of the Rs 1200 Crores
Sonalika Group. The Company is promoted by Mr. L.D.Mittal, Chairman, Mr. A.S.Mittal, Vice
Chairman & Mr. Deepak Mittal, Managing Director, who have vast experience in manufacturing
of tractors, Farm machines & Automobiles.

Plant Area Details:-
 Total plant area – 23 acres (93,000 Sq. M.)
 Total covered area – 10.5 acres (42,000 Sq. M.)
 Major shop details :
 Press shop – 4,300 Sq. M.
 Body shop – 3,900 Sq. M.
 Paint shop (PT/CD & Top coat) – 5,400 Sq. M.
 Assembly shop – 6,440 Sq. M.

Press Shop:-
Sheet metal components are developed in-house using two giant hydraulic presses of 1200 and 600
T. Rapid prototyping facility with 5 axis laser cutting machine for automated cutting program and
automated fixture designing & manufacturing that results in trimmed surface with no burr or bum
marks. The press shop of I.C.M.L. located in I.T.L Hosiarpur, the area of press shop is 43, 00 sq.
M.
Manufacturing Facilities:-
The manufacturing facility of ICML is located in Amb District Una Himachal Pradesh in the
picturesque Shivalik foothills of the Himalayas, about 38 Kilometers from the Group’s principal
tractor manufacturing plant in Hoshiarpur. Being under tax free zone, the move to locate the plant
in Amb is a major strategic move since the company will enjoy a distinctive cost advantage and
will be able to deal with competitive business environment through aggressive price positioning for
its products. Spread in a 56 acre plot and
an investment of close to Rs. 200 Cr., and an installed capacity to produce 24,000 units per annum,
the company has put in place a state-of-the-art globally integrated production facility which will
employ all forms of modern production techniques and quality systems. This is India’s only
completely pressurized automobile plant that will help to manufacture vehicles in total dust free
and temperature & humidity controlled environment. The plant has built-in capacity strength for
future expansion needs.
Torture Test Tracks:-
ICML vehicles that will roll out of the assembly line will be subjected to very stringent torture tests
to withstand highly demanding road conditions prevalent in the country. Custom-built to
international standards, the test track has sine wave, rumbles, rough road, corrugated pot holes,
stone paved roads, gradient, water wading zone, under body inspection ramp and smooth road for
long distance driving at different speeds. Testing on these different simulated road conditions for
acceleration & braking, ride & handling, gradient test, body squeak noise & rattling test, under
body inspection & leakage will make the end-product highly road worthy.

Protection of environment:-
The company rigidly adheres to the discipline of ‘respect for the environment’ and has established
all standards that will help to protect the environment from industrial abus
PROJECTIONS:-
CUSTOMER EXPECTATIONS:-
 Price matters
 Easy and economic repairbility
 Fuel economy is very important
 Comfort and seating capacity
 Easy finance
 Reliability
 Safe.
Particulars 05 – 06 06 – 07 07 – 08 08 – 09 09 – 10 10 - 11
MUV Nos. 100 5000 11000 15000 20000 24000
Capital inv.
(Cum. In Rs.
Cr.)
120 135 145 150 156 157

STRENGTHS:-
 Price positioning of RHINO is on highest volume and growth segment.
 Sitting comfort offered is best in its class.
 Our product operating expense is expected to be the minimum in the category.
 Vendors among the best in the country.
 Strong dealership network under stringent selection norms.
 All dealerships to project uniform and high quality corporate identity of ICML.
 ICML will undertake dealer sales/service manpower selection & training.

TERMS AND DEFINATIONS:-
1) BLANK SIZE: - Total size of the sheet from which one component can be drawn is known
as blank size. It is the minimum rectangular area of the sheet which for making the
component and to be cut from the base sheet which of the size 2500 mm X 1250 mm.
2) VOLUME: - Volume is the area of the blank size of the sheet multiplied by thickness of the
sheet i.e. the mass of the material.
3) ORIGINAL WEIGHT: - this is the weight of the component after the complete
development. In it the weight of the waste material is not included.
4) SCRAP: - It is defined as the material that is left after the total processing of the component.
5) PROCESS COST: - The cost of all the processes that has been done to make a certain
component is known as process cost. Several processes have been done to get the desired
component. It is calculated as per tonnage capacity & per tonnage price.
6) SCRAP COST: - The cost of the scrap material is known as the scrap cost. It is the total
weight of the scrap multiplied by the rate of the material of the scrap.
7) MATERIAL COST: - The material cost is the actual cost of material that is being used to
obtain the desired component shape. It is in Rs. per kg.

WELDING SHOP:-
WELDING:-Welding is the process of permanently joining two or more metal parts, by melting
both materials. The molten materials quickly cool, and the two metals are permanently bonded. Spot
welding and seam welding are two very popular methods used for sheet metal parts. Spot welding is
primarily used for joining parts that normally up to 3 mm (0.125 in) thickness. Spot-weld diameters
range from 3 mm to 12.5 mm (0.125 to 0.5 in) in diameter.
Welding joins different metals and alloys with the help of number of processes in which heat is
supplied either by electrically or by means of a gas flame.
Heat is the most essential requirement of welding, pressure is also required in many processes.
The use of welding in today's technology is extensive. The common uses we experience daily are: -
automobiles, furniture, Electronics, house hold ship, aircraft etc...

BODY WELD SHOP
As the name suggests the shop in which the body or shell of Car is produced with the help of
different types of welding, is known as
BODY WELD SHOP
Body shop has facilities for on-line
inspection of welded assemblies by
checking fixtures and gauges to ensure
consistent body quality.
Need of welding:
Welding is the most efficient & economical method of joining s automobile & other sheet metal
industry sheet metal components. It is widely used in
Body Shop Layout: -
The body shop layout is based on modern layout of plants. It is a product layout (sequence
grouping of machine). Various specialties available show its modern layout.

Specialties of Body Welding Shop:-
 Before the body is handed over to paint shop, it is fully inspected by a quality enng for
detecting any kind of defects.
 Metal finishing and door fitting is done on conversed line to ensure smooth flow.
 The Body is manufactured in Body Shop.
 The whole shop is air pressurized to avoid any kind of dust & dirt entrance.
 The Body Shop is further divided into 6 stages.
 Each stage is having a team leader with associates working with him.
 Each stage is delivering material to next stage to complete body shell.
 The spot welding on the body shell is done with specially designed welding fixture with
inbuilt fool proofing to ensure consistency in body quality.
 Specially designed guns are used to reach every nook and corner and to ensure a proper
strength is given at every place of body.
 The strength of welding is tested with special machine before making the first Sub Assy for
the day.
 All major sub assy are welded on pneumatically actuated fixture to give it a shape of
complete shell.
 Stage wise quality is ensured through in process audit and ownership of operators
 All comp and sub assy are stored and moved on specially designed bins and fixture to avoid
any damages on parts.

WELD SHOP FLOW CHART:-
Sub-Assembly Floor Assembly
Engine Room
Engine Room +Floor Assembly
Main Frame
Open Parts Assembly
Final Inspection
Door Assembly
To Paint shop

VARIOUS SECTIONS OF BODY WELD SHOP:-
1. Sub Assembly Area
2. Side Body Area
3. Floor Area
4. Main Frame Area
5. Resptting & Surface Finish Area
1.Sub Assembly Area:-
As the name suggests, in this area all small assemblies are produced, , which are used
in completion of other assemblies, such as for side body (A-pillar, B-pillar, D-pillar, R/F D-pillar),
for floor area (Engine room assy LH, RH, Console assy, Side bottom assy LH, RH, X-mbr A, B, C,
E, F, Wheel arc assy RH, LH, R/F frt. floor) for main frame area ( RR skirt , Roof spt. B,
Windshield header ) are produced in this area .All major sub assy are welded on phumatically
actuated fixture to give it a shape of complete shell.
2. Side Body Area: -
The side part of the shell is produced in this areaby using different parts and sub assemblies. The
inner & outer assy of side body are produced with the help of suitable fixture & guns. The spot
welding on the side body is done with specially designed welding fixture with inbuilt fool proofing
to ensure consistency in body quality.
3.Floor area: -
In this area the floor & engine room assy is producedby using different parts. The whole assy is
complete in six steps on different fixtures, first of all mid to wheel arch assy is produced, then mid
to rear floor, front floor to rear floor, then load the floor assy on engine room assy fixture & join
with the engine room assy RH,LH, & Console assy pass to main frame area.

4. Main Frame Area: -
After the floor area next work is done in the main frame area. All comp and sub assy are stored
and moved on specially designed bins and fixture to avoid any damages on parts. Specially
designed guns are used to reach every nook and corner and to ensure a proper strength is given at
every place of body. The spot welding on the body shell is done with specially designed welding
fixture with inbuilt fool proofing to ensure consistency in body quality. Pneumatically operated
fixture is used in main floor area to assemble the shell.
5. Respiting & Surface Finish: -
In this area, the shell is properly checked and take remaining spots on the shell. The spot welding
on the body shell is done with specially designed welding fixture with inbuilt fool proofing to
ensure consistency in body quality. Metal finishing and door fitting is done on converised line to
ensure smooth flow. The body is put under a highly illuminated area (which is illuminated by 75
lectric tubes) to detect surface defects. Before the body is handed over to paint shop, it is fully
inspected by a quality engineer for detecting any kind of defects.

Materials:-
 Low carbon steel is most suitable for spot welding. Higher carbon content or alloy steels tend to
form hard welds that are brittle and could crack. This tendency can be reduced by tempering.
 Austenitic Stainless steels in the 300 series can be spot welded as also the Ferrite stainless steels.
Martenstic stainless steels are not suitable since they are very hard.
 Aluminums can be welded using high power and very clean oxide free surfaces. Cleaning the
surface to be oxide-free, adds extra costs (that can be avoided with low carbon steel).
 Dissimilar materials cannot be spot welded due to different melt properties and thermal
conductivities. Plated steel welding takes on the characteristics of the coating. Nickel and
chrome plated steels are relatively easy to spot weld, whereas aluminum, tin and zinc need
special preparation inherent to the coating metals.

Types of Weld Joints:-
 Butt, T, corner, lap, and T joints are the common types of joints used in sheet metal welding.
These can all be used with MIG and TIG welding.
 Corner joints are used frequently in sheet metal cabinet construction.

Type of Welding Processes:-
 There are more than 30 types of welding, brazing & soldering process.
 Mainly they are classified on the basis of “source of heat”, i.e. Flame & electricity.
 In automobile industries commonly use welding processes are :-
 Co2 welding: - metal – carbon di-oxide welding.
 Resistance welding: - Spot welding, seam welding.

Resistance Welding:-
 Spot welding
 Seam welding
 Projection Welding
Arc Welding:-
 CO2- MIG welding
 Brazing
 TIG welding
Suitable Processes Used in ICML Weld Shop:-
Resistance Welding:-
 Spot welding
Arc Welding:
 CO2- MIG welding

What is Resistance Welding?
A resistance welding process wherein coalescence is produced by the heat obtained from resistance
to flow of electric current through the work parts held together under pressure by electrodes. The
size and shape of the individually formed welds are limited primarily by size and contour of the
electrodes.
Resistance Spot Welding is the joining of overlapping pieces of metal by applying pressure and
electrical current. These joints created by resistance spot welding form a "button" or "fused
nugget." Resistance spot welds are found typically on flanges, staggered in a single row of
consecutive welds. Vehicle manufacturers use resistance spot welding in the factory because they
can produce high quality welds at a very low cost.
Resistance Spot Welding:-
A resistance welding process wherein coalescence is produced by the heat obtained from resistance
to flow of electric current through the work parts held together under pressure by electrodes. The
size and shape of the individually formed welds are limited primarily by size and contour of the
electrodes.

Generated heat is calculated using the following equation.
H=I2Rt
H – Heat generated, J
I – current, A
R – Resistance, ohm
t – Time of current flow, s
Terms Used In Spot Welding:-
Continuous Weld - A weld which extends without interruption for its entire length.
Cool Time - The time interval between successive heat times, in multiple impulse welding and
seam welding, or during the pre-weld or post-weld interval.
Heat Time - The percent of time current flows during any half cycle during the weld.
Hold Time - Time that pressure is maintained after weld is made.
Off Time - Time electrodes separated to permit moving of material for next spot or number of
cycles current is off on a pulse weld.
Squeeze Time - The time interval between the initial application of electrode force on the work
and the first application of current.

Important Factors:-
 Surface must be clean and smooth to optimize bond strength
 Shape and surface condition of the electrode tip.
 Require access to both sides of the joint.
Basic Conditions:-
 Surface must be clean and smooth to optimize bond strength
 Shape and surface condition of the electrode tip.
 Require access to both sides of the joint
Resistance Welding Benefits:-
 High speed welding
 Easily automated
 Suitable for high rate production
 Economical

Spot Welding Parameters: -
There are different parameters in resistance spot welding, as listed below.
 Welding Current
 Pressure
 Tip Diameter
 Hold Time
 Weld time
 Heat
Sequence in ResistanceSpot-Welding

Welding Current: -
Welding current settings are very important when spot welding is used. If weld current is at the low
end of the range, weld time must be increased. (NOTE 1: Using low current on the welds can cause
overheating of the welding tools and the welder's transformer.)
Conversely, if weld current is high then weld time is decreased. (NOTE 2: Using high weld current
increases the problem of expulsion. Expulsion is molten metal squirting from between the layers of
steel. The galvanized coatings found on today's automotive steel aggravate the problem of
expulsion.) So we can see, welders that do not control weld current will be more difficult to
use.There are two types of weld current controls, Analog: uses a knob and it is set like a radio
knob. Digital: uses a LED display that tells the technician n the exact power setting. The usual
interface is a push button.
Weld Time: -
Time is the simplest variable of the equation to describe. This is controlled simply by the number
of cycles of 60Hz current allowed to flow through the work piece. The "heat" or "phase shift"
circuits will control the amount of current during each cycle, but the overall cycle duration will
remain the same.It is the time period during which current flows through the metal pieces to raise
the temperature
Relation Between Weld Current and Weld time:-
Weld current and weld time are inversely proportional. Welding current and time are used to bring
the metal to welding temperature (2550 Degree F.).
Weld Temperature = i2 x t x R.
Welding current in a body shop environment has a range of 3000 to 5000 amperes. Welding current
(I) and weld time (t) are to be controlled by the technician. Resistance (R) is determined by the
gauge of the parts being welded. Since welding current is squared, changes in weld current are
much more dramatic than changes in weld time.

Pressure: -
The amount of pressure that is applied to the weld is important. If too little pressure is applied, the
joining area will be small and weak. If too much pressure is applied, then cracking can occur in the
weld because of the quenching effect of the welding tips. Also, high pressure can cause thinning of
the metal and cause a weakness. The depth of depression on the sheet surfaces caused by welding
electrodes should never exceed 25 percent of the sheet metal thickness.
Welding Tip Diameter: -
Welding tip diameter is very important. The TITE-SPOT Pliers has the welding tips sharpened to
3/16" diameter when new. The tips can be allowed to fatten to 1/4" diameter before they need to be
sharpened. Welding tips have a flat face when new. This face crowns quickly with use, and this
crowning effect should be encouraged. The crowning radius should be about 1.5 to 2 inches. A
sharpening tool is provided with the TITE-SPOT Pliers. (NOTE: The closed height of the welding
tips is 1 1/2" when new.) Discard welding tips when closed height is 1 3/8". DO NOT SHIM
WELDING TIPS.

Arc Welding:-
 Heat is produced from electric arc
between work piece and electrode
material.
 Both AC and DC are used
 The rod
-Consumable (melts and
serves as a filling material)
-Nonconsumable.
- Coated or uncoated
 Coating
Metal Inert Gas (MIG) Welding:-
 Metal Inert Gas (MIG) Welding: An arc is struck between a consumable electrode and the
sheet metal to be welded. The consumable electrode is in the form of continuous filler metal.
An inert gas surrounds the arc and shields it from the ambient to prevent oxidation.
 Carbon steels, low alloy steels, stainless steels, most aluminum alloys, zinc based copper
alloys can be welded using this process.

PAINT SHOP:-
Introduction:-
Ensuring strict adherence to quality standards of ASTM& IS , The paint shop for sheet
metal & plastic components has been set up by Haden International. Setting better than
industry standards, the facility boasts of a 3-coat paint process involving cathodic electro
deposition, primer, top coat and finish coat that can withstand estimated 1200 hrs. The
paint shop also has dedicated spray lines for each color which eliminates the need for batch
painting thereby providing flexibility to quickly respond to color choice. The paint shop is
one of the most modernized shops of Sonalika International Cars & Motors Ltd. The out
looking and surface finish is of world-class quality. Paint gives protection from corrosive
effluent for enhancing the appearance for a longer period and at the same time it protects the body
from rust. The paint consists of Linseed oil, Pigment (as per requirement of master piece)
and Turpentine oil or some other solvent to reduce the viscosity of the mixture. The
drying time, hardness and elasticity of paint film depends mainly on the drying oil,
temperature of the oven, and the time for which it is kept in the oven.

PAINT SHOP - FLOW CHART:-
Oil Cleaning
ED Process
Under Coat/Sealer
Primer Coat
Top Coat
Final Audit

Material Flow In Paint Shop:-
Body Shell Received from
Weld Shop
Paint Shop
Painted Body
Shell Handed over
assembly
Pre-Treatment &
Electro-Deposition
Top Coat Area

Pre-Treatment:-
Pre-treatment chemically treats the body surface and prepares the surface for further processes.
 To remove all foreign particles e.g. dust, iron chips.
 Remove Oil, grease etc.
 Provide grease free surface.
 Make substrate surface ready for electro-deposition.
 Broadly, process consists of De-greasing following by rinsing & finally phosphating
CathodicElectro Deposition:-
DEFINITION:
“It is dipping process in which electrically conductive
substrate is immersed in a waterborne paint and the paint
dispersed in water is electrically deposited on the substrate
to form a uniform & water insoluble film.”
CED prevents rusting of the sheet metal during normal course of use of vehicle and provide an
excellent processed surface for top-coat paint. ED provides a uniform coating on the complete
surface of body shell, including inside area & box section.
Broadly, process consists of electro-deposition following by paint-recovery & rinsing

Top Coat Section:-
 Whereas PT-CED is more of behind the scene action, Top Coat area gives the body shell its
visible appeal, the as we see it thing.
 In Top Coat, the processes in sequence are Dry Sanding, Under Coat, Sealant, Tag Rac/IPA
cleaning, Primer, Wet Sanding, Top Coat & Re-finish
 Processes in Top Coat area are specialized manual process, with cycle time expected to be
around 16 mins.
Dry Sanding & Undercoat/Sealer:-
 ED body shell received is dry sanded to make surface rough, which provides better adhesion.
 PVC application is done on the underside of the body. Undercoat prevent the floor from
water as well as other object on road, such as pebbles
 Sealer application is done on all the joints, seams & hamming to prevent leakage of water
inside body/components.
Paint Booth Area:-
 Body Shell received after dry sanding is cleaned by using a special cloth(Tac Rag) &Iso-
Propyl Alcohol (IPA). Dust is one of the major problem in Paint Shop and it is absolutely
necessary to eliminate it as far as possible.
 After this painting process is started. This is the most important task in Paint Shop and
parameter maintenance is absolutely necessary for defect-free product.

After Painting:-
 The painted surfaces of the piece should be bone-dry. If there are transfer lines showing, use
a cotton swab dipped in a small amount of mineral spirits to remove them do not use an
eraser which leaves a residue and will mar your finish.
• Distressing gives a piece an old, used look. It consists of making dents, scratches, gouges,
and banged up edges. This is done with anything on hand from a hammer to coins, keys, or
even an ice pick.
• Antiquing is a technique that gently ages a piece, making the painting look softer and
creating depth and highlights if the wood is textured. Always antique in a well-ventilated
area. Using an antiquing medium, dip a clean rag into to the solution and apply accordingly.
• Polyurethane provides a durable finish, ease of application, and enhances the colors on the
piece.
Re-Finish:-
• Despite our best efforts, some small defects still creep in, and they are removed in final
repair.
• Additionally the shell may also require some buffing and baking before shell is tagged OK &
handed over to assembly.

Precautions:-
• Prevent entry of dust in Paint Shop
• Do not enter ED zone without authorization.
• Do not touch body shell with bare hands.
• Do not open barrel lids with dust on it.
• Do not feed paint at fast rate.
• Do not add additives without conformation of smell and visual check.
• Do not add DI water in ED system without checking conductivity and pH.
• Do not fiddle with valves.
• Do not ignore any observation.
QUALITY CHECKING POINTS IN PAINT SHOP:-
• Dry Film Thickness (15 to 30 microns)
• Adhesion Test 1 mm
• Hardness Test 3H Pencil
• Visual Inspection
FINALLY THE OK PAINTED SHELL HANDED OVER TO THE ASSEMBLY SHOP.

ASSEMBLY SHOP:-
Assembly shop:-
As the name suggest in this shop assy of all the components of vehicle is done . For assy of
various parts, there are different lines used.
These are:-
 Trim 1
 Trim-2
 Chassis line
 Final line

Trim 1:-
After the paint shop the shell is passed to Trim-1 then the shell is properly checked and if
the shell is ok then assy of different parts is completed as logo ,door fitment, glass fitment.
Trim 2:-
After the completion trim-1 operation the
shell is then passed to trim2. When shell
passed to Trim-2 then shell is again
checked and then different Fitments of
Trim-2 are completed. When both trim-
1&2 operations completed then shell is
passed to Final line.
Chassis line:-
This is a conventional chassis used for staff cars, radio vehicles, and other specialized types
and consisting of two parallel side members and various cross members and brackets. The
engine is fitted at the front, and the wheels are sprung independently by two coil springs with
double-action, hydraulic shock absorbers. The spare wheels are carried one on each side of
the chassis on stub axles to prevent bellying when traveling over rough ground. In the chassis
line passes chassis to final line. There are so many parts are attached to chassis as differential
,brakes,tyres , fuel tank , steering mechanism, suspension system, engine assembly.
Final line:-
When the shell is completed from trim-1&2 at the same time chassis required for the Fitment
operations of the final line. such as fitment of seat, stereo systemetc.
TRIM-2

PROCESSFLOW ASSEMBLYSHOP:-

PROCESS FLOW CHART
PAINTSHOP TRIM-I
TRIM-II
FINAL LINE
CHASSIS LINE
WHEEL
ALIGNEMENT
BRAKE ROLLER
TEST
SHOWERTEST
ROAD TESTFINAL AUDIT

OBJECTIVE:-
To Produce World Class Vehicles with Best Quality which Include Quality Management
Principles, Latest Manufacturing Techniques,
Total Team Involvement, Value Analysis &Time Management.
PRODUCT:-
S.N Model Seating Capacity
1 Winner 9-Seater
2 Xciter 8-Seater & 9-Seater
3 DLX 8-Seater
4 Royal (CRDFi) 8-Seater
5 INSPIRE UNDER R& D
Colours : White, Golden, Silver, Blue, Wine Red, Black

SPECIFICATIONS OF MUV RHINO:-
PARAMETER SPECIFICATIONS
Overall length 4440 mm
Overall width 1645 mm
Overall Height 1885 mm
Wheel base 2541 mm
Track: front 1360 mm
Rear 1373 mm
SPECIFICATIONS:-
Max. Speed 136 km/hr in 5th Gear
Min. turning radius 5.6 mtr.
Final drive ratio 4.88
Engine:
Type
Water Cooled,4 Cyl. In Line T/C
& I/C Diesel.
Valve Train SOHC
Engine displacement 1995 cc
Bore x Stroke 84 mm X 90 mm

SPECIFICATIONS: -
Air filter Dry Type
Fuel filter Dual – Primary & Secondary
Clutch:
Type
Single plate, Dry type, cable
operated.
Tyre size 205/65 R15
Rim size 5.5 J x 15
Fuel Tank capacity 50 Litres
Maximum Torque 15.5 kg-m / 2500 rpm
Compression Ratio 21:1
Maximum Power 75 ps / 4200 rpm
SPECIFICATIONS:-
Battery 12 V, 65 amp-hr
Alternator V AMP 12 V, 75 amp
Brake:
Front wheel Ventilated Disc
Rear wheel Drum
Steering system:
Manual Rack & Pinion

SPECIFICATIONS:-
Suspension:
Front Independent with double wishbone
Rear Semi elliptical leaf spring
Shock absorber Hydraulic, double acting telescoping
type
Antiroll bar V – type, Provided in front only
Power Hydraulically assisted Rack and
Pinion

LUBRICANT/FLUID CAPACITY AND GRADE:-
LUBRICANT CAPACITY GRADE
Engine oil 5.8 ltr API C14,SAE 15W40
Coolant 8.5 ltr Mix of 70% distilled water+
30% monoethylene glycol
based JIS 2234 k (coolant).
Brake Oil 0.8 ltr SAE J 1703 for DOT 3.
Power Steering 0.8 ltr Automatic Transmission
fluidDexron 2D.
Gear Oil 2.5 ltr SAE 75 W-90,GIL 4 or 5.
Differential Oil 2.2 ltr GL 585 W140.
Battery Terminal Small Quantity Petroleum jelly.

MACHINES & EQUIPMENTS:-
 SINGLE SLAT CONVEYOR:- TRIM- I &TRIM -II
 DOUBLE SLAT CONVEYOR :- FINAL LINE
 SINGLE SLAT CONVEYOR:-CHASSIS
 BODY TRANSFER/CHASSIS TRANSFER SYSTEM
 FLUID FILLING MACHINES:- FINAL LINE
 CHASSIS INVERSION SYSTEM
 HYDRAULIC PRESS
 WHEEL ALIGNMENT MACHINE
 ROLLER-BRAKE TESTER
 WHEEL BALANCER
 SHOWER TEST BOOTH
AWARENESS PROGRAM IN ASSEMBLY SHOP:-
 5’S & HOUSEKEEPING.
 MATERIAL HANDLING & STORAGE.
 HANDLING DEFECTS –DENT,CHIP & SCRATCHES .
 PROCESS CONTROL SHEET.
 STAGEWISE WORK OWNERSHIP.
 PRECAUTIONS TO AVOID ACCIDENT

SAFETY PRECAUTIONS:-
 USE SAFETY SHOES.
 USE HELMETS WHERE NECESSARY.
 ALWAYS AVOID OIL SPILLAGE.
 ALWAYS COVER BELT BUCKLE,WRIST WATCH,RING WHILE WORKING ON
LINE TO AVOID DENT-PAINT SCRATCHES.
 FOLLOW THE TEST TRACK RULES WHILE VEHICLE DRIVE TEST.
 USE MASK WHILE DOING PAINT SPRAY.
 PUT HAZARDOUS WASTE IN PROPER BIN.
 SWITCH OFF THE M/C AFTER USE.
DO’S & DON’TS:-
 DO NOT DRIVE VEHICLE WITHOUT AUTHORIZATION.
 KEEP VEHICLE CLEAN.
 DON’T SIT IDLE IN VEHICLE.
 DO 5’S DAILY IN YOUR AREA.
 KEEP TOOLS PROPERLY AFTER USE.
 DO MAINTENECE& CALIBRATION OF TOOLS IN TIME.
 DO ALWAYS PAINT MARK AT TORQUING FOR CONFIRMATION.

QUALITY CHECKING POINTS IN ASSEMBLY SHOP:-
In process Inspection:-
 QP-1 at Trim-I
 QP-2 at Trim-II
 QP-3 at Chassis
 QP-4 at Final
QUALITY PROCESS AT TRIM-1:-
Visual Inspection of Following :-
• Wiring Harness Fitment & Routing
Front wind shield & Back Glass (No Damage, Scratch, Gap etc)
• Door Glass fitment & movement
Inside Grommets, Insulation
• A/C fitment. Dash Board & Head liner Fitment
QUALITY PROCESS AT TRIM-2:-
Visual Inspection of Following:-
• Head Lamp & Tail Lamp fitment
• Door Trims Fitment
• Seat Belts & Torque
• Pillar Trims Fitment
• Control Panel Fitment

QUALITY PROCESS AT CHASSIS LINE:-
• Oil Levels: E/G, RR Axle, Gear Box
• Torque of Prime Important Joints
• Fitment of Major components Engine, RR Axle, Propeller shaft, Leaf springs, Control Arm,
Shock absorbers, Fuel Tank etc.
QUALITY PROCESS AT FINAL LINE:-
• Oil Level i.e. Brake oil, Power steering
• Seats fitment Locking & Unlocking
• Torque of shell & chassis mtg
• A/C cooling & Function
• Electrical function of vehicle
• Body Gap & offset checking

Road Testing: -
ICML vehicles that will roll out of the assembly line will be subjected to very stringent torture
tests to withstand highly demanding road conditions prevalent in the country. Custom-built to
international standards, the test track has sine wave, rumbles, rough road, corrugated pot holes,
stone paved roads, gradient, water wading zone, under body inspection ramp and smooth road for
long distance driving at different speeds. Testing on these different simulated road conditions for
acceleration & braking, ride & handling, gradient test, body squeak noise & rattling test, under
body inspection & leakage will make the end-product highly road worthy.
Road Test’s of The Vehicle for the
Following:-
• Rough Road test Grumblers, Sine Wave &
rumble strips : for Shockers, Body squeak
noise, loose parts & rattling noise etc
• Smoke test
• Gradient : For Vehicle Pick Up & Parking
Brake efficiency
• Water Wading: To check water entry from
bottom.
• Normal Test Track: For Acc. Test, Brake test, Vehicle Pulling, Steering wheel wobbling etc.
• Under Body Ramp : For Leakage Testing

QUALITY CONTROL SHOP:-
It is Systematic control of those variables encountered in manufacturing process, which, affect the
excellence of the product. Such variable result from the application of material, men, machine &
manufacturing conditions only when these variables are regulated to the extent that they do not
detract unit is main shop of ICML. In necessarily from the excellent of the ring-ring process as
reflected in the quality of the finished product, can the control of quality be said to exist.
Generally, inspection, which is the process of sorting good from bad, is the process of sorting
good from bad, is considered as a form of quality control. But quality control and inspect-ion are
different. Conceptually, a Q.C. aim of prevention of defects at the very source relies on effective
held back system and corrective action procedure. Acceptance of material after subjecting them to
in section at inward goods store is inspection concept. Q.C. concept is to take early step to ensure
that the material to be supplied is going to be manufactured to the plant's requirements. So as to
ultimately eliminate the in ward goods inspection. Discovering that the components produced are
not as per required dimensional specifications due to wrong tool or improper settling after the
production is over is inspection concept. To prevent the issue of a wrong tool and to have a set up
approval procedure prior to starting continuous production and keeping a simple check during
OBJECTIVES OF Q.C.: -
Following are main objectives: -
• Evaluation of quality standards of incoming material, product in actual manufacture, & have
out going product.
• Judging the complicity of the process to the established standard & taking suitable action
when deviations are noted.
• Evaluation of optimum quality obtainable under given conditions.
• To improve quality &productivity by process control & experimentation.
• Developing procedures for good vendor relations.
• Developing quality consciousness both within & outside the organization.

QUALITY CHARACTERISTICS:-
Following are main quality characteristics for components used in ICML.
1) A dimension is a characteristic. A chemical properties is a characteristic
2) A sensory property is a characteristic.
All these characteristics contribute towards the quality of the product. So we can say that
appearance of product is quality characteristic ices of the product. Similarly performance,
length of life, dependability, reliability, durability, maintainability, fed, sounded. All
characteristics are like a building block that goes in to the construction of say, an arch, which
may be considered to be quality.
FACTS OF QUALITY: -
The quality characteristics can be grouped in to following categories in Somalia ICML.
1) Quality of Design
2) Quality of Conformance
3) Availability
4) Customer Service

1) QUALITY OF DESIGN:-
The design must meet all the requirements of the customers. The designer has to take into
account the question of appearance, reliability, maintainability of the products. The designer
should aim at the design, fulfills all the qualities or almost all qualities desired by the
customers.
2) QUALITY OF CONFORMANCE:-
The degree or extent to which a product actually conforms to in accordance with the
specification &drawing is called the quality of conformance.
3) AVAILABILITY: -
This includes such characteristics as reliability, maintainability &length of life. All these
indicate as to what extent the product will be available for use. Reliability of the product may
be taken as the extent to which it can give continuous service.
4) CUSTOMER SERVICE:-
This indicates the extent to which the customer can get assistance from the manufacture or
keep the product in continuous use. This service is an after sale function.

METHODS OF QUALITY CHECKING : -
(1) APPEARANCE
(2) DIMENSIONS
(3) WEIGHT
(4) FITMENT
(5) FUNCTION/PERFORMANCE
(6) MATERIAL/MECHANICAL PROP.
(7) PROCESS
(8) CHEMICAL COMPOSITION
(9) WELD STRENGTH
1. APPEARANCE: -
It is the first step of the checking the appearance of the component means how the component
looks like. Whether its surface is smooth. Whether its edges are sharp or not? Its welding, its
surface treatment and its machining. Means its physical structure.
2. DIMENSIONS: -
It is the most important step of the quality testing of the various components. The
dimensioning means the checking of the dimensions of the component, whether these are
correct or not? The dimensioning is done by certain components like the VERNIER
CALLIPER, MICROMETER, BEVEL PROTECTOR, HEIGHT GUAGE, etc. These
dimensions are checked with respect to the dimensions given in the drawings i.e. the required
dimensions. By these measuring equipments the measurement of the dimensions of the
component becomes very easy.
3. WEIGHT: -
The weight of the component is also necessary to it gives the correct idea of the material
required to manufacture the component. The weight of the component is measured by
weighing machine. This machine can measure the weight from 500 g to 50000g. Procedure
is very easy just place the component on the dashboard. There is a digital screen, which
shows the reading of the weight in numbers.

4. FITMENT: -
Fitment means fitting of the component actually in the vehicle. The component of the vehicle
checked whether it is get fitted on the vehicle or not. If the vehicle is get fitted then the
component get accepted, if the component is not get fitted then it is rejected. So the
acceptation or rejection of the component is also based on the fitment of the component.
5. FUNCTIONAL PERFORMANCE: -
The functional performance of the component is measured after the fitment of the component.
So to make fitting of the component it is very necessary that it will get fitted in the vehicle.
Functional performance means how well the component is functioning in the vehicle. In it the
functional processes of the component are checked, like the stresses produced in it, its fatigue
strength and its reliability etc.
6. MATERIAL/ MECHANICAL PROP: -
The material of the component should be able to absorb the stress produced in that
component. The mechanical proportions means the is the material is reliable to be used to
manufacture the component. Is it looks good by appearance or not. The material may be
brittle or hard or tensile as required.
7. PROCESS: -
In this step of the quality control of the components the processes of the components are
checked. For making a certain component there are certain processes by which a component
should go through. These processes are made in serial wise and the component should follow
these processes in serial wise. If the serial wise processes, which are required to make it,
make a component only then that component can be made exactly that which is required.
These processes can be checked only at the production work i.e. where the component is
manufactured. So in case of our industry the processes can only be checked on the vendor
side where the product is manufactured. The processes can be the drilling, punching,
tapering, lathing, heat treatment, machining etc.

8. CHEMICAL COMPOSITIONS: -
There are the standard materials, which can be used to make a certain component. For a
specific component there is specific material, by only which, that component is
manufactured. For the certain component, the material is selected as its requirements like the
stresses produced in the component, its working climate, working conditions, working time
etc. So it is very necessary to make the component with the required and reliable material.
Material checking is done by the certain equipments and requires lots of research. In the
I.T.L. the material checking is not done, but the samples of the components are sent to the
other companies for the inspection purpose.
9. WELDING CHECKING: -
Welding checking is also an important process in the quality testing of the different
components. Welding checking means checking of the strength of the welding. The
components are made of different parts, which are welded with each other to make the
suitable and complete.two parallel side members and various cross members and brackets.
The engine is fitted at the front, and the wheels are sprung independently by two coil springs
with double-action, hydraulic shock absorbers. The spare wheels are carried one on each side
of the chassis on stub axles to prevent bellying when traveling over rough ground. In the
chassis line passes chassis to final line. There are so many parts are attached to chassis as
differential ,brakes,tyres , fuel tank , steering mechanism, suspension system, engine
assembly.
Final line:-
When the shell is completed from trim-1&2 at the same time chassis required for the Fitment
operations of the final line. such as fitment of seat, stereo systemetc.

5 S
The 5S Process, or simply "5S", is a structured program to systematically achieve total
organization, cleanliness, and standardization in the workplace. A well-organized
workplace results in a safer, more efficient, and more productive operation. It boosts the
morale of the workers, promoting a sense of pride in their work and ownership of their
responsibilities. "5S" was invented in Japan, and stands for five (5) Japanese words that
start with the letter 'S': Seiri, Seiton, Seiso, Seiketsu, and Shitsuke.
5S Definitions
Japanese
Term
English
Equivalent
Meaning in Japanese Context
Seiri Tidiness
Throw away all rubbish and
unrelated materials in the
workplace
Seiton Orderliness
Set everything in proper place for
quick retrieval and storage
Seiso Cleanliness
Clean the workplace; everyone
should be a janitor
Seiketsu Standardization
Standardize the way of maintaining
cleanliness
Shitsuke Discipline
Practice 'Five S' daily - make it a
way of life; this also means
'commitment'

SEIRI:-
The first step of the "5S" process, seiri, refers to the act of throwing away all unwanted,
unnecessary, and unrelated materials in the workplace.
Before After
SEITON:
Seiton, or orderliness, is all about efficiency. This step consists of putting everything in
an assigned place so that it can be accessed or retrieved quickly, as well as returned in
that same place quickly. If everyone has quick access to an item or materials, work flow
becomes efficient, and the worker becomes productive.
Before After

SEISO:
The third step in "5S", says that 'everyone is a janitor.' Seiso consists of cleaning up the
workplace and giving it a 'shine'. Cleaning must be done by everyone in the
organization, from operators to managers.
Before After
SEIKETSU:-
The fourth step of "5S", or seiketsu, more or less translates to 'standardized clean-up'.
It consists of defining the standards by which personnel must measure and maintain
'cleanliness'. Seiketsu encompasses both personal and environmental Cleanliness
Before After

SHITSUKE:-
The last step of "5S", Shitsuke, means 'Discipline.' It denotes commitment to maintain
orderliness and to practice the first 4 S as
a way of life. The emphasis of shitsuke is elimination of bad habits and constant
practice of good ones. Once true shitsuke is
achieved, personnel voluntarily observe cleanliness and orderliness at all times, without
having to be reminded by management.
Before After

RHINO:-

CONCLUSION:-
In my industrial training, I was introduced to industrial environment. I learned discipline and
cooperation during my industrial training.
International Cars & Motors Ltd was a challenging place for students to do their industrial
training. By this training, I have gained a wide knowledge about technical works of
Automobiles, their parts, working etc.
The company provides me with the real working environment. Not only learning the general
work scope here but the practical students also have got the opportunities to implement the
work scope with their own strength and abilities during the training. It was an advantage for
me to be in the Assembly Division where I have boosted up my skills and abilities.

BIBLIOGRAPHY:-
http://www.wikipedia.com
http://www.howstuffworks.com/
http://www.sonalika.com
http://www.icml.co.in
Manufacturing Technology Vol.1ByB S Raghuwanshi
Automobile Engineering Vol. I & II By Dr. Kirpal Singh

International Cars & Motors Ltd.(ICML) Sonalika Training Report

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