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INDUSTRIAL TRAINING WORK REPORT
Submitted in Partial Fulfillment of The Requirement for The award of Degree
Of
Bachelor of Technology
in
MECHANICAL ENGINEERING
Submitted By
PRATEEK KOUL
(University Reg.No: 12-GGCEG-0091)
An ISO 9001:2008 Certified Institution
Approved by AICTE, New Delhi & Affiliated to M.D.University, Rohtak
Mechanical ENGINEERING DEPARTMENT
GURGAON COLLEGE OF ENGINEERING
GURGAON-122413
JUNE 2016

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Mechanical ENGINEERING DEPARTMENT
GURGAON COLLEGE OF ENGINEERING
CANDIDATE‘S DECLARATION
I hereby certify that the work which is being presented in the Project report entitled
Introduction of SIGNA Cabs on PRIMA TRIM LINE in partial fulfillment of the
requirements for the award of Bachelor of Technology in Mechanical Engineering, and
submitted in Mechanical ENGINEERING DEPARTMENT, GURGAON COLLEGE OF
ENGINEERING. Maharishi Dayanand University, Rohtak is an authentic record of Project
of my own work carried out during a period from 30/01/2016 to 07/05/2016 under the
supervision of Mr. ABHISHEK DEEP, Senior Manager, Prima Trim Line (Cab & Cowl
Factory) Tata Motors Jamshedpur Ltd.
The matter presented in this report has not been submitted by me for the award of any
other degree/diploma of this or any other Institute.
(PRATEEK KOUL)
This is to certify that the above statement made by the candidate is correct to the best of
our knowledge.
Signature of Senior Manager Signature of Head, Mech
Engg.

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PROJECT REPORT ON
Introduction of SIGNA Cabins in
Prima Trim Line

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AIM OF THE PROJECT
Introduction of SIGNA Cabins in Prima Trim Line
DELIVERABLES:
1. Creation of Process Flow Diagram (PFD)
2. SIGNA Process Mapping with Prima in Prima trim line
3. Line Balancing and identifying bottleneck
Stations / processes
4. Time Study
5. Work Instruction Sheet (WIS)

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INDEX
I. PREFACE 4
II. CERTIFICATION 5
III. ACKNOWLEDGEMENT 6
IV. PROFILE 7-10
V. TATA SIGNA RANGE
VI. DEPARTMENT ASSIGNED 14
VII. DELIVERABLES
 Creation of Process Flow Diagram (PFD)
 SIGNA Process Mapping with Prima in Prima trim line
 Line Balancing and identifying bottleneck
Stations / processes
 Time Study
 Work Instruction Sheet (WIS)
VIII. CONCLUSION

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PREFACE
The Project titled ’Introduction of Signa in the Prima Trim Line’ had
been ideated by my project guide, Mr. Hrushikesh Thodge. The project,
due to its relevance to the ongoing works of the Prima Trim Line and the
overall vision of Tata Motors Ltd. is a motivation in itself. The project
involved challenging practical assignments as well as careful thought
processes to make it a reality.
The project report describes the time study of the operations in the Prima
Trim Line, World Truck Factory and finding out the bottlenecks of the
Trim Line. As part of introduction of Signa, the project report describes
the Operation Mapping of the Prima and Signa cabs, Process Mapping
for Prima Cabs as well as Process Mapping for Signa Cabs.
The Project Report is intended to acquaint the reader with various
operations and processes of the Prima Trim Line as well as the steps
that should be necessarily followed for the implementation of a new
project on an already existing facility. The project and hence the project
report has been an experience in itself.
There is no suggestion as to how the reader should approach this report.
The reader is just advised to go through the topics as they appear in the
report and have an analytical approach towards the assessment of the
same.

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CERTIFICATION
This is to certify that Mr. Prateek Koul has successfully
completed the project work titled ‘Introduction of Signa in
the Prima Trim Line’ in fulfillment of requirement for the
award of B. Tech Degree in Mechanical Engineering
prescribed by Gurgaon College of Engineering.
The project is the record of authentic work carried out during
the months of January and May, 2016.
Abhishek Deep
Senior MANAGER
PRIMA TRIM LINE, WORLD TRUCK FACTORY

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ACKNOWLEDGEMENT
To start a project from scratch and realize it requires the support and contribution
of many people, without whom the project would be incomplete.
Many people have played a pivotal role in the completion of the project titled
‘Introduction of SIGNA in the Prima Trim Line’.
Firstly, I take this opportunity to express my profound gratitude and deep regards
towards my principal guide, Mr. Hrushikesh M. Thodge, Assistant Manager Mr.
Prochet Sarkar, Assistant Manager, World Truck Trim Line, for his exemplary
guidance, monitoring and constant encouragement in completion of this project
report.
I am equally thankful to Mr. Abhishek Deep, Senior Manager, World Truck Trim
Line and Mr.Rakesh Kumar, Line Head, Prima Trim Line for providing me with
an opportunity to work on this project.
I am also obliged to the staff and members of the Prima Trim Line, World Truck
Factory (Jamshedpur Works, Tata Motors Ltd.) for the valuable information
provided by them in their respective fields. I am grateful for their cooperation
during the period of my assignment.
Lastly, I thank my parents for their encouragement without which this assignment
would not have been possible.
PRATEEK KOUL

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PROFILE
Tata Motors Limited is India's largest automobile company, with revenues of
INR 2,62,796 crores (USD 42.04 billion) in 2014-15. It is the leader in commercial
vehicles in each segment, and the third largest in the passenger vehicles market
with winning products in the compact, midsize car and utility vehicle segments.
The company is the world's fourth largest truck manufacturer, and the world's
second largest bus manufacturer.
The company's 60,000 employees are guided by the vision to be "Most admired
by our customers, employees, business partners & shareholders for the
experience and value they enjoy from being with us."
From Left Jamshedji Nusserwanji Tata, Dorabji Tata, Ratanji Tata(standing back), Naval Tata
Established in 1945, Tata Motors' presence indeed cuts across the length and
breadth of India. Tata Motors is a part of the Tata and Sons Group, founded
by Jamshetji Tata and J. Baker. The company was established in 1945 as a
locomotive manufacturing unit and later expanded its operations to commercial
vehicle sector in 1954 after forming a joint venture with Daimler-Benz AG of
Germany. Over 4 million Tata vehicles ply on Indian roads, since the first rolled
out in 1954. The company's manufacturing base in India is spread across
Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh) and
Pantnagar (Uttarakhand).

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Following a strategic alliance with Fiat in 2005, it has set up an industrial joint
venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce
both Fiat and Tata cars and Fiat power trains. The company is establishing two
new plants at Dharwad (Karnataka) and Sanand (Gujarat). The nation-wide
dealership, sales, services and spare parts network comprises over 3500 touch
points; Tata Motors also distributes and markets Fiat branded cars in India.
Tata Motors, the first company from India's engineering sector to be listed in the
New York Stock Exchange (September 2004), has also emerged as an
international automobile company. In 2004, it acquired the Daewoo Commercial
Vehicles Company, South Korea's second largest truck maker. The rechristened
Tata Daewoo Commercial Vehicles Company has launched several new
products in the Korean market, while also exporting these products to several
international markets. Today two-thirds of heavy commercial vehicle exports
out of South Korea are from Tata Daewoo. In 2005, Tata Motors acquired a 21%
stake in Hispano Carrocera, a reputed Spanish bus and coach manufacturer, with
an option to acquire the remaining stake as well. Hispano's presence is being
7expanded in other markets. In 2006, it formed a joint venture with the Brazil-
based Marco polo, a global leader in body-building for buses and coaches to
manufacture fully-built buses and coaches for India and select international
markets. In 2006, Tata Motors entered into joint venture with Thonburi
Automotive Assembly Plant Company of Thailand to manufacture and market
the company's pickup vehicles in Thailand. The new plant of Tata Motors
(Thailand) has begun production of the Xenon pickup, with the Xenon having
been launched in Thailand at the Bangkok Motor Show 2008.
Tata Motors' is also its international footprint, established through exports since
1961. The company's commercial and passenger vehicles are already being
marketed in several countries in Europe, Africa, the Middle East, South East
Asia, South Asia and South America. It has franchisee/joint venture assembly
operations in Malaysia, Kenya, Bangladesh, Ukraine, Russia and Senegal.
The foundation of the company's growth over the last 50 years is a deep
understanding of economic stimuli and customer needs, and the ability to
translate them into customer-desired offerings through leading edge R&D.
With over 1,400 engineers and scientists, the company's Engineering Research
Centre, established in 1966, has enabled pioneering technologies and products.
The company today has R&D centers in Pune, Jamshedpur, Lucknow, in India,
and in South Korea, Spain, and the UK.
It was Tata Motors, which developed the first indigenously developed Light
Commercial Vehicle, India's first Sports Utility Vehicle and, in 1998, the Tata
Indica, India's first fully indigenous passenger car. Within two years of launch,
Tata Indica became India's largest selling car in its segment. In 2005, Tata

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Motors created a new segment by launching the Tata Ace, India's first
indigenously developed mini-truck .
In January 2008, Tata Motors unveiled its People's Car, the Tata Nano, which
India and the world have been looking forward to. A development, which
signifies a first for the global automobile industry, the Nano brings the comfort
and safety of a car within the reach of thousands of families. When launched in
India later in 2008, the car will be available in both standard and deluxe
versions. The standard version has been priced at Rs.100, 000 (excluding VAT
and transportation cost).
Designed with a family in mind, it has a roomy passenger compartment with
generous leg space and head room. It can comfortably seat four persons. Its
mono-volume design will set a new benchmark among small cars. Its safety
performance exceeds regulatory requirements in India. Its tailpipe emission
performance too exceeds regulatory requirements. In terms of overall pollutants,
it has a lower pollution level than two-wheelers being manufactured in India
today. The lean design strategy has helped minimize weight, which helps
maximize performance per unit of energy consumed and delivers high fuel
efficiency. The high fuel efficiency also ensures that the car has low carbon
dioxide emissions, thereby providing the twin benefits of an affordable
transportation solution with a low carbon footprint.
In June 2009, the exciting new range of premium luxury vehicles from Jaguar
and Land Rover were introduced for the Indian market. These include the Jaguar
XF, XFR and XKR and Land Rover Discovery 3, Range Rover Sport and Range
Rover.
Tata Motors is equally focused on environment-friendly technologies in
emissions and alternative fuels. . It has developed electric and hybrid vehicles
both for personal and public transportation. It has also been implementing
several environment-friendly technologies in manufacturing processes,
significantly enhancing resource conservation .
The years to come will see the introduction of several other innovative vehicles,
all rooted in emerging customer needs. Besides product development, R&D is
also focusing on environment-friendly technologies in emissions and alternative
fuels.
Through its subsidiaries, the company is engaged in engineering and automotive
solutions, construction equipment manufacturing, automotive vehicle
components manufacturing and supply chain activities, machine tools and
factory automation solutions, high-precision tooling and plastic and electronic
components for automotive and computer applications, and automotive retailing
and service operations.

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TATA MOTORS (JAMSHEDPUR PLANT)
With 603 acres for Tata Motors’ Jamshedpur’s manufacturing, engineering and
support services, Tata Motors has a township made up of 1250 acres, housing a
residential quarters, hospitals and schools. While making technological, product and
service advancements, the plant has been deeply committed to the community within
which it operates. Working closely with various NGOs, it has pioneered initiatives in
Health, Education, Livelihood and Environment. These initiatives have resulted in
significant progress in community and social forestry, sustainable development of
wastelands, road construction, rural health and education, development of rural
industries, water supply and family planning.
The plant manufactures Tata Motors’ entire range of medium and heavy commercial
vehicles (M&HCV), including the Tata Prima, both for civilian and defense
applications.

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With the plant manufacturing over 200 truck variants, ranging from multi-axle trucks,
tractor-trailers, tippers, mixers and special application vehicles, the Jamshedpur
facility has led the company’s evolution into a manufacturer of global repute. Besides
India, these vehicles are sold in South Africa, Russia, Myanmar, the SAARC region
and the Middle East.
The Jamshedpur facility was Tata Motors’ first, set up in 1945, to manufacture steam
locomotives. It led the company’s foray into commercial vehicles in 1954. It has been
modernized through the decades, with a particularly intense scale in the last 10 years.
World-class facility equipped with:
 State-of-the-art equipment and assembly lines to produce a truck every five
minutes.
 Over 200 models, ranging from multi-axle trucks, tractor-trailers, tippers,
mixers and special application vehicles, catering to civilian and defence
requirements.
 3D visualization of new models.
 Engine assembly shop, capable of supplying upto 200 engines per day.
 Modern testing facilities.
The company has over 130 models of light, medium and heavy commercial
vehicles ranging from two tonnes to forty tonnes, buses ranging from 12-seaters
to 60-seaters, tippers, special purpose vehicles, off-road vehicles and defense
vehicles.

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PRIMA TRIM LINE
Prima Trim Line is the department where all the cabins after getting
welded and painted at Fabrication factory and Central Paint Shop
respectively, is brought for the essential fitments. Fitments like
Dashboard, Windscreen glass, mirror, seats ECU panels, door add-ons
etc. As PRIMA is a very high range truck product, defects in smallest
form will not be accepted in the before delivery inside the company.
The Prima Trim Line has 16 stations which can be expanded into 30
stations for future expansions but currently it meets the needs for the
production requirements. All the outer and inner fitments are carried
out in the first 15 stations where at their respective stations operators
carry out their process. The Cabins are fitted on dies or pegs which are
fixed on the moving conveyors. The parts which have to be fitted under
the cabin are done in another station which is separated from the main
line. This station is called the Under Body Station. Here the die is at
more height than the usual dies or pegs in the main line. This is done so
that the operators have ease in fitting parts under the cabin. The cabin is
lifted from the main line with the help of a machine, cab lifter and then
its dropped at Under Body (UB) station.

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There are 4 sub assembly stations where the parts are assembled first
and then fed into the line for its fitment on cabin. Some essential
machines are also used in this line which are the Glass Glazing Robot,
Dashboard manipulator and the seat manipulators. Manipulators are
machines that are used to lift parts and insert them in cabin. Glass
Glazing Robot is an automatic robot made by KUKA Corporation to
add adhesive and seal on the perimeter of Wind Screen Glass.
The fitments of these parts are done at stations where these machines
are located or are closest.
The total manpower in the line including the sub assembly is 120. The
distribution is done using the Process Flow Diagram, Process mapping
and the Load Balancing. The details of all the fitments of PRIMA
cabins with manpower is given below.

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Tata SIGNA Range
SIGNA Range Highlights:
 Launch of a new SIGNA range of Medium & Heavy Commercial Vehicles,
offering trucking solutions from haulage to construction segments
 Aerodynamic front fascia signature design
 A large cabin accommodating improved ergonomics, NVH levels for superior
in-cab experience
 Large Windscreen for good all-round visibility & road view for more safety
 In-built telematics system – Tata FleetMan
 Proven and reliable drive

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Tata Motors launched its new range of Medium and Heavy Commercial
Vehicles – the new TATA SIGNA, at Auto Expo 2016. With the new Tata
SIGNA range, Tata Motors will bring modern trucking mainstream, addressing
emerging needs for a safe, comfortable and connected commercial vehicle
experience.
With its smartly designed cabin space, improved ergonomics and NVH levels,
the TATA SIGNA range of cabins are built to offer a superior in-cab experience,
enabling drivers to operate fatigue free over long hauls, which in turn offers
significant improvement in productivity. With an inbuilt telematics system, by
TATA FLEETMAN, the new TATA SIGNA empowers fleet operator with a
more connected experience, to better manage their transport business through
optimum driver, vehicle and fuel management.
The new range will continue to retain Tata Motors largest selling, proven and
reliable driveline, which along with Tata Motors service support will offer best
business return to customers.
Ideal for customers who want to upgrade to better in- cab experience, connected
vehicle and proven and reliable aggregates, the SIGNA range will be offered as
Tractor-trailer, Multi-axle truck and Tippers, with the products on display being
the SIGNA 4923.S, SIGNA 3118.T and SIGNA 2518.K .

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Following is a descriptor of the products on display –
The Tata SIGNA 4923.S is a tractor offering from Tata Motors new SIGNA
range of commercial vehicles. With Gross Combination Weight (GCW) of
49000 Kg when coupled with suitable trailers, the Tata SIGNA 4923.S proven
and reliable Cummins ISBe 5.9 Common Rail engine, delivers power of 230 PS
and a torque of 850Nm, with best-in-class Fuel Efficiency and is based on a
proven
power train and aggregates, like the G1150 Gearbox and RA109SRT rear axle.
The Tata SIGNA 4923.S empowers customers with the lowest Total Cost of
Ownership and is offered with multiple fully-built load body options, makes the
vehicle a preferred choice for transporters for various applications.

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The Tata SIGNA 3118.T is an MAV truck from Tata Motors new SIGNA
range of commercial vehicles. It is the first MAV Truck in India, with a unique
feature of a Lift Axle, for the flexibility to disengage the vehicles fifth axle in
case of less load, resulting into better fuel efficiency. With a Gross Vehicle
Weight
(GVW) of 31 ton, the Tata SIGNA 3118.T is powered by a world-class Tata
Cummins B5.9 L– 6 cylinder engine, with an optimum combination of 180 PS
and flat torque of 675 Nm at lowest rpm range, delivering best-in-class fuel
efficiency and highest engine life. The lowest Total Cost of Ownership (TCO) of
a commercial vehicle, coupled with a strong and sturdy chassis and vehicle
aggregates make the Tata SIGNA 3118.T, most suitable for all applications.

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The Tata SIGNA 2518.K is a Construction and Mining offering from Tata
Motors new SIGNA range of commercial vehicles. With a Gross Vehicle
Weight (GVW) of 25 ton, the Tata SIGNA 2518.K is powered by a world-class
Tata Cummins B5.9 L– 6 cylinder engine, with an optimum combination of
180 PS and flat torque of 675 Nm at lowest rpm range, delivering best-in-class
fuel efficiency and highest engine life. With a reliable and proven power train,
the new Tata SIGNA 2518.K offers its customers better productivity and lowest
cost of operations, for a construction vehicle. Multiple options of aggregates
combinations and load bodies make the Tata SIGNA 2518.K a versatile
workhorse for various applications.

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DEPARTMENT ASSIGNED
PRIMA TRIM LINE, WORLD TRUCK FACTORY, TATA MOTORS
LTD. (JAMSHEDPUR WORKS)
Prima Trim Line is involved in the production of prima cabs, for domestic and
international needs. Recently, the Prima Trim Line team has been assigned with
the task of assembling cabs for the Heavy Cab SIGNA.
 Variants:
 .S (Tractors)

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 .K (Tippers)
 . T (Trucks)

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Creation of Process Flow Diagram (PFD)
Process Flow Diagram: - A flow diagram in standard symbols showing the
sequence & branches of process.
Operation Description: - Brief description of the operation being performed.
Process Characteristics: - Required man, machine, method & environment
parameters for this operation only.
Product Characteristics: - Desired outcomes from this operation.
Rev. No : 1
Rev. Date : 16.03.16
Transportation Storage Assembly
Operation Operation & InspectionDelay
Opn No.
Work Stn
No /
Machine
No
Main Assly
Flow
Offline
Assly Flow
Plant : Jamshedpur Model : Signa
Tata Motors Cross Functi
Part No/s.: NA Part Name/ Process:
CAB Trim
Varun Jha
Opn. Description
Product
Characteristics
Process Characteristics
PU/ Shop : Prima Trim
Line
Approved by : PFC Date(Orig) : 01
Module Name : Fitted
Trim Cab
Legends
/
Abbreva
tions
Critical
Char: <CC>
Team Member : Prateek Koul
Latest Change Letter:NAJA-PL-P17-PFD-TR5-002
Process Flow Diagram ( PFD ) Hrushikesh T
Aggregate No.: NA Aggregate Part Descrptn : Signa CabReviewed by :
Complete Cabin
Cab not per Sequence Cab per Sequence
Door alligned and no
paint rub
400020 0
Sub assembly of Rear
Window Mould
400010 0
Receive the cab from
CPS in good condition.
Cab Damaged/ Paint
issue
Significant
Char :
<SC>
Operator' s
KnowledgeProper seating of Rear
window with Rubber
Operator' s skill
400040 0
Sub Assembly of Side
Window
400030 0 Fitment of Rear window
No gap between
rubber beading & the
Rear Window Beading
Cut
Proper seating of Rear
window beading withRear Window Glass
Crack
No gap between
rubber beading endsRear Window
hardness high
Operator' s
KnowledgeProper seating of Rear
window with Rubber
Operator' s skill
400060 0
Sub assembly of
Turning Window
Mould
400050 0
Fitment of Side
window
No gap between
rubber beading & the
Proper seating of Side
window beading with
Operator' s
KnowledgeNo gap between
rubber beading ends
Operator' s skill
Condition of Assy
fixture
Operator' s
KnowledgeProper seating of
Turnng window with
Operator' s skill400070 0
Fitment of Turning
window
No gap between
rubber beading & the
Proper seating of
Turning window
Operator' s
KnowledgeNo gap between
rubber beading ends
Operator' s skill
Condition of Assy
fixture

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PROCESS MAPPING
Process mapping can be defined as the process of
comparing operations of production of two different
cabs.
Below the process mapping is done between the PRIMA
Cabs and SIGNA Cabs.

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Station No.Process No. Process Description for Prima Process Description for SIGNA
1 Arrange cab for dropping
Receive the cab from CPS(P-III) in good
condition
2 Fitment of Glass & Seal quarter Fitment of Rear window
3 Fitment of glass & Seal rear Fitment of Side window
4 Fitment of Antenna & Grommet Fitment of Turning window
5 Fitment of Antenna Main Wiring Harness Set layout on cab
6 Fitment of Top Marker lamp LH&RH Insulation on bonnet
7 Edge Beading Roof Fitment Cab Dropping on Conveyor
8 Fitment of plug roof hole & Roof Cable Layout
9 Barcode Sticker & Cab no. Plate Tapping of all weld nuts
10 Cab Dropping Dummy cap fitment
1 Gear Shift Lever Unit Pasting of engine hood rubber beading
2 Steering Column Rubber Bellow Fitment of steering ring with bellow
3 Retainer Plate
Fitment of Wiper Motor Assy on cab with linkage
& wheel box housing
4 Accelerator Pedal Fitment of Front Upper Bracket (For Ac Veh only)
5 Integrated Pedal Unit AC Pipe Routing ( For AC Vehicle only)
6
Blower unit/ ac unit with front tube
support bracket
Fitment of HVAC Unit (For Ac Veh only)
7
Steering column mounting bracket
& magnetic valve
Fitment of Top & Bottom Duct mtg bkt on cab.
8 Assembled steering column Fitment of top marker lamp
9 Blower duct
10 Tipper Valve Bracket
11 Center Carpet
12 Floor Console Harness
13 Pneumatic pipes for HYVA bracket
1 Rear Vent Fitment of dovetail
2 Snorkel Mounting Bracket Fitment of clutch pedal into the cab
0
1
2

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Line Balancing
Line balancing is the process of assigning tasks to workstations,
so that workstations have approximately equal time
requirements. We use line balancing to
- minimize idle time
- balance bottlenecks
Rules for Line Balancing: -
 Identify the cycle time and minimum number of work stations.
 Make assignments to work stations in order, beginning with
Station 1. Tasks are assigned to work stations moving left to right
through the precedence diagram.
 Before each assignment, use the following criteria to determine
which tasks are eligible to be assigned to a workstation:
 All proceeding tasks in the sequence have been assigned.
 the task time does not exceed the time remaining at the workstation
 If no tasks are eligible, move to the next workstation.
 After each task assignment, determine the time remaining at the
current workstation by subtracting the sum of task times already
assigned to it from the cycle time.
 Break ties that occur using rules:
 Assign the task with the longest task time.

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 Assign the task with the greatest number of followers.
 If there is still a tie, choose one task arbitrarily.
 Continue until all tasks have been assigned to work stations.
Compute appropriate measures (percent idle time and efficiency)
for the set of assignments.
SIGNA LOAD
CHART1.xlsx
Line Balancing Formulas:
Minimum Cycle Time = longest single task time
Maximum Cycle Time = sum of all task times
N min = theoretical minimum number of stations
OT = operating time/day
CT = cycle time
D = desired output rate
N min = 3t CT = OT Output Capacity = OT
CT D CT
PRECEDENCE DIAGRAM
A (.1min)
B (1.0 min )
D (.5 min)
C (.7min )
E (.2 min )

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BOTTLENECKS
What is a bottleneck? Literally what is it?
In product layouts, when we want to improve productivity,
we need to find and improve critical operations, known as
bottlenecks. Productivity improvements to any non
bottleneck operation will NOT improve productivity of the
system.
Basically bottlenecks are defined as the time consuming
processes in the production as per the operation cycle.
The steps suggested avoiding or preventing shifting
bottlenecks are:
Step 1) Re-evaluate the maximum load of every machine,
process or work center when accepting a new order.
Step 2) Find the bottleneck in the system and identify its surplus
capacity.
Step 3) Fill the bottlenecks surplus capacity.
Step 4) Find out the release time of the material as a result of the
new bottlenecks scheduling.

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As per the Load Chart the bottlenecks are present in the
following Stations: -
Station No.- 1 ( Steering Sub Assembly )
Station No.- 11 ( Dashboard Cover )

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TIME STUDY
The Time Study is the process of identifying the actual time
taken to complete an operation in the production line.

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400010 RECIEVE THE CAB FROM CPS IN GOOD CONDITION
400020 FITMENT OF REAR WINDOW
400030 FITMENT OF SIDE WINDOW
400040 FITMENT OF TURNING WINDOW
400050 MAIN WIRING HARNESS SET FUSE BOX ASSEMBLY
400060 MAIN WIRING HARNESS SET LAYOUT
400070 INSULATION ON BONNET
400080 CAB DROPPING ON CONVEYOR
401010 ROOF CABLE LAYOUT
401020 TAPPING OF ALL WELD NUTS
401030 DUMMY CAP FITMENT
401040 PASTING OF ENGINE HOOD RUBBER BEADING
401050 FITMENT OF STEERING RING WITH BELLOW
401060 FITMENT OF STEERING SUB ASSY ON CAB
401070 FITMENT OF WIPER SUB ASSY
402010 FITMENT OF LINKAGE
402020 FITMENT OF FRONT UPPER BRACKET (FOR AC VEH ONLY)
402030 AC PIPE ROUTING (FOR AC VEH ONLY)
402040 FITMENT OF HVAC UNIT (FOR AC VEH ONLY)
402050 FITMENT OF TOP & BOTTOM DUCT MTG BKT. ON CAB
402060 FITMENT OF TOP MARKER LAMP
402070 FITMENT OF DOVETAIL
402080 FITMENT OF CLUTCH PEDAL INTO THE CAB
402090 ACCELERATOR PEDAL FITMENT
403010 FITMENT OF ACCELERATOR CABLE
403020 AIR DUCT FITMENT ON CAB
403030 DOOR CHECK STRAP FITMENT
403040 DC-DC CONVERTER FITMENT
403050 FITMENT OF DT VALVE ON COWL/CAB
404010 FITMENT OF AUTO DRAIN
404020 ECU FITMENT ON CAB
404030 FITMENT OF PRE-FILTER/SNORKEL
404040 FITMENT OF WASHING UNIT BOTTLE & PIPES
405010 FITMENT OF CLUTCH FLUID BOTTLE MOUNTING BKT FITMENT
405020 FITMENT OF CLUTCH FLUID BOTTLE SUB ASSY INTO THE CAB
405030 FITMENT OF AIR FILTER BKT
405040 SLD FITMENT
405050 FITMENT OF REAR VENTILATION GRILL
405060 CENTER PANEL STAY ROD FITMENT
406010 FITMENT OF ROOF TRIM
406020 FITMENT OF REAR WALL TRIM
0.7 min
2.1 min
5.1 min
4.3 min
1.2 min
3.10 min
5 min
2.40 min
1.0 min
0.5 min
5.2 min
4.7 min
9.5 min
8.4 min
2.5 min
6.1 min
2.4 min
0.50 min
0.60 min
11 min
2 min
1.5 min
5 min
3 min
6 min
5.49 min
4.3 min
3.2 mins
3 min
2 min
2 min
6 min
8 min
9 min
1 min
1.62 min
10 min
TATION WISE PROCESS SEQUENCE & ITS TIMING (Time St
Process PROCESS DESCRIPTION Time
2 min
1.50 mins
1.45 mins

32. Page | 32
WORK INSTRUCTION SHEET (WIS)
In Work Instruction Sheet (WIS), we have to create sheet with: -
 Job Sequence
 Symbols and
 Responsibility
 Operation Sequence (What is to be done and how it is to be done)
 Check Method (Measure, Visual, Touch, Feel, Count, Listen)
 Operation (Time in Seconds)
 Quality Standards, Risks Involved, Mitigation (safety)
 Quality (Effect on down Stream process, End user)
 Process Steps/ Sketch / Photographs
 Part details including health safety tools.
Here is the excel sheet of SIGNA CAB: -
Work Instruction
Sheet Signa.xlsx

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DROPPING OF SIGNA CAB IN THE PRIMA TRIM LINE
The SIGNA Cab is in the working stage. All the steps
necessary to ensure the dropping of the SIGNA Cab are
presently running smooth. Since the SIGNA Cab is almost
similar to the Heavy Cab in terms of the fitment of parts,
the operators are trained by expert operators from HCFL
Line on a Cab placed beside the Prima Trim Line.
Height of the pegs is adjusted for dropping of the cabs,
from the initial height of 1150 cm. As of now, the SIGNA
Cab is dropping properly as per schedule. The peg-heights
are adjusted to suit the requirements.

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FINAL OUTCOME OF SIGNA CABS

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CONCLUSION
The project ‘Introduction of SIGNA in Prima Trim Line’ required the
detailed knowledge of the different processes and operations of the
Prima Trim Line. This required rigorous fact-finding, observation,
knowledge of the inventory and continuous dialogue and discussion
with the people involved in these processes. Observation of the WIS of
different processes, verifying the part numbers of the materials to be
used in the cab, tools required to do these operations and finally
preparing the WIS brought about the thorough understanding of the
work at hand. Bottlenecks for the line were necessary to be identified
and suggestions for removing these bottlenecks were to be provided.
The suggestions include the proper arrangement of bins as per the
stations, increased use of the kitting trolleys, and educating the
operators about the exact part numbers of the materials to be used as
mentioned in the Work Instruction Sheets (WIS): all of these would
ensure that lesser time would be required to complete the operations.
For ensuring the introduction of SIGNA, processes of the HCFL line
needed to be studied and observed. Load Charts for the Prima Trim
Line, showing all the operators for the operations involved, needed to
be prepared. Operation mapping for the Prima Cab and the SIGNA Cab
had to be done. Finally, Load Balancing had to be suggested for the
Signa cab, based on the usage of parts and materials in the complete
assembly of a big cab. The problems were faced during the production
of Signa, which was causing delay in the production of Signa but with
the help of the employees the error has been sorted out.
Now the SIGNA Cab is running properly in the Prima Trim Line.

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REFERENCES
 Process Mapping
FP&M World Class Journey
Chris Ahoy,
Facilities Planning & Management
Iowa State University
 Process Flow Diagram
Learn about Quality
ASQ Org
 Line Balancing
Principles of Management &
Production
Dr. Allison W. Pearson
MISSISSIPI University
 Tata Motors Ltd. Work guide
 Wikipedia
Thanks