Design for Assembly/Design for Manufacturing (DFMA) for 988H LWL, Rapid Improvement Workshop (RIW) for 988H Large Wheel Loader (LWL), KITTING done for 777D, Work Stations - 1, 2, 3, Paint Before Assembly (PBA) for Hydraulic Excavator (HEX), 5S Auditing for 777D, Work Stations 1 to 11, SPAGHETTI mapping for 777D, Work Station -1.

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India Private Limited
A Report on, DFA/DFMIDEA GENERATIONS IN988H LWL,
CYCLE TIME IN 988H LWL, WORKSTATION 4,
RIW IDEA GENEREATION IN 988H LWL,
DATA COLLECTIONS IN WORK STAIONS 1, 2, 3 – KITTING,
PBA IN HYDRAULIC EXCAVATION,
SPAGHETTI MAPPING FOR 777D,
Submitted to, Mr. THEJASVI,
HUMAN SERVICES,
CATERPILLAR PVT LTD,
THIRUVALLUR, INDIA.
Submitted by, Mr. ADITYA VELAYUTHAM, B.S. III YEAR,
MECHANICAL ENGINEERING & TECHNOLOGY,
PSG INSTITUTE OF ADVANCED STUDIES,
COIMBATORE, INDIA.
Under the guidanceof, Mr. DHARMARAJ PARAMESHWARAN,
MANUFACTURING ENGINEERING ASSEMBLY PROCESS,
CATERPILLAR PVT LTD,
THIRUVALLUR, INDIA.

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TABLE OF CONTENTS
ACKNOWLEDGMENTS…………………………………………………….3
PREFACE…………………………………………………………………….4
ABOUT CATERPILLARINC……………………………………………...…5
CATERPILLARINDIA PVT LTD (CIPL) ……………………………..…..… 6
DFA/DFM IDEA GENERATIONSIN 988H LWL………………………..…8
CYCLE TIME IN 988H LWL, WORKSTATION 4……………………........11
RIW IDEA GENEREATION IN 988H LWL…………………………………13
DATA COLLECTIONSIN WORK STAION 1, 2, 3 – KITTING..................16
PBA IN HYDRAULICEXCAVATOR…………………………………..….20
SPAGHETTI MAPPING FOR 777D,WORKSTATION 11…………….....24
CONCLUSION………………………………………………………….….27

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ACKNOWLEDGMENTS
Currently I am completing my 3rd year mechanical
engineering and technology in PSG Instituteof Advanced studies,
Coimbatore, India. And I will be pursuing my final year in
Farmingdale State College, New York, USA.
The reason I chose to do my internship in Caterpillar is that
they havegot all kinds of machines, equipment’s and software’s
to manufacturean engine, start from scratch, since they are the
world's leading manufacturer for construction, mining equipment,
diesel and naturalgas engines, industrial gas turbinesand diesel-
electric locomotives. With more than US$89 billion in assets, so I
wanted to get exposed and gain knowledge from the company.
I am also very much interested in the field of automotive
sector, as it offers great potential for career development and
many research and development activitiesare taking place due
to its significance of reducing the impact of environmental
pollution and climate change.
To simply put,I could havenot done this work without the
help and guidance I received cheerfully from the Engineers in
whole process management team and the labours working in
each workstationsand substations in off high way truck, large
wheel loader and hydraulicexcavator.The work culture in
Caterpillar is really really enthusiastic. Everybodyis such a friendly
and cheerful companion here that,work stress is never comes in
way. I am also highly indebted to my supervisors Mr. Dharmaraj
and Mr. Shiyam, who seemed to have guided me to all the
problems which I havefaced.
Thank You

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PREFACE
In this internship report I will describe my experiences
during my internship period. The internship report contains an
overview of the Caterpillar Inc. and the activities, tasks and
projects that I haveworked. I havetried my best to keep report
simple yet technically correct. I hope I succeed in my attempt.

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ABOUT CATERPILLAR INC
Caterpillar Inc. is an American corporation which
designs, manufactures,markets and sells machinery and engines
and sells financial products and insurance to customers via a
worldwide dealer network.Caterpillar is the world's leading
manufacturer of construction and mining equipment, diesel and
naturalgas engines, industrial gas turbines and diesel-electric
locomotives. With more than US$89 billion in assets, Caterpillar was
ranked number one in its industry and number 44 overall in the
2009 Fortune500.
Caterpillar stock is a component of the Dow Jones Industrial
Average.Caterpillar Inc. traces its origins to the 1925 merger of the
Holt Manufacturing Company and the C. L. Best Tractor Company,
creating a new entity,the California based Caterpillar Tractor
Company. In 1986,the company re-organized itself as a Delaware
corporation under the current name; Caterpillar Inc. Caterpillar's
headquartersare located in Peoria, Illinois, United States.
Caterpillar machinery is recognizable by its trademark "Caterpillar
Yellow" livery and the "CAT" logo.

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Caterpillar India Private Limited (CIPL)
Caterpillar Inc. has a significant presence in India
through threekey ventures:
• Caterpillar India PrivateLimited (CIPL) is a wholly-owned
subsidiary of Caterpillar Inc., formed after the acquisition of the
earthmoving equipment division of Hindustan Motors by
Caterpillar in February 2001,for an estimated US$ 71 million. The
company manufacturesconstruction and mining equipment at its
facility in Thiruvallur,about 45 kilometres from Chennai, Tamil
Nadu.
• Caterpillar also has a majority-owned subsidiary called
Hindustan Powerplus Limited (HPL) which manufacturesdiesel
engines and generating sets in the 180 KVA to 2250 KVA range.
HPL was incorporated in 1988 and has a manufacturingfacility for
internal combustion diesel engines and generator sets at Punapalli
village near Hosur in Tamil Nadu. The company also sells spare
parts for the engines.
• Caterpillar Commercial PrivateLimited is a 100 per cent
subsidiary of Caterpillar Inc. Established in 1998,the company
deals with variousCaterpillar products such as machines and
large and medium speed engines. The company is also involved
in the operations and maintenance of mega power plants.
Over thepast 3 years, Caterpillar has been consolidating its
position in the Indian market. Two world-class dealers, GMMCO
Ltd. and TIL Ltd., support Caterpillar in India. The company
launched the first CAT brand earthmoving equipment to be
manufactured in India (424 series I backhoe loader), in August
2003.Before the launch, of CAT brand machines, motor graders,
hydraulic excavatorsand even wheel loaders were imported.

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Factors for success
Focus on quality and operational efficiency:
From the outset, CIPL has had a strong focus on quality. To this end,
it focused on implementing Six Sigma and the pursuit of
operational excellence using Class A disciplines.
Superior product development capabilities:
Caterpillar’s unique New Product Introduction (NPI) process gives
guidance, direction and accountability to all stakeholders while
ensuring its overall success. The cornerstone of this product
development process is the customer validation exercise where
machines are placed in a non-clinical environment and
evaluated for more than 3,500 hours. The company uses tools like
the Prediction of Estimated Reliability Growth Plan (PERG) and
statistical tools such as the Weibull Analysis for checking machine
performance prior to launch. Such processes and tools enabled
the company to successfully launch their products, and assure
success in a competitivemarket.
Engineering capabilities:
Caterpillar has its Engineering Services Division (ESD) in India.
Located at Thiruvallur,thedivision caters to the engineering
design needs of Caterpillar Inc.’s variousfacilities located across
the world. It convertsthe 2D legacy drawings to 3D compatible to
Pro E software, Caterpillar’s own software.
Future plans:
• CIPL plans to launch more models after the backhoe loader,
such as the 1025 Series I truck
• Caterpillar plans to outsource autocomponents from Indian
component suppliers.

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DFA/DFM IDEA GENERATIONS IN 988H LWL
Design for Assembly:
DFA is a tool used to assist the design teams in the design of
products that will transition to productions at a minimum cost,
focusing on the number of parts, handling and ease of assembly.
Design for Manufacturing:
DFM is a tool used to select the most cost effectivematerial and
process to be used in the production in the early stages of
product design.
Principles:
 Minimize part count
 Design parts with self-locating features
 Design parts with self-fastening features
 Minimizereorientation of parts during assembly
 Design parts for retrieval,handling,& insertion
 Emphasize ‘Top-Down’ assemblies
 Standardize parts…minimum use of fasteners.
 Encouragemodular design
 Design for a base part to locate other components
 Design for component symmetry for insertion
Benefits:
• Lower Assembly Cost
• Shorter Assembly Time
• Increased Reliability
• Shorter Total Time-To-Market

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CYCLE TIME STUDY IN 988H LWL, WORKSTATION 4
Cycle time :
Cycle time is the period it takes for a manufacturer to
complete development and production of a new or modified
product.The time it takes for this process is significant because it
impacts the ability of a company to reach market windows or to
react to changes in customer needs or desires. Reducing your
cycle time can improveefficiency and optimize profit potential.
Operator cycle time
Total time required for a worker to complete one cycle of an
operation.
Machine cycle time
Total time for a machine to finish one complete cycle, it includes
loading and unloading.
BENEFITS
• Improved Capacity
• Lower Unit Costs
• Shorter Cycle Times
• Improved Man Power
• Improved Customer Satisfaction
• Greater Productivity
• Quicker Time to Market
• Increased Effectiveness
• Improved Profitability

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RIW IDEA GENEREATION IN 988H LWL
Caterpillar productionsystem 8 wastes :
The ultimate goal of CPS is the elimination of waste. Waste is any
activity thatconsumes resources, but creates no valuefor the
customer.
Agenda of caterpillar productionsystem:
Make it Visual/Alignthe Targets–Communicategoals and post
results so that employees can see progress.
Go, See, Act –Empower employees to make suggestions and
report activitiesthat don’t comply with procedures (Continuous
Improvementcards).
Drive Standard Work -Standard Work created to shutdown boilers
and other high energy use equipment during extended shutdown
periods.
Develop People –Establish training program for all employees on
waste minimization and recycling program.
Validateour Processes–Investigation of water usage created
6Sigma project to reduce water consumption through flow
restriction and recycling of water.

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Lifting magnet:
Observation:
Lifting magnets are permanent magnets used for lifting
some metal objects which cannot be carried easily by workers.
These magnets used are in rectangular shape are not convenient
to place it on the parts of the body properly, so the workers are
keeping it in different positions to choose the right place, so that
the centre of gravity lies. If this goes on it will take some time.
Solution:
In order to reduce time, we can use circular lifting magnets
which has surface area lesser than other shapes used.
Rectangular
lifting magnets
have higher
surface area

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GENEIE SCISSORS LIFTS:
OBSERVATION:
Genie scissor lifts are generally used for temporary, flexible
access purposes such as maintenanceand manufacturingworks.
They are designed to lift limited weights — usually less than a ton,
although some havea higher safe working load. They are usually
capable of being set up and operated by a single person.
While using this lift, workers are unable to carry the tools
and equipment’s with them to work since they are breadth is small
for them to rate around, so what they do is that they place all the
required tools and equipment’s needed for the working in the
platform of the lift itself. Due to this the workers are bending down
each time to take the required tools. So this results in wasting of
time and man power.
Solution:
By mounting a removabletool palette on the sides of the scissors
lift will help them to reduce their energy and time.
Tools are been kept on
the platform

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DATA COLLECTIONS IN WORK STAION 1, 2, 3 – KITTING
Kitting:
Kitting is the gathering of components and parts needed for
the manufactureof a particular assembly or product. Individual
components are gathered together,as a kit, and issued to the
point of use.
Benefits:
 Savefacility space by reducing stock.
 Make operations more efficient by keeping parts at hand at
each station in the line and allowing storage of components
and assemblies at a centralized location.
 Ease production changes by keeping bulk parts at a kitting
area offline.
 Improveproductivityby eliminating the need for assembly
employees to search for parts.
 Decrease employee training time.
 Improvequality control by pushing parts inspection and
verification to an earlier point in the production process

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Flow chart:
MACHINE
ASSEMBLY
PARTS WILL
BE FROM KIT
BOX
LEFT OUT
PARTS IN THE
BOX
ADD TO LIST

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PBA IN HYDRAULIC EXCAVATOR
Paint before assembly :
To enhance assembly process for Paint before assembly in HEX
assembly
CASUSES:
 Damage during movement
 Foot marks on Machine
 Paint parts stacked one over above
 Birds droppings
 Cylinder rested on wood
 Tub placed over component
 Pendant left over and sides on paint finished machine
REMEDIES:
These are mats which has magnets in the end of it are been
used to place it on each of its respectiveparts in order to prevent
it from the damages.
Mat
Introduction

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One point lesson:
OBSERVATIONS:
Workers while working in 320D hydraulic excavator,they are
standing on the upper frame performing operations without
wearing shoe protectivecover.
IMPLEMENTATION:
Workers were provided with shoe protectivecover while
performing operation over theupper frame. From now the upper
frame coming from ware house is prevented from damages and
dirt.

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Characteristicsmatrix:
Trolley trial has been taken & observed few points for modification
UF00 UF01 UF02 UF03 UF04 UF05 UF06 UF07 UF08 UF09 BF01 BF02 BF03 BMO1 BM02 BM03 BM04 BM05 VMC FF01 FF02
Additional
Quantity
Available
Quality
WK-559009411 COVERBF-LHREXINEWITHMAG 1 1 1 1 1 1 1 1 1 1 1 11 5
WK-559009412 COVERBF-RHREXINEWITHMAG 1 1 1 1 1 1 1 1 1 1 1 11 5
WK-559009413 COVER OC -REARREXINEWITHMAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 5
WK-559009418 COVER OC -LEFTREXINEWITHMAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 5
WK-559009419 COVEROC LEFTSIDEDOOR1 REXINEWITHMAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 5
WK-559009420 COVEROC LEFTSIDEDOOR2REXINEWITHMAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 5
WK-559009421 COVERTOOLBOX REXINEWITHMAG 1 1 1 1 1 1 1 1 1 1 1 1 12 5
WK-559009422 COVERUF FRONTFLOORING MATREX.WITHMAG 0 5
WK-559009423 COVER-UF FRONTLEFTGUARDPANELREX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 5
WK-559009424 COVER-UF RIGHTLEFTGUARDPANELREX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 5
WK-559009425 COVER-UF LEFTBACKCHANNELREX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 5
WK-559009426 COVER-LEFTFRONTFLOORG MATUF REX./MAG 1 1 1 3 5
WK-559009427 COVER-UF LEFTHORIZTLCHANN1REX./MAG 1 1 1 1 4 5
WK-559009428 COVER-UF LEFTFLOORING REARMATREX./MAG 1 1 1 3 5
WK-559009429 COVER-UF LEFTINNERCHANNEL REX./MAG 1 1 1 1 4 5
WK-559009430 COVER-UF LEFTLONG VERTICHANNL1REX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 5
WK-559009431 COVER-UF LEFTLONG VERTICHANNL2REX./MAG 0 5
WK-559009432 COVER-UF RIGHTBACKSIDECHANNELREX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 5
WK-559009433 COVER-UF RIGHTINCLINEPLATE1 REX./MAG 0 5
WK-559009434 COVER-REARFLOORING MATUF REX./MAG 1 1 1 1 4 5
WK-559009435 COVER-UF RIGHTINCLINEPLATE2REX./MAG 1 1 1 1 4 5
WK-559009436 COVER-UF REARLEFTGUARDPANELREX./MAG 1 1 1 1 4 5
WK-559009437 COVER-UF REARRIGHTCHANNELREX./MAG 1 1 1 1 4 5
WK-559009438 COVER-UF REARRIGHTGUARDPANELREX./MAG 1 1 1 1 4 5
WK-559009439 COVER-UF RIGHTINCLINEDCHANNEL2REX./MAG 1 1 1 1 4 5
WK-559009441 LHDoorCoverEngside LH 1 1 1 1 1 1 1 1 1 1 10
WK-559009442 LHDoorcoverRearside 1 1 1 1 1 1 1 1 1 1 10
WK-559009443 RHDoorcoverrearside 1 1 1 1 1 1 1 1 1 1 10
WK-559009444 RHdoorcoverFrontside 1 1 1 1 1 1 1 1 1 1 10
WK-559009440 COVER-UF RIGHTINCLINEDCHANNEL3REX./MAG 1 1 1 1 4 5
ATTACHINGCOVER REMOVINGCOVERSFLOW
CAB SA/ UF04
Door SA/ UF08

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IMPACT ON CYCLE TIME:
Cycle time was noted for before and after using mats and
flow chart were done.
Add and Remove cover list station wise:
Cover list were put up for each workstation for workers to
understand which all coverswill be used for each operations.

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SPAGHETTI MAPPING FOR 777D, WORKSTATION 11
Spaghetti is a method of viewing data to visualize possible
flows through systems. Flows depicted in this manner appear like
noodles, hence the coining of this term. This method of statistics
was first used to track routing through factories. Visualizing flow in
this manner can reduce inefficiency within the flow of a system.
PURPOSE
The purpose of spaghetti mapping is to identify whether thereis
waste of movement in a process.
BENEFITS
 Savesresources such as money, time, and energy
 Visualizes improvement ideas prior to implementation
 Providesa graphic display of overlapping movement paths
that could cause delay
OBSERVATIONS:
No of workers in work station 11 = 4
Area of the work station = 10m x 6m
Cycle start time =10:05am
Cycle end time =11:45am
Total cycle time taken =1hour 50 minutes
Total movementstaken by workers=50

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Distance travelled by operators:
Lift operator taking away the fixtures to the tools rack –
Movement-4
Removing fixtures for rear right suspension – Movement – 2
Removing fixtures for rear left suspension – Movement – 2
Removing adapter from front side – Movement – 3
Removing adapter in from middle – Movement – 2
Lift operator taking away the front adapter – movement -3
Lift operator taking away the middle adapter – movement -3
Nitrogen and oil charging – movement - 5
Body mounting – movement – 3
Mounting left body pin – movement - 3
Mounting right body pin- movement – 3
Mounting steps in front (2) - movement – 4
Mounting left hoist pin – movement – 2
Mounting right hoist pin – movement – 2
Mounting left Shock pad – movement-3
Mounting right shock pad – movement-3
Removing suspension C- Clamp – movement - 3

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CONCLUSION
The whole experience of working at Caterpillar Inc. was
great. I got insight into professional practice. I learned the different
facets of working within the company. This organization has an
amazing work culture, great minds and very high quality of work. I
learned a lot of about Design for assembly and design for
manufacturing,cycle time study,Rapid improvement workshop
Kitting, Paint before assembly, and about Spaghetti Mapping. The
work I could complete here was very satisfactory. I hope my work
on Caterpillar Inc. meet its goals. The internship was also good to
find out what my strengthsand weaknesses are. This helped me to
define what skills and knowledge I haveto improvein the
upcoming time. On the whole, this internship was a useful
experience. I havegained new knowledge, skills and met many
new people.
*******