The document is an in-plant training report from Daimler India Commercial Vehicles Pvt. Ltd. It summarizes the following key points: 1. The trainee completed a 15 day training program at Daimler focusing on their fully built vehicle (FBV) assembly process. 2. The training report describes the 7 assembly stations in FBV production including the operations, tools, and safety measures at each station. 3. The trainee conducted a study on 5S methodology and identified opportunities for improvement in the FBV shop to increase efficiency and quality. 4. The training provided valuable technical knowledge about commercial vehicle production and assembly that will benefit the trainee's career.

1. INPLANT TRAINING REPORT
03.12.2014 - 18.12.2014
NAME: V.JAYAPRAKASH
ROLL NO: 11A118
BRANCH: AUTOMOBILE ENGINEERING
COLLEGE: KARPAGAM COLLEGE OF ENGINEERING
PROJECT LEAD: MR. VIDYA BHUSHAN PRASAD
DEPARTMENT HEAD:MR.PRASANTA SWAIN
TRAINING CO-ORDINATOR: MR. SURIYANARAYANAN.N

2. DECLARATION
I hereby declare that the report work entitled “IN PLANT TRAINING
REPORT” submitted to KARPAGAM COLLEGE OF ENGINEERING,
COIMBATORE is a record of an original work done by me at Daimler India
Commercial Vehicles private limited.
Date: Signature of student

3. BONAFIDE CERTIFICATE
This is to certify that the In-Plant training report is a bonafide
record of work done by
JAYAPRAKASH V
Register No: 11A118
B.E AUTOMOBILE ENGINEERING
KARPAGAM COLLEGE OF ENGINEERING
COIMBATORE
Mr. Suriyanarayanan Mr. Karunakaran Mr. Prasanta Swain

4. TRAINING COORDINATOR PLANT- HR Department
Head
PREFACE
Currently I am pursuing a Bachelor’s degree in Production
Engineering at PSG COLLEGE OF TECHNOLOGY. I am in my third year
and therefore I would like to go for an In-Plant Training in an established
industry. The reason I choose to do my training in Daimler is because I
wanted to benefit myself from the experience of knowing the German
way of running an industry, their industrial culture, methodologies and
ultimately gaining knowledge. I wanted to do my training to experience the
international business across the world and to learn about an industry in the
global market, improve and develop new sets of skills. My main goal is to
improve my technical knowledge in engineering and industries. This is why
I choose to follow my training here which helps me to learn and develop
new sets of skills and to experience working abroad.
In this report I will describe my experiences during my training
period. The report contains an overview of the company and the activities,
tasks and projects that I have worked on during my training. Writing this
report, I also will describe and reflect my learning objectives and personal
goals that I have set during my training period.

5. ACKNOWLEDGEMENT
I owe a great thanks to many people who supported me during the project.
For this opportunity I thank:
Mr. Suriyanarayanan N (Training incharge and internship
coordinator):
I want to thank him for guiding me right from the beginning,
explaining about industry life and helping me out with my doubts, in spite
of his busy schedule. I would also like to thank for allocating his time for
showing and explaining us about the entire Daimler plant.
Mr. VIDYA BHUSHAN PRASAD (Project Lead)
I would like to thank him, for being friendly and constantly
motivating me during my project sessions and clearing my technical doubts,
despite of his busy schedule.
My deep sense of gratitude to Mr. Karunakaran (Plant HR),
Mr. Mohan Raj (Plant HR – Head), Mr. Prasanta Swain(EOL and FBV
head) ,Mr. Swaminathan.G (Safetydepartment) and Mr. Rameshpriyan
K V (safety department), Daimler India Commercial Vehicles Pvt. Ltd.

6. Thanks and appreciation to the people and operators at the company for their
support.
I would also like to thank my department HOD, my institution and
faculty members without whom this training would be a distant dream. I also
extend my heartfelt thanks to my family and well-wishers.
SYNOPSIS:
 EXECUTIVE SUMMARY
 COMPANY PROFILE
 PROJECT UNDERTAKEN ON 5’S IMPROVEMENT IN FBV.
 TRAINING DESCRIPTION
 CONCLUSION
EXECUTIVE SUMMARY:
Daimler AG is a German multinational automotive corporation. Daimler AG is
headquartered in Stuttgart, Baden-Württemberg, Germany. By unit sales, it is the
thirteenth-largest car manufacturer and second-largest truck manufacturer in the
world. In addition to automobiles, Daimler manufactures buses and provides
financial services through its Daimler Financial Services arm.
As of 2014, Daimler owns or has shares in a number of car, bus, truck and
motorcycle marques including Mercedes-Benz, Mercedes-AMG, Smart
Automobile, Freightliner, Western Star, Thomas Built Buses, Setra, BharatBenz,

7. Mitsubishi Fuso, MV Agusta as well as shares in Denza, KAMAZ, Beijing
Automotive Group, Tesla Motors, and Renault-Nissan Alliance. The Maybach
marque was closed at the end of 2012, but was revived in November 2014 as
"Mercedes-Maybach", an ultra luxury edition of the Mercedes-Benz S-Class.
COMPANY PROFILE
There is a great desire among Indian customers for a world-Q class
truck which they can proudly call their own. The need of the hour is a truck
that will give them a high value on their investment. With this perspective,
Daimler AG incorporated Daimler India Commercial Vehicles (DICV) as a
wholly-owned subsidiary in 2008, in order to create world-class products, to
be manufactured indigenously in partnership with Indian suppliers.
Currently, Daimler is present in the Indian market with the Mercedes-Benz
brand of trucks. Beginning 2012, DICV initiated production of commercial
vehicles under the uniquely Indian brand ‘BharatBenz’. Towards this
objective, DICV had invested Rs.4,400 crores in establishing a state-of-the-
art manufacturing plant at Oragadam near Chennai, including an extensive
research & development arm.
Subsequent to the launch of an all new brand "BharatBenz", DICV set to
take its vision and mission into the market. After a successful Premiere of its
trucks in March 2012, DICV inaugurated its state-of-the art plant at
Oragadam, near Chennai, in April 2012. Later, in June 2012, it began

8. production of the Heavy-duty trucks. This was followed by a slew of
dealerships that were inaugurated. On 26 September 2012, DICV launched
its Heavy-duty trucks after an intense period of testing. February 2013,
witnessed the launch of the Light/Medium duty range. . DICV also launched
the new FUSO range of trucks at its plant on 23 May 2013, as part of its
well-coordinated Asia Business Model.
Daimler India Commercial Vehicles Pvt. Ltd (DICV), a 100% wholly owned
subsidiary of Daimler AG, on 10th July 2013, rolled out the 5000th truck
from its plant at Oragadam, near Chennai. DICV is stabilizing its production
line of all its launched models. Currently, DICV produces the 2523, 3123,
2528, 914, 1214 & 1217 (Heavy, Medium/Light-duty rigid & tipper trucks)
with several variants.
ON MARCH 6TH 2014, Daimler laid the foundation stone for its new bus
plant.The new Bus manufacturing plant is spread across an area of 27.91
acres will be constructed within the existing premises of DICV. The bus
plant will manufacture and assemble buses under the Mercedes-Benz and
BharatBenz brands and will be completed by the 2nd quarter 2015. The
DICV plant in Oragadam will thus be the only Daimler Truck plant
worldwide, that manufactures three brands of Trucks and Buses, as well as
engines under one roof. Daimler India buses will be offered in 9t, 16t and
above 16t categories in both front and rear engine configurations. An
investment of INR 425 Cr has been earmarked for the bus project in India
for an installed capacity of 1500 units in the initial phase. The capacity can
be further expanded to 4000 units subsequently. On 10th April 2014,
Daimler’s BharatBenz trucks rode on high gear and crossed 10,000 units
sale. In the beginning of 2014, Daimler achieved the following:

9.  Crosses sale of 1,000 units in a month in March 2014
 Sales up by 67.4% in the first quarter of 2014
 Gains 5.3% Market Share in the addressable market above 9T
segment
STUDY ON 5’S:
 5’S basic powerful toolfor improving quality.
 5’S is fundamental clean up of the work environment .
 Clean up leads to improved efficiencies improved quality and reduced
costs.
 5’S is a technique that provides the foundation for visual management.
THE 5’S :
 SORT.
 SET IN ORDER.
 SHINE.
 STANDARDIZE.
 SUSTAIN.
SORT:
1. Sort through items in the area.
2. Keep what is needed.

10. 3. Eliminate what is not needed.
4. Reduce the number of items to the quantity.
SORT CHECKLIST:
 Review and use the Item Disposition List as the criteria for red tagging.
 Gather needed supplies, including Red Tags.
 Set up a red tag Holding area. Mark the location, identify a red tag holding
area manager, write and poststandards and rules for disposition.
 Create and implement initial sort plan to purge the for unnecessary items.
 Fill out a log sheet listing all items removed from the area.
 Continue to Sort, through Red Tagging,as the other 5S System steps are
implemented.
SET IN ORDER:

11.  Analyse the current situation by updating the Workplace Scan Display
Checklist.
 Target specific issues.
 Decide where things belong.
 Make it visually obvious where and how things belong.
SET IN ORDER CHECKLIST:
 Determine the criteria for relocating out of place items.
 Identify and gather needed supplies (bins, labels, tags, colour tapes, etc).
SHINE:
 Check to see if everything is in its place.
 Check to see if you need to replace anything.
 Check everything; see if deep cleaning, repair, or replacement is needed.
 Shine and inspect through cleaning every shift.
SHINE CHECKLIST:
 Systematically determine targets and assignments.
 Determine appropriate cleaning methods.

12.  Get the right tools and supplies.
 Perform initial cleaning of targets.
STANDARDIZE:
 Identify and categorize a condition to standardize.
 Assign responsibilities for condition maintenance.
 Maintain and monitor those conditions.
STANDARDIZE CHECKLIST:
 Prepare the standardization chart.
 Identify standardization issues.
 Identify and attain desired conditions for Sort, Set in Order, and Shine.
 Make all standards clear and obvious.
 Monitor and improve all standards.

13. SUSTAIN:
 The first four pillars rely on sustain .
 Stick to the rules to keep the workplace well-ordered and run by
agreed-upon standards.
 Ensure that all workers have been trained in the procedures.
SUSTAIN CHECKLIST:
 Create a plan for Sustaining.
 Ensure that you have management support for the plan.
 Inform everyone in the area about the 5S standards and their
purposes.

14. STATIONS IN FULLY BUILT VEHICLE:
 STATION -1 (Chassis preparation).
 STATION -2 (Load Body mounting).

15.  STATION -3(U-Blot /Hydraulic /
Mudguard fitment).
 STATION -4(Load body fastener
tightening).
 STATION -5(SUPD & Wheel Choke
fitment).
 STATION -6(Mudguard tightening).
 STATION -7(Quality Gate & In-line
Rework).
 Rework Bay-1.
 Rework Bay-2.
 Logistics bay-1.
 Logistics bay-2.
STATION-1:
Chassis preparation for vehicle is done here for both HDT (Heavy
Duty Trucks) and MDT (Medium Duty Trucks) Vehicles.
Operation:
1. Workers remove tail lamp by removing bolts .
2. Balata pasting. Balata is aligned properly along the chassis.
3. Workers make note of time in and
Time out vehicle.
4. Documentation checking.

16. SAFETY MEASURE:
1. Safety gloves.
2. Safety shoes.
TOOLS USED:
1. Balata clam.
2. Torque wrench.
3. Cable tie cutter.
4. Ring spanner.
STATION-2:
Load bodyis mounted for both MDT and HDT at this station where
respective bodyfor the vehicles are supplied through logistics bay 1.
Operation:
From logistics bay 1 the bodyis carried to station 2 with a help of
the crane and it is mounted to chassis and it is literally clamped. The various types
bodymounted are rock, box and Rigid.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.

17. 3. Goggles.
4. Safety helmets.
STATION -3:
In this station clamping of U-Bolt and Mudguard fitment is done.
Operation:
The workers clamp the U-blot by using tools like pneumatic gun and spanners
where the materials are supplied through Logistics Bay. After clamping with the
help of the tools the vehicle is moved to next station using Easy mover.
TOOLS USED:
1. Torque wrench.
2. Ring spanner.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
3. Safety helmets.
STATION-4:
In this station fitted load body fastener tightening is done .
Operation:
The fitted load bodyis fastener tightening is done using
pneumatic gun and ring spanner along the chassis and fitting of back light is done

18. which is removed in the station 1 . After clamping with the help of the tools the
vehicle is moved to next station using Easy mover.
TOOLS USED:
1. Torque wrench.
2. Ring spanner.
3. Spanner.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
3. Safety helmets.
STATION -5:
In this station SUPD (Side Under Protective Device ) and Wheel choke Fitment
is done .
Operation:
Fitting protective guards along both sides of vehicle and and
fitting wheel choke along both sides . After clamping with the help of the tools
the vehicle is moved to next station using Easy mover.
TOOLS USED:
1. Torque wrench.
2. Ring spanner.
3. Spanner.

19. SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
STATION -6:
In this station the clamped mudguard is tightened and quality of the mounted body
is checked.
Operation:
The Mudguard tightening is done using pneumatic spray gun and
quality of the mounted bodyis checked other than paint all the quality of the
mounted bodyis checked and after checking the quality it is moved to the next
station.
TOOLS USED:
1. Torque wrench.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
STATION -7:
In these station quality and In-line rework are done.
Operation:
In this station minor rework which can done within 10 minutes are
done at these station and quality of the mounted bodyis checked . If quality is

20. checked without any issues then the vehicle comes under FTT. If it is not under the
quality it is moved to rework bay which doesn’tcomes under FTT.
TOOLS USED:
1. Hammer.
2. Pneumatic spray gun.
SAFETY MEASURE:
1. Safety shoes.
2. Safety gloves.
REWORK BAY:
In this station major rework like painting are done both on the bodyand along the
chassis and inside the chassis. The rework which cannot be done within 10
minutes are done here.
TOOLS USED:
1. Torque wrench.
2. Ring spanner.
3. Pneumatic spray gun.
4. Hammer.
SAFETY MEASURE:

21. 1. Safety shoes.
2. Safety gloves.
3. Goggles.
LOGISTICS BAY:
Through Logistics Bay materials are supplied to the respective station on the
requirements for every station .
5’S Improvement In FBV Shop:

24. CONCLUSION:
Thus the training at DICV was successfully completed with the guidance of
the training coordinator and FBV department. I personally gained some technical
knowledge about commercial vehicles, their working, parts, process layout,
industry and its management, the problems that arise while assembling even a
minute part etc. I look forward to join this company if given an opportunity in the
near future. And if I am recruited, I would assure that I will be proactive and work
for the progress of this esteemed company.