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INTERNSHIP – (18ME74)
PRESENTATION PHASE 1
COMPANY : Toyota Kirloskar Motors
Internal Guide: Girish Kumar R
Submitted by
Manthan B (1RV20ME063)
External Guide: Harisha S K
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Introduction
• Toyota Kirloskar Motor Private Limited (TKM) is an Indian joint venture
between Toyota Motor Corporation (89%) and Kirloskar Group (11%), for
the manufacture and sales of Toyota cars in India.
• Toyota Kirloskar Motor Pvt. Ltd. (TKM) was established on October 6,
1997, at Bidadi industrial area in a 432-acre land.
• It is a subsidiary of Toyota Motor Corporation of Japan, with the Kirloskar
Group holding a minority ownership.
• TKM aims to play a major role in the development of the automotive
industry and the creation of employment opportunities in India.
• The company follows a business philosophy of "Putting Customer First,"
emphasizing customer satisfaction.
• Currently, TKM is the 5th largest car maker in India, following Maruti
Suzuki, Tata Motors, Hyundai, Mahindra.
• The current manufacturing plant at Bidadi, Karnataka, is spread across 432
acres. The plant has a total capacity of 3,10,000 vehicles per annum, with
Plant 1 having a capacity of 1,00,000 vehicles per annum and Plant 2
having a capacity of 2,10,000 vehicles per annum.
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Departments and Their Functions
The manufacturing process followed at Toyota Kirloskar Motor plant along with the systems and
processes in place that make this facility and its ideologies truly one of a kind. The production
unit or shop floor is primarily composed of the below divisions
1.Inventory Storage
2.Press Shop
3.Weld Shop
4.Paint Shop
5.Assembly Shop
6.Final Inspection
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Departments and Their Functions
1.Inventory Storage
The parts that are required for the manufacturing of the vehicle are
stored in inventory. Toyota follows the Just in Time production
technique i.e. vehicles are produced according to their demand.
Therefore, Parts that are present in the inventory are only for that
day’s production and maybe the next day’s. This way the storage
and maintenance cost is reduced
2. Press Shop
The basic function of the press shop is to press the sheet metal
into the required shape. There are 4 stages in press shop. The first
two are stamping, in which the sheet metal is cut into required
size using templates called “DIES” and holes are made. The 3rd
and 4th stages are press stages. The machines that are used for
pressing the sheet metal use hydraulic control since the Pressure
required is high.
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Departments and Their Functions
3.Weld Shop
The Weld shop is responsible for welding every single part of the
vehicle. When the chassis is welded the frame structure is held on a
fixture which operates on the principle of pneumatic air pressure.
Then all the small parts to be fitted to the chassis are welded using
butt welding. This process is done manually. For body related
welding there is a different segment e.g. welding of fenders etc.
After the completion of welding, the body is inspected for defects.
The door of the body is fixed temporarily for painting purpose.
4. Paint Shop
In the paint shop the complete body is dipped into a solution
filled in a tank. This is done to clean the body and make it
corrosion proof. After this, primer coating is done which is
performed by a robot because the primer needs to be sprayed
uniformly. A quality check is done to ensure that uniform
thickness of paint is maintained.
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Departments and Their Functions
5. Assembly Shop
The assembly shop is responsible for the assembly of the various
parts to make a vehicle. The chassis assembly line and body trim
line move side by side. On these lines, the various parts, Systems
and sub assemblies of the chassis and the body are fitted. Once the
assembly of the various parts like door hinges, wire housing,
engine, transmission etc. is completed, the chassis is brought under
the body and fitted.
6. Final Inspection
During final Inspection, the entire vehicle is checked for any
defects in weld, paint and assembly. The engine is started and
checked and steering alignment is verified. Also a shower test is
performed to ensure that there are no leaks in the car. In case of
any persisting problem, the vehicle is sent to the repair shop
where the defect is rectified.
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Departments and Their Functions
In the above mentioned areas I specifically worked at the Weld Shop of Plant 1. In a weld shop many
areas come into existence, and in that the Main body plays a major role in providing a shape and
accurate dimensions to the car. Accuracy in car body is achieved in main body. Comparing other
department’s, main body plays a prominent role in production efficiency of the cars. In main body joining
of the side member and underbody takes place.
The following are the important areas of the Main body group,
Pre-Set Area: In the pre-set area, body part joining occurs as LH and RH side members join the
underbody.
M-JIG: The semi-automated M-JIG, with logical circuits and a complex clamping system, shapes the
body using sensors, actuators, and pressure gauges.
MBC: In this area the body transfer takes place from m-jig area through skidder, addition of roof takes
place by a upper area hoist and is welded after clamping it.
Re-spot Lines: These are the areas where spot welding is carried out at the various required locations
on the main body of the vehicle. There are re-spot lines starting from 1 to 5.
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Application of Engineering Knowledge
Spot welding is a widely used manufacturing process in the automotive industry, including at Toyota
manufacturing plants. However, one common challenge encountered during spot welding is the
generation of spatter. Spatter refers to small droplets of molten metal that are ejected during the
welding process. Spatter not only causes aesthetic issues, such as undesirable surface roughness and
deformations, contaminate sensitive areas within a vehicle. The spot welding process is carried out
utilizing a combination of robotics and manual labour.
The robots are programmed to perform spot welds with precision, following predetermined welding
parameters and instructions, but sometimes the robots require teaching so that don't lead to
generation of spatter.
So my main task was to reduce the spatter that was being generated.
The occurrence of spatter can be attributed to various factors such as panel gap, panel mismatch,
panel material, and welding parameters.
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Application of Engineering Knowledge
Currently Toyota uses Anti-Spatter oil(type of oil that is used in welding processes to prevent spatter
from sticking to welding equipment and work surfaces) to minimize spatter on the body, and the
method employed to apply the oil is very ineffective. It involves using a long brush to apply the oil,
which leads to spillage and wastage of the oil product.
A more efficient and effective system was to be implemented to minimize spillage, reduce health
hazards, and ensure proper coverage on all parts of the side body.
My proposition to them was to use pump and a flow regulating system to apply the oil.
Pump: A pump is used to create pressure and transfer the oil from the container to the side member.
It can be an electric, hydraulic, or pneumatic pump, depending on your specific requirements.
Container or reservoir: This holds the oil and ensures a continuous supply to the pump.
Flow regulating device: This ensures that the oil is delivered to the side member at a controlled flow
rate. It can be a valve, throttle, or flow control device.
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Application of Engineering Knowledge
• Thus addressing the ineffective anti-spatter oil application involved the application of key
mechanical engineering principles.
• In spot welding, understanding basic welding, thermal dynamics and material properties was
crucial.
• Combating spatter required insights into metallurgy and heat transfer.
• Designing the pump system demanded expertise in fluid dynamics, while hose selection involved
considerations of material science.
• The implementation of a precise flow regulating device required knowledge of control systems
and fluid mechanics.
This interdisciplinary approach showcased the diverse mechanical engineering expertise applied to
enhance the efficiency and quality of the manufacturing process at Toyota Kirloskar Motors.
