The document provides information about Fiat India Automobile Pvt. Ltd.'s manufacturing plant in Ranjangaon. It discusses the company profile, the layout of the plant, and details of the power train and car divisions. The plant uses World Class Manufacturing methodology and has body, paint, and assembly shops. It also describes two student projects - modifying the roller test process to improve safety and reducing issues during the shower test to improve quality.

1. DEPARTMENT OF MECHANICAL ENGINEERING
SHAHEED BHAGAT SINGH STATE TECHNICAL CAMPUS
FEROZEPUR
TRAINING
IN
FIAT INDIA AUTOMOBILE PVT. LTD.
SUBMITTED TO: SUBMITTED BY:
Dr. A.K. ASATI KARTIKEY KUMAR GUPTA (1322560)

2. COMPANY PROFILE
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Fiat S.P.A., an acronym for Fabbrica Italiana Automobili Torino.(English: Italian Automobile
Factory of Turin), is an automobile manufacturer, engine manufacturer, financial and industrial
group based in Turin in the Piedmont region. Fiat was founded in 1899 by a group of investors
including Giovanni Agnelli. Fiat has also manufactured railroad vehicles, tanks and aircraft. As of
2009-10, Fiat is the world's sixth largest carmaker as well as Italy's largest carmaker.
Fiat-based cars are constructed all around the world, with the largest number produced outside
Italy being built in Brazil, where they are best-sellers. It also has factories in Argentina and
Poland. Fiat has a long history of licensing its products to other countries regardless of local
political or cultural persuasion. Joint venture operations are found in Italy, France, Turkey, India,
Serbia and Russia.

3. The group's activities were initially focused on the industrial production of cars, industrial and
agricultural vehicles. Over time it has diversified into many other fields, and the group now has
activities in a wide range of sectors in industry and financial services. It is Italy's largest industrial
concern. It also has significant worldwide operations, operating in 61 countries with 1,063
companies that employ over 225,000 people, 111,000 of whom are outside Italy.
Fiat has variety of Car Manufacturing brands such as:-
 Fiat
 Chrysler
 Maserati
 Alfa Romeo
 Abarth
 Lancia
 Iveco
 Dodge
 SRT
 Jeep
FIAT GROUP OF AUTOMOBILE (F.G.A.)
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4. RANJANGAON PLANT LAYOUT
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PLANT 178

5.  The power train division has the capacity to produce FPT-Fiat Power Train Technologies
products.
 Power Train Division includes Engines, Transmissions and Trimming Plants.
 The products from include SDE Engine (1.3 Multijet Diesel Engine), FIRE Engine (Fully
Integrated Robotized Engine).
 FPT division has capacity to produce 3,50,000 (2,50,000 SDE & 1,00,000 FIRE Engines) Engines
annually and nearly 3,00,000 Transmissions.
 Engine quality is ensured by automatic in-process verification stations, by leak test benches &
final cold/hot test cells.
POWER TRAIN DIVISION
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6.  The Car division of Fiat India Automobiles Pvt. Ltd. Established at Ranjangaon has capacity to
produce maximum 2,00,000 cars per year.
 As it is a Joint Venture with Tata Motors, the products represent both the entities. It produces
Linea, Punto, Avventura, Urban Cross for Fiat & Zest, Bolt, Indica for Tata Motors.
 Though the plant produces cars specifically for Indian market, it also exports considerable
number of cars to other countries as well, such as South Africa & Brazil.
 The car division includes two car plants.
1. New Car Plant - Linea, Punto, Avventura, Urban Cross, Zest, Bolt & Jeep Compass
2. Plant 178 - Tata Indica eV2 (LS & LX Models). (The plant was formerly built for Fiat Palio)
 The car division includes Body Shop, Paint Shop & Assembly Shop. These shops are again
subdivided in different UTEs.
 UTE stands for Unit Technological Element. It is an Italian word which means Section.
CAR DIVISION
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7. WORLD CLASS MANUFACTURING (WCM)
The Plant works according to World Class Manufacturing (WCM) methodology that refers
to improving the cycle of production and logistics. The main objective of the method is to
increase quality and reduce production costs. The World Class Manufacturing is a concept
developed by Fiat and partnering companies in 2005. It includes 11 technical and 10
managerial pillars.
Following are the 11 technical pillars of WCM:-
1. Safety
2. Cost Deployment
3. Focused improvement
4. Autonomous maintenance
5. Workplace organization
6. Professional maintenance
7. Quality control
8. Logistics & Customer service
9. Early equipment management
10. People development
11. Environment

8. MANUFACTURING TECHNOLOGY
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Manufacturing
Technology
Body Shop
1. Planning for introduction
of new model.
2. Modification of exixting
mixtures and equipments
for better productivity.
Paint Shop
1. Planning for introduction
of new colour.
2. Modification of exixting
layouts as well as
functioning to adapt the
change.
Assembly Shop
1. Planning for new
infrastructure required..
2. Modification and
adaption of new
technology.

9. This shop is mainly related to sheet metal part’s welding. The pressed parts of the car’s body are
received from vendor in the body shop. After receiving those pressed parts, they are welded together
largely by means of Spot Welding process.
BODY SHOP

10. When the body is fully assembled and before it gets painted it is called as B.I.W. (Body In White).
This BIW goes to the Paint Shop by means of Conveyor. Painting in Fiat Automobiles is carried out
in very high accuracy & optimum finishing is always desired. It is 7 step process in Paint Shop.
 PTCED (Pre Treatment Cathode Electro Deposition ~ 28 μ)
 Sealer Line (N.V.H., Leak proofing)
 PVC application (Underbody Antistone)
 Primer Application (For Surface Preparation & Internal Adhesion ~ 35 μ)
 Base Coat (First Coat of Paint ~ 15 μ)
 Top Coat (Topmost coat of the Paint.)
 Clear Coat (For Glossy & aesthetically appealing look ~ 35 μ)
PAINT SHOP

11. Painted body from Paint shop is received and transferred to assembly line through floor conveyor
and stored at PBS. It passes from many UTEs (Unit Technological Element) such as:-
 UTE 1 (Trim Line)
 UTE 2 (Mechanical Side Assembly)
 UTE 3 (Power & Free 1,2)
 UTE 4 (Power & Free 3,4)
 UTE 6 (Door Line)
 UTE 5 (Final Line)
ASSEMBLY SHOP

12. 178 plants is the oldest plant of the Tata motors at
Ranjangaon. At this plant 75 cars are manufactured per
day.
The plant 178 has the assembly line for the TATA INDICA
eV2 LS & LX models.
It is also divided in UTEs such as:
 UTE 1 (Door Line)
 UTE 2 (Trim Line & Underbody)
 UTE 3 (Completion Line)
After performing the roller test the car is send for
quality checking.
PLANT 178
OFFICE
W/A Test
REST AREA
M Point
SHOWER 2
Engine Dressing line
LOGISTICS super
market area
TRIM II
START
PF 4
PF 3
TRIM 1
TRIM 2
TO TRACK
FROM TRACK
SHOWER 1
FINISHING LINE 2
FINISHING LINE 1
BOLLENO VERDE
BOLLENO VERDE
SALE
S
YARD
FEMSUBASSY
DOORLINETRIMI
RBT SMOKE & HA
UnderbodyCompletion
TRACK
Test

13.  Roller test modification for a safe environment
Result:-
1. Smoke of car will be exhausted from the plant.
2. Modification will be automated so this will reduce cycle time of testing.
 To improve shower FTQ (First Time Quality)
Results:-
1. Time will be saved for fixing door pad.
2. Cost will be reduced for repairing on offline cars.
PROJECTS

14. Objective:-
Exhaust chimney of roller test to be modified by giving a plate with pneumatic cylinder for
preventing health issues.
Description:-
A roller brake tester is a method of allowing the dynamic assessment of the braking system of a
motor vehicle, whilst the vehicle itself is in a static condition.
The driving rollers operate at a low (known) speed using a gearbox and motor arrangement and
during a test measurements of the maximum braking force are taken by applying the vehicle
brakes which induces a reaction force on the electric motor itself.
Advantage :-
All the smoke, exhausted by the car will be sucked by blower so there will no health issues and
atmosphere of plant will safe and healthy.
“ROLLER TEST MODIFICATION FOR SAFE ENVIRONMENT”

15. Actions to be taken
 Widened the chamber.
 Make the frame according the chamber.
 Make a suitable gate with frame.
 Fitting the cylinder with the surface of chamber to
the gate for chamber.
 Fitting a valve with roller m/c.
 Make a suitable electrical circuit for executing this
cylinder automatically.
Spare parts required
 Pneumatic Cylinder
 One Way Valve
 Valve Base
 Pneumatic Pipe
 Wire Cables
 Hinges/Brackets

16. When the car comes for the roller test then after pressing the start button, rollers will start to
engage with tyres of car and for engaging the rollers with car, pressure in roller area will release
and at that same time pressure in the cylinder will increase so both phenomenon, engaging of
rollers with tyres and opening of chamber will occur simultaneously. Then operator starts the
blower which will suck all the smoke which will be exhausted via silencer of car at the time of
testing. After completion of test we press stop button and air from cylinder will be released and
roller area gain pressure and chamber will close and rollers will be disengaged.
PNEUMATIC CIRCUIT

17. ROLLER TEST (BEFORE & AFTER MODIFICATION)

18. SCHEDULE OF PROJECT

19. Objective:-
Objective of this project is to improve shower First Time Quality of Door Pad.
Description:-
During the assembly of door pad, the paper film is stick to the door profile to prevent the water
from coming inside the car during raining.
To check this, we do a process i.e. Shower Test during a final quality check in which the car
passes from the shower tunnel which consists of multipoint water nozzles in all directions
having a pressure of 3.2bar.
Advantage :-
The main advantage of Shower FTQ is Time Reduction and Cost Saving which are occurred during
Repairing after the Shower Test.
“IMPROVEMENT OF SHOWER FTQ”

20.  IPA (Iso Propene Alchohal) cleaning not done on door profile before applying paper
film
 Roller stops rotating after a certain time
 Cable tie is not cut by the operator (It ruptures the paper film)
 Wrinkles are observed after roller application
 Thickness of butyl is not uniform
 Butyl adhesiveness is not upto benchmark
 IR lamp has unequal heat supply
PROBABLE REASONS

21. 4M ANALYSIS

22. THANK YOU