The document details an industrial training experience at General Motors India Pvt. Ltd., covering the company's history, product offerings, and major operational areas of the Halol plant. It includes a project focused on increasing productivity in the paint shop, analyzing defects, and proposing process improvements. Additionally, various manufacturing aids like Andon, Kanban, and Kaizen concepts are mentioned to enhance efficiency within the organization.

1. Industrial Training
at
General Motors India Pvt. Ltd.
VIVEK NIRWAL
GBPEC
PRODUCTION ENGG.
Batch:- 2011-2015

2. Content
 1. General Motor Corporation
1.1 Introduction
1.2 Chevrolet history
 2. General Motors India Pvt. Ltd.
2.1 GMI-HALOL
2.2 GMI products
2.3 Major areas in GMI
 3. Project Done at GMI-HALOL
3.1 To increase productivity in paint shop
3.2 Defect analysis in Paint Shop
3.3 Process study and Time study in Paint Shop

3. Contd…
 4. Aids to Manufacturing
(Various approaches for efficient functioning of the organization)
4.1 Andon concept
4.2 kanban concept
4.3 kaizan concept
4.4 VIN Number
4.5 AGV
4.6 QCOS
4.7 PFMEA
 5. Bibliography

4. 1.1 Introduction to General Motors
• American multinational corporation
headquartered in Detroit, Michigan.
• Designs, manufactures, markets and
distributes vehicles and vehicle parts.
• Produces vehicles in 37 countries under ten
brands.
• Chevrolet, Buick, GMC, Cadillac, Opel,
Holden, Vauxhall, Wuling, Baojun, Jie Fang,
and UzDaewoo.
• Has strategic partnerships:
 Fiat Auto Spa of Italy
 Daimler Chrysler AG & BMW of Germany
 Toyota Motor Corporation of Japan
 Suzuki Motor Corporation of Japan

5. 1.2 Chevrolet history
 1909- Louis Chevrolet, William Durant came up with the car design
 1911- Establishment of the Chevrolet Motors Car Company
 1912- Chevrolet launched its “Classic Six”-Top speed of 65 mph
 1914- Chevrolet “bowtie” logo appears for the first time
 1918- First Chevrolet truck sold. Chevy joins GMC
 1927- Chevrolet outsold Ford in the US by topping 1million units
 1965- First to build over over 3 million cars and trucks in a single year
 1979- A momentous year as Chevrolet rolled out its 100 millionth car
 2014-Part of the global landscape selling more than 150 million cars.

6. 2.1 General Motors India (Halol)
 Incorporated on 15th August 1994
 100% subsidiary of General Motors Corporation (GMC)
 Site area : 172 Acres
 Plant area : 68,000 m2
 Total plant size : 44000 m2
 Utilized area : 27000 m2
 Start of Production : June 1996
 Capacity : 1,80,000 unit / year
 Management sys. : GM Global Manufacturing System
: ISO 9001
: ISO 14001

7. 2.2 Products of General Motors India
(Halol,Vadodra)
1) CRUZE (J-300)
Pros
 Chevrolet Cruze Pros :
1. Striking exterior appearance
2. Equipped with several impressive convenience aspects
3. Engine performance is good with decent acceleration and pick up
4. Available in both manual and automatic transmission gearbox
5. Level of safety standards are at par with other sedans

8. Contd…
2) TAVERA (I-163)
Pros
 Chevrolet Tavera Pros :
1. Spacious internal cabin
2. Less expensive price tag
3. Decent ground clearance
4. Dual tone exteriors
5. The 10-seater option

9. Contd…
3) ENJOY (CN-100)
Pros
 Chevrolet Enjoy Pros:
1. Lavish interior space with luxurious seating arrangement
2. Ideal vehicle for families
3. Budget friendly price tag adds to the advantage
4. Fuel economy of diesel version is impressive
5. Utility aspects are at par with other MPVs

10. 2.3 Major Areas In GMI
 General Motors India, Halol plant is divided into five major departments:
• I. Press Shop
• II. Body Shop
• III. Paint Shop
• IV. General Assembly
• V. Quality
Press
shop
Quality
Body
shop
Paint
shop
GA
shop

11. I. Press Shop
 Starting point of the car manufacturing process
 Major equipment In use are:
A)- Dies
B)- Flywheels
C)- Robot Arms
D)- CNC Machines
Scope of work
 Has function of converting blank metal sheets into different shapes as required
 Produce the outer skin panels of I-163 & outer and inner panels for CN-100
 These parts employ about 120 dies & 4 presses
 These 4 presses are of :-
• 2250T- Press for forming or drawing operation
• 1000T- Press for trim operation
• 1000T- Press for trim and pierce operation
• 1000T- Press for final flanging operation
 Employs a Die-spot press used for checking of dies

12. II. Body shop
 Build of a car starts with body shop
 Body parts are assembled by spot
welding
 Body shop can be broadly divided
into two parts:
a) Weld Sub-Assembly (WSA) line
b) Body in White (BIW) line
Scope of work
 Consists of three separate lines for I-163 Tavera, J-300 Cruze and CN-100 Enjoy
 The BIW line consists of 20 stations required for the body to take the final shape
 Final body passes through DRL station under the quality team

13. III. Paint Shop
 Function of the paint shop is to provide an even coat of paint upon the car body
without any defects and with a luster or shine
 From customer point of view, it is one of the most important processes
 Paint shop is kept as a company secret in a number of automobile industries
 Paint shop is further divided into:
: Metal Body Paint shop
: Plastic Part Paint shop
 Paint Ingredients like binders, pigments, solvents, additives are added into paint to
enhance paint property

14. IV. General Assembly Shop
 At GM, Halol currently there are two lines running parallel :
• Truck line (I-163) dedicated for production of Tavera
• T&J car line producing Cruze (J-300) and Enjoy (CN-100) simultaneously
 On Truck line there are 38 stations, out of which 18 are on trim line and 20 are on
Chassis line
 There are total 41 stations in T&J Car Line, out of which 21 are on trim line and 20
are on chassis line
 In trim line the first 10 stations includes installation of electrical harnesses, floor mat,
roof mat, air ducts for intake, head lamps, parking lights, fluid lines etc
 In next 10 stations suspension, gear box lever, cockpit, steering, wind shield (front
and rear), front and rear bumper etc
 The car is then moved to the chassis line where the crucial parts of the car are bolted
and fitted in the body
 The car gets tires, seats, and all sorts of fluids wherever required like brake fluid,
coolant, engine oil etc.
 The final status of the car is checked by software called NGFTT (New generation
flashing testing tool).

15. Contd…
Scope of work
 The variants manufactured at GM , Halol are:-
• CN-100 Enjoy has three feature variants – LS, LT and LTZ varied into 6, 7
and 8 seated With two engine variants of Petrol and Diesel
• J-300 Cruze has two feature variants of – LT and LTZ with engine types as
Petrol and Diesel
• I-163 Tavera is the longest running production vehicle in the history of GMI,
 It has feature variants of five types – Base, B1, B2, LT, and Ambulance with
diesel engine
 GA shop thus handles volumes of production

16. Trim Line Chassis Line

17. V. Quality Shop
 Quality operation is divided into two parts:
 DRL: To repair any defects that have been left out
: In case of a major fault the car is made offline and repaired , which is
referred as Direct Run Rate
 SIP : (Standardized Inspection Process) After GA shop, it is checked visually and
passed through a series of test to assure its quality
: The following tests are carried out;-
 Caster, Camber and Toe : The wheels checked using various sensors, and
accordingly altercations are made
 Dynamic Vehicle Testing : The ECM (Engine Control Module) of the car is checked,
it is accelerated, braked for a specified
 Squeak & Rattle : The vehicle on aspecially made track to check its feasibility on all
road conditions
 Head Lamp Alignment : It is checked via a machine
 Water Test : The vehicle is showered with water to check for leakages
 Then goes to CARE (Customer Acceptance Review and Evaluation) line.

18. Contd…
DRL Line SIP Line/CARE Line

19. 3. Project Done at GMI-Halol

20. 3.1
To increase the productivity in paint shop
 Observation 1:- The elpo and primer sandings are done by operators with the bare
sand papers
 Harmful effects:-
• This may injure the fingers of operators
• It takes much time in sanding the body of car

21. Contd….
 Recommendation:-
• Well suited sandpaper holder should be used to hold the sand paper
• Sandpaper holder for complex shapes should be used
• Operators should be given proper gloves to wear which reduces the chances
of injury to fingers

22. Contd…
 Observation 2:-While painting the plastic parts in plastic part paint shop, only one
type of gun is used to paint the both smaller & larger parts which
causes the wastage of paint

23. Contd…
 Recommendation:- A conical shape nozzle should be mounted on gun ends for
smaller parts like valence, osrvm, garnish and spoilers in order
to reduce the wastage of paint
• The new design is more ergonomic

24. Contd…
 Observation 3:- The door fixtures are attached to body panel at station 0 in paint
shop just after elpo baking oven and at station 2 elpo sanding is
done to the doors
 Recommendation :- The fixture trolley should move from fixture station to the door
sanding station no. 2 in order to save the cost of a station
 Benefits :-
• This reduces the cost of electricity
• Reduces manpower
• Reduces downtime

25. Contd…
 Observation 4:- Both side fixtures are kept on left side of body panel and fixtures
are thrown to the right sides of body.
 Effects:-
• May cause damage to body
• It takes time to shift the fixture to respective sides
 Recommendation:-
• There should be different trolleys for fixtures on respective sides

26. 3.2 Defects analysis in Paint Shop
 Defects generally found at body buffer:
 Rust
 Hairline crack

27. Contd…
 Excess sealer
 Chip

28. Contd…
 Dent
 Weld bud (spatter)

29. 3.3 Process study in Paint Shop
 Process flow (metal body paint shop):-
 I) Pre-Treatment:- In this process the car is dipped in various tanks and held
at various angles to clean the body completely
Loading
area
Spray
wash
DI wash
spray
Immersion
wash
Activation
Immersion
phosphate
ELPO
Oven
ELPO
PT Line Flow Diagram

30. Contd…
 Station 01 – Immersion degreasing: This process removes oil; metal and grease
from car body by immersing the entire car body in a degreasing solution
which is a basic solution of NaOH at a temperature of about 55 to 60’C
 Station 02 – Spray rinse soft water : Here soft water is sprayed to remove
degreasing material (NaOH) from car body.

31. Contd…
 Station 03 - Spray rinse activation: This process is used to activate car body by
freeing all ions from it before Phosphating
 Station 04 - Spray Phosphate: Phosphating process takes place for rust prevention
and uniform paint concentration

32. `Contd…
 (II) ELPO line – It is the process of depositing basic paint on all the car body parts.
 Elpo process is Cathodic Electro Deposition process carried out to
prevent rust

33. Contd…
 (iii) Oven - After the ELPO process the car is baked in oven to make the coating
bond strongly with the car body
– Oven has five zones: Radiation (190’C), Convection 1 (172’C),
Convection 2, Convection 3 and forced Cooling (60’C)

34. Contd…
 (iv) Sealing – Here Sealant is applied to prevent water leakage and reduce
vibrations.
 Apart from sealant, PVC is also applied in the underbody section to
prevent chipping and deadener is applied on the floor so as to
reduce vibrations and prevent inflow of engine heat.

35. Contd…
 (v) Primer application - Before applying the final paint, primer is applied so that
the top coat can adhere strongly
 Initially solvent wiping and tag rack wiping is done
manually so as to remove all accumulated dirt prior to
paint application
 The inner parts of the car body undergo primer application
manually using electro static spray gun
 The outer parts of the car body are applied with primer by
the help of three robots.
 The last stage is flash off where the primer is dried and
finally sent to primer oven for baking

36. Contd…
 (vi) Top coat application - Top coat is the final colour that has to be applied on the
car body.
 It consist of two process Base coat and Clear coat
 Clear coat is basically varnish is used to give a shining effect on the body
 The last stage is flash off where the paint is dried and then sent to top coat
oven
 In case of two coat models the process is repeated twice

37. Contd…
 (vii) Finesse it and Cavity wax - Final touch up stage where the painted car body
is thoroughly inspected by the quality team for any damage of paint in terms of
scrapping, unevenness or shades and if required repairs are undertaken
 Quality checks related to DRL, DRR, are done here before sending the painted car
body to General Assembly shop for final assembly
 Wax is applied in the interior where paint cannot reach properly so as to avoid
rusting.

38. Contd…

39. Contd…
 Process flow (Plastic part paint shop):-
• All the plastic parts such as bumpers, door handles,OSRVM, spoilers, grills,valence.
undergo the painting process
• Masking process is followed in case of bumpers which are not to be painted
completely
• The final stage is flash off to ensure the coat of paint to be permanent followed by
oven for baking
• The processes carried for primer and paint in this shop resemble those in the Metal
Body Paint shop

40. Flow diagram of PPPS
Unpacking
Contd…
Wiping Loading
Conductive Primer application
Top coat application Flash off
Oven baking
Sanding & Buffing Spot repair

41. Contd…

42. 4. Aids to Manufacturing

43. 4.1 Andon Concept
 Refers to a system used to notify management, maintenance, and other workers of a
quality or process problem
 Gives the worker the ability, and moreover empowers them, to stop production when
a defect is found, and immediately call for assistance
 Common reasons for manual activation of the Andon are part shortage, defect
created or found, tool malfunction, or the existence of a safety problem
 It facilitates the identification of the root cause of the problem
 Some applications of the Andon concept provide a visual display of the status of a
run, or downtime tracking
Andon Board Control Switch Andon Board

44. 4.2 Kanban Process
 Kanban means signboard or billboard which is a scheduling system for lean and just-in-
time (JIT) production
 Kanban is a system to control the logistical chain from a production point of view
 Developed by Taiichi Ohno at Toyota
 One method through which JIT is achieved
 Part of an approach where the "pull" comes from the demand

45. Contd…
 Ensures that intermediate stocks held in the supply chain are better managed, and
are usually smaller
 Kanban cards are a key component of kanban and signal the need to move materials
within a manufacturing or production facility
 Trigger the replenishment of that product, part, or inventory
 Kanban cards therefore help create a demand-driven
system.

46. 4.3 Kaizen
 Refers to activities that continually improve all functions, and involves all employees
from the CEO to the assembly line workers
 The cycle of kaizen activity can be defined as:
• Standardize an operation and activities,
• Measure the operation (find cycle time and amount of in-process inventory).
• Gauge measurements against requirements.
• Innovate to meet requirements and increase productivity.
• Standardize the new, improved operations.
• Continue cycle.

47. 4.4 VIN Number
 VIN Number (Vehicle Identification Number)

48. 4.5 AGV (Auto Guided Vehicle)
 Mobile robot that follows markers or wires in the floor, or uses vision, magnets, or
lasers for navigation
 Used in industrial applications to move materials around a manufacturing facility or a
warehouse
 Automatic guided vehicles can be grouped into four general types:-
• Tow vehicles (tuggers)
• Unit load carriers
• Carts
• Fork vehicles
 Increase efficiency and reduce costs
by helping to automate a manufacturing
facility or warehouse

49. 4.6 QCOS
 Quality Control Operation Sheet
 It is a sheet maintained for every operation taking place in every shop
 Includes the the job name , part number, job number, name of tool used and tool
number
 Also includes the time taken to do the job
 Is important to maintain as in case of any fault, the inspection team can directly
revert back to the station where the job was done and look for the reason
 It is easy to find which tool was not working well and thereby caused the problem
 Essential part of the quality check procedure and acts as a powerful tool to maintain
quality standards

50. Contd…

51. 4.7 PFMEA
 Process Failure Mode Effects Analysis
 Helps to establish the impact of the failure, and identify and prioritize the action items
with the goal of alleviating risk
 PFMEA evaluates each process step and assigns a score on a scale of 1 to 10
 Severity — Assesses the impact of the failure mode (the error in the process)
 Occurrence — Assesses the chance of a failure happening
 Detection — Assesses the chance of a failure being detected
 RPN — Risk priority number = Severity * Occurrence *Detection
RPN=S*O*D

52. 5. BIBLIOGRAPHY
 Guidance by mentors
 GMI ME department study material
 Guidance by operators and workers
 www.gm.com
 www.wikipedia.com
 www.google.com