This document provides an overview of Avinish Kumar Jain's internship presentation at Renault Nissan Automotive India Private Limited (RNAIPL). The objectives of the internship were to get exposed to the organization's functions, structures, and operations, and to learn about various manufacturing and managerial concepts, tools, and techniques applied in the automotive industry. The presentation describes RNAIPL's manufacturing process, from stamping body parts to painting and assembling the final vehicle. It summarizes the key stages in body shop, paint shop, and plastic molding operations to manufacture vehicles like the Nissan Micra.
Basically it is a point point presentation of the work which I have done / observed during my internship at RNAIPL.
When I started making this PPT, I was in great confusion about how a internship PPT looks like. I think it would help many of you. Please let me know if there is any mistake in this PPT , so that I could make a note of it and would not repeat that mistake further.
thank you
This document provides an overview of vehicle body engineering, including:
1. It defines key terms related to vehicle body design such as chassis, body, suspension system, and power train.
2. It describes the basic requirements for automobile body design including strength, stiffness, providing adequate space, minimizing air drag, and protecting occupants from weather, corrosion, and accidents.
3. It discusses important considerations for vehicle body design like visibility, terminology, and methods to improve space requirements. Diagrams are included to illustrate factors that influence visibility and space.
The document summarizes the key steps in the painting process of a car body:
1. The process begins with pre-treatment which includes degreasing, activating, and phosphating the body to prepare the metal surface for painting.
2. Primer is then applied through both manual and robotic spraying to protect and promote adhesion of subsequent paint layers.
3. The primer is baked and sealed before applying the top coat paint through base coating and clear coating.
4. The painted body undergoes a final baking before cavities are sealed to complete the painting process.
Internship report of mechanical studentRitika Vyas
This document is an industrial training report submitted by Sudeep Mathur to fulfill requirements for a Bachelor of Technology degree in Mechanical Engineering. It provides details of a training project completed at VE Commercial Vehicles Ltd from May 10th to July 10th 2018 under the guidance of Mr. Vaibhav Vinayaka. The project focused on improving build quality for UD 1104 export vehicles to Indonesia by addressing part availability, quality, and manufacturing processes over 300 vehicles with a goal of reducing defects from 850 to 100 per vehicle.
Automotive Manufacturing Process OverviewTal Vagman
Hexagon a leader in manufacturing intelligence solutions explains briefly the automotive production process and key engineering and data challenges facing global producers.
The automotive design process involves several key steps: establishing a design brief, generating concepts, selecting themes, clay modeling, class A surfacing, design evaluation, prototype development and testing, and product launch. Designers create thousands of sketches inspired by the brief and their design thoughts. Themes are selected that meet the design intent, look great, and match the brief. Clay modeling and class A surfacing using computer-aided tools help visualize the product. Prototypes are built and tested before a vehicle is unveiled at an auto show and manufacturing begins.
AUTOMOBILE INDUSTRY - CAR - INDUSTRY ANALYSISaseel m
The document analyzes India's automobile industry. It notes that India has one of the largest automobile markets in the world and is the second fastest growing market after China. The car market is dominated by Maruti Suzuki, which has a 47% market share. Hatchbacks make up 49% of cars sold. Most cars sold are manufactured in India by companies like Maruti, Hyundai, and Mahindra. The industry provides opportunities for growth but also faces challenges like a lack of skilled labor and infrastructure. The conclusion predicts that India will become the third largest automotive market by 2016 if sales continue their growth trajectory.
Industrial training presentation (mechanical engineering)Rahul Banerjee
Giving all the details on what are the process happen in a industry.Main focus on estimation.Effects are implanted too.
The presentation gives all the details of this industry as a trainee.
Basically it is a point point presentation of the work which I have done / observed during my internship at RNAIPL.
When I started making this PPT, I was in great confusion about how a internship PPT looks like. I think it would help many of you. Please let me know if there is any mistake in this PPT , so that I could make a note of it and would not repeat that mistake further.
thank you
This document provides an overview of vehicle body engineering, including:
1. It defines key terms related to vehicle body design such as chassis, body, suspension system, and power train.
2. It describes the basic requirements for automobile body design including strength, stiffness, providing adequate space, minimizing air drag, and protecting occupants from weather, corrosion, and accidents.
3. It discusses important considerations for vehicle body design like visibility, terminology, and methods to improve space requirements. Diagrams are included to illustrate factors that influence visibility and space.
The document summarizes the key steps in the painting process of a car body:
1. The process begins with pre-treatment which includes degreasing, activating, and phosphating the body to prepare the metal surface for painting.
2. Primer is then applied through both manual and robotic spraying to protect and promote adhesion of subsequent paint layers.
3. The primer is baked and sealed before applying the top coat paint through base coating and clear coating.
4. The painted body undergoes a final baking before cavities are sealed to complete the painting process.
Internship report of mechanical studentRitika Vyas
This document is an industrial training report submitted by Sudeep Mathur to fulfill requirements for a Bachelor of Technology degree in Mechanical Engineering. It provides details of a training project completed at VE Commercial Vehicles Ltd from May 10th to July 10th 2018 under the guidance of Mr. Vaibhav Vinayaka. The project focused on improving build quality for UD 1104 export vehicles to Indonesia by addressing part availability, quality, and manufacturing processes over 300 vehicles with a goal of reducing defects from 850 to 100 per vehicle.
Automotive Manufacturing Process OverviewTal Vagman
Hexagon a leader in manufacturing intelligence solutions explains briefly the automotive production process and key engineering and data challenges facing global producers.
The automotive design process involves several key steps: establishing a design brief, generating concepts, selecting themes, clay modeling, class A surfacing, design evaluation, prototype development and testing, and product launch. Designers create thousands of sketches inspired by the brief and their design thoughts. Themes are selected that meet the design intent, look great, and match the brief. Clay modeling and class A surfacing using computer-aided tools help visualize the product. Prototypes are built and tested before a vehicle is unveiled at an auto show and manufacturing begins.
AUTOMOBILE INDUSTRY - CAR - INDUSTRY ANALYSISaseel m
The document analyzes India's automobile industry. It notes that India has one of the largest automobile markets in the world and is the second fastest growing market after China. The car market is dominated by Maruti Suzuki, which has a 47% market share. Hatchbacks make up 49% of cars sold. Most cars sold are manufactured in India by companies like Maruti, Hyundai, and Mahindra. The industry provides opportunities for growth but also faces challenges like a lack of skilled labor and infrastructure. The conclusion predicts that India will become the third largest automotive market by 2016 if sales continue their growth trajectory.
Industrial training presentation (mechanical engineering)Rahul Banerjee
Giving all the details on what are the process happen in a industry.Main focus on estimation.Effects are implanted too.
The presentation gives all the details of this industry as a trainee.
Google announced its first fully functional driverless car ready for testing on public roads, marking a breakthrough in automotive technology. Automakers are also developing automated manual transmissions, vehicle-to-vehicle communication technologies, and advanced driver assistance systems using sensors and automatic braking to increase safety and prevent collisions. Meanwhile, new infotainment systems are allowing smartphone-like interfaces in vehicles, and materials like aluminum are making cars lighter and more fuel efficient.
CEAT Ltd. is an Indian tyre manufacturer established in 1958 through collaboration between CEAT International and the Tata Group. The company manufactures over 6 million tyres annually through its plants in Mumbai, Nasik, and Halol. The tyre manufacturing process involves five main stages: compounding and mixing rubber and other materials; constructing components through calendaring and extrusion; assembling components onto a drum; curing and vulcanizing the assembly in a press; and final inspection. CEAT's vision is to be among the most profitable tyre companies in India and achieve leadership in select international markets.
Ashok Leyland overhauled its supply chain to revive the company during a recession. It formed a single window vendor management agency combining sourcing and quality teams. This centralized negotiations for price and supplier allocation. Production units then pulled materials from approved suppliers in line with plans. Suppliers now had a single point of contact at Ashok Leyland. Supplier tiering also pruned direct suppliers, with tier-one suppliers supporting lower tiers. System buying reduced costs, such as negotiating tool kits for all vehicles through one supplier. These supply chain changes helped lower costs and revive Ashok Leyland.
The document summarizes the bike manufacturing process in 7 steps:
1. Raw materials are delivered just-in-time to the plant.
2. The frame is fabricated from metal through computer-controlled welding.
3. Plastic parts are injection molded from melted resin pellets.
4. Metal and plastic parts are powder coated for painting.
5. Painted parts are assembled onto the frame through overhead conveyors.
6. The engine is mounted and other components are fitted as the bike moves down the assembly line.
7. Additional parts like wheels and seats are installed and quality control testing is conducted before shipping.
What is a Chassis?
Different Types of Chassis
Ladder frame chassis
Tubular space frame chassis
Aluminum space frame
ULSAB Monocoque chassis
Back bone frame chassis
Introduction to Monocoque Design
What is Monocoque construction?
Where is this used?
Origin of Monocoque design
History of Monocoque Frame
1) The document describes a study investigating the effects of variable intake plenum length on the performance of a spark-ignition engine with electronically controlled fuel injectors.
2) Engine tests were conducted with additional plenum lengths of 16mm, 32mm, 48mm, and 64mm added to the original intake manifold.
3) The results showed that a 32mm plenum extension improved engine thermal efficiency, especially at lower engine speeds up to 3000rpm, while also reducing fuel consumption at high loads and low speeds.
The document provides an overview of Mahindra First Choice Services, which is part of Mahindra & Mahindra's aftermarket sector. It discusses the foundation and business units of Mahindra, as well as details about Mahindra First Choice Services workshops. The workshop operates in cycles, providing services such as engine repair, brake repair, steering/suspension work, air conditioning, wheel balancing, denting/painting, and car grooming. It describes the process a vehicle goes through from entry to exit and highlights the various engine and vehicle services performed.
Summer training AT HONDA CARS INDIA LTDravivikram121
Honda has been the world's largest motorcycle manufacturer since 1959 and one of the largest car manufacturers. It established its India subsidiary, Honda Cars India Ltd (HCIL) in 1995 through a joint venture. HCIL operates two manufacturing plants in India and produces various Honda car models including the City, Jazz, Amaze, and Mobilio. The presentation describes HCIL's plant in Kasna, Greater Noida, and provides details on the car manufacturing process from painting to the final check and repair stage. Key equipment used includes tanks, spray nozzles, ovens, and burners.
project report on mahindra and mahindraamit prasad
The document discusses Yogesh Kumar's project report on his industrial training at Mahindra & Mahindra, which was submitted in partial fulfillment of the requirements for a Bachelor of Technology degree. It includes declarations by Yogesh Kumar and his supervisor, as well as acknowledgements and a table of contents outlining the chapters to be included in the report. The report will cover Yogesh Kumar's experience during his industrial training at Mahindra & Mahindra and analyze various aspects of the company.
This document provides information about the manufacturing processes at the Rail Wheel Factory in Bangalore, India. It describes the key steps in producing wheels, axles, and wheel sets, including: melting scrap steel in electric arc furnaces, casting steel wheels in molds, forging axles from billets, heat treating wheels and axles, and assembling wheel sets by pressing wheels onto axles. It also discusses the large electricity usage at the factory and quality assurance processes to meet standards.
Honda Project Report Internship( koushik tak bba) koushik tak
This training report summarizes Kousik Tak's summer training at Honda. It includes sections on the company profile of Honda, their operations in India, manufacturing and distribution systems, current market position, and promotional strategies. Honda is a large multinational corporation involved in motorcycles, automobiles, engines and other machinery. The report provides an overview of Honda's history, leadership, products and global presence.
Manufacturing process & assembly of automobileYashraj Patil
The document summarizes the key processes involved in automobile manufacturing, including chassis production, e-coating, surface finishing, pre-assembly, and final assembly. It describes how the chassis is constructed through welding and how the body is coated to prevent corrosion before major components like doors and instrument panels are added. Quality inspection occurs at various stages before cars move to the final assembly line where numerous units further prepare the vehicle for production.
Hero MotoCorp Ltd. is the largest motorcycle manufacturer in India. It was originally formed in 1984 as a joint venture between Hero Group and Honda Motor Company. In 2010, Honda ended the joint venture, leading Hero to become an independent company. Hero MotoCorp aims to achieve annual revenues of $10 billion and sales volumes of 10 million vehicles by 2016-17 by expanding exports and launching new products. It plans numerous investments to increase production capacity and develop new facilities.
This document provides an overview of the Ford automobile company's entry into the luxury and premium car market in India. It discusses Ford's history and global presence. It then explains that in 2006, Ford focused on entering the Indian luxury and niche car market, seeing an opportunity for growth. Ford established a subsidiary, Ford India, and initially invested 1.4 billion Indian rupees. The document concludes by noting that Ford entered the Indian market to take advantage of the growing premium automobile sector in India, which was around 1.3% of the market but growing rapidly.
This document discusses vehicle testing at proving grounds. It begins by defining a proving ground as an area where vehicle performance is tested, often over hundreds of acres with various road conditions. It then describes different types of test tracks at proving grounds for evaluating vehicles at high speeds, slow speeds, off-road, and custom conditions. Specific tests are outlined for each track type to gather data on braking, engine performance, durability, and more. Sensors are used to record data which is analyzed to assess the vehicle. Finally, a general layout of a proving ground is shown along with facilities commonly available.
This document discusses three Honda products - the Activa scooter, Unicorn motorcycle, and CB 1000R motorcycle. It provides details on each product like launch year, key features, pricing strategy used, and promotional activities. For the Activa, it mentions the first scooter launched by Honda in India in 2001. For the Unicorn, it highlights the mono-suspension design. And for the CB 1000R, it focuses on the powerful engine and transmission system.
The document discusses the manufacturing process of ball bearings and tapered roller bearings. It begins by describing the raw materials used, which is typically steel alloyed with carbon and chromium. It then outlines the major steps in ball bearing manufacturing, which are: cutting the outer and inner races to rough size from steel tubing, heat treating the races to harden them, finishing the races to precise sizes after heat treating, producing steel balls from wire in a cold heading process, assembling the balls and races along with a steel or plastic cage. The document also provides details on the manufacturing processes for individual parts of tapered roller bearings.
Aastik Chawla completed an industrial training at Honda Cars India Ltd from December 2014 to January 2015 to fulfill requirements for a Bachelor's degree in Mechanical Engineering. The training provided practical experience in design, production, administration and technical discussions. It aimed to develop leadership, innovation and management skills. Chawla acknowledges the support received from Honda officers and staff during the informative and disciplined training. A certificate confirms the successful completion of the training under guidance of the Head of Painting Department.
Volvo Eicher Commercial Vehicles (VECV) is a joint venture between Volvo Group and Eicher Motors that manufactures commercial vehicles. The intern completed a two-week time study of non-automotive engine peripherals production at VECV. The time study involved direct observation using a stopwatch to measure cycle times and identify value-added versus non-value added activities. Key findings were that the cycle time for a CPCB 1 engine was 52 minutes with 88% for value-added activities, and the cycle time for a CPCB 2 engine was 58 minutes with 88% for value-added activities. The time study aims to improve efficiency and reduce costs.
This document provides a training report submitted by Atish Kumar to fulfill the requirements for a Bachelor of Technology degree in Mechanical Engineering. The 6-month industrial training took place at SML ISUZU Ltd. in the Quality department. The report includes sections on the objectives of the training, acknowledgements, contents, and an introduction to the Indian automobile industry with statistics on production levels and key players.
A project report on orgnoziation study of tata motorsBabasab Patil
The automobile industry in India has grown significantly over the past few decades. It is now the 11th largest in the world, with annual production of around 2 million vehicles. India has a large market potential given its population of over 1.1 billion and low vehicle ownership rate. The industry employs over 13 million people and contributes around 3% to India's GDP. Motorcycles dominate the two-wheeler segment, while cars make up 79% of passenger vehicle sales. Tata Motors has over 60% market share in commercial vehicles. The industry has attracted many global automakers and is an important part of the Indian economy.
Organizational Design for Effective Software DevelopmentDev9Com
The document discusses organizational design for effective software development. It outlines problems with traditional matrix organizations and introduces team-based structures that can address these. Specifically, it advocates for cross-functional teams that are responsible for entire projects or products, rather than individuals being assigned to multiple projects. This allows teams to be accountable for delivery and improves collaboration, quality and outcomes.
Google announced its first fully functional driverless car ready for testing on public roads, marking a breakthrough in automotive technology. Automakers are also developing automated manual transmissions, vehicle-to-vehicle communication technologies, and advanced driver assistance systems using sensors and automatic braking to increase safety and prevent collisions. Meanwhile, new infotainment systems are allowing smartphone-like interfaces in vehicles, and materials like aluminum are making cars lighter and more fuel efficient.
CEAT Ltd. is an Indian tyre manufacturer established in 1958 through collaboration between CEAT International and the Tata Group. The company manufactures over 6 million tyres annually through its plants in Mumbai, Nasik, and Halol. The tyre manufacturing process involves five main stages: compounding and mixing rubber and other materials; constructing components through calendaring and extrusion; assembling components onto a drum; curing and vulcanizing the assembly in a press; and final inspection. CEAT's vision is to be among the most profitable tyre companies in India and achieve leadership in select international markets.
Ashok Leyland overhauled its supply chain to revive the company during a recession. It formed a single window vendor management agency combining sourcing and quality teams. This centralized negotiations for price and supplier allocation. Production units then pulled materials from approved suppliers in line with plans. Suppliers now had a single point of contact at Ashok Leyland. Supplier tiering also pruned direct suppliers, with tier-one suppliers supporting lower tiers. System buying reduced costs, such as negotiating tool kits for all vehicles through one supplier. These supply chain changes helped lower costs and revive Ashok Leyland.
The document summarizes the bike manufacturing process in 7 steps:
1. Raw materials are delivered just-in-time to the plant.
2. The frame is fabricated from metal through computer-controlled welding.
3. Plastic parts are injection molded from melted resin pellets.
4. Metal and plastic parts are powder coated for painting.
5. Painted parts are assembled onto the frame through overhead conveyors.
6. The engine is mounted and other components are fitted as the bike moves down the assembly line.
7. Additional parts like wheels and seats are installed and quality control testing is conducted before shipping.
What is a Chassis?
Different Types of Chassis
Ladder frame chassis
Tubular space frame chassis
Aluminum space frame
ULSAB Monocoque chassis
Back bone frame chassis
Introduction to Monocoque Design
What is Monocoque construction?
Where is this used?
Origin of Monocoque design
History of Monocoque Frame
1) The document describes a study investigating the effects of variable intake plenum length on the performance of a spark-ignition engine with electronically controlled fuel injectors.
2) Engine tests were conducted with additional plenum lengths of 16mm, 32mm, 48mm, and 64mm added to the original intake manifold.
3) The results showed that a 32mm plenum extension improved engine thermal efficiency, especially at lower engine speeds up to 3000rpm, while also reducing fuel consumption at high loads and low speeds.
The document provides an overview of Mahindra First Choice Services, which is part of Mahindra & Mahindra's aftermarket sector. It discusses the foundation and business units of Mahindra, as well as details about Mahindra First Choice Services workshops. The workshop operates in cycles, providing services such as engine repair, brake repair, steering/suspension work, air conditioning, wheel balancing, denting/painting, and car grooming. It describes the process a vehicle goes through from entry to exit and highlights the various engine and vehicle services performed.
Summer training AT HONDA CARS INDIA LTDravivikram121
Honda has been the world's largest motorcycle manufacturer since 1959 and one of the largest car manufacturers. It established its India subsidiary, Honda Cars India Ltd (HCIL) in 1995 through a joint venture. HCIL operates two manufacturing plants in India and produces various Honda car models including the City, Jazz, Amaze, and Mobilio. The presentation describes HCIL's plant in Kasna, Greater Noida, and provides details on the car manufacturing process from painting to the final check and repair stage. Key equipment used includes tanks, spray nozzles, ovens, and burners.
project report on mahindra and mahindraamit prasad
The document discusses Yogesh Kumar's project report on his industrial training at Mahindra & Mahindra, which was submitted in partial fulfillment of the requirements for a Bachelor of Technology degree. It includes declarations by Yogesh Kumar and his supervisor, as well as acknowledgements and a table of contents outlining the chapters to be included in the report. The report will cover Yogesh Kumar's experience during his industrial training at Mahindra & Mahindra and analyze various aspects of the company.
This document provides information about the manufacturing processes at the Rail Wheel Factory in Bangalore, India. It describes the key steps in producing wheels, axles, and wheel sets, including: melting scrap steel in electric arc furnaces, casting steel wheels in molds, forging axles from billets, heat treating wheels and axles, and assembling wheel sets by pressing wheels onto axles. It also discusses the large electricity usage at the factory and quality assurance processes to meet standards.
Honda Project Report Internship( koushik tak bba) koushik tak
This training report summarizes Kousik Tak's summer training at Honda. It includes sections on the company profile of Honda, their operations in India, manufacturing and distribution systems, current market position, and promotional strategies. Honda is a large multinational corporation involved in motorcycles, automobiles, engines and other machinery. The report provides an overview of Honda's history, leadership, products and global presence.
Manufacturing process & assembly of automobileYashraj Patil
The document summarizes the key processes involved in automobile manufacturing, including chassis production, e-coating, surface finishing, pre-assembly, and final assembly. It describes how the chassis is constructed through welding and how the body is coated to prevent corrosion before major components like doors and instrument panels are added. Quality inspection occurs at various stages before cars move to the final assembly line where numerous units further prepare the vehicle for production.
Hero MotoCorp Ltd. is the largest motorcycle manufacturer in India. It was originally formed in 1984 as a joint venture between Hero Group and Honda Motor Company. In 2010, Honda ended the joint venture, leading Hero to become an independent company. Hero MotoCorp aims to achieve annual revenues of $10 billion and sales volumes of 10 million vehicles by 2016-17 by expanding exports and launching new products. It plans numerous investments to increase production capacity and develop new facilities.
This document provides an overview of the Ford automobile company's entry into the luxury and premium car market in India. It discusses Ford's history and global presence. It then explains that in 2006, Ford focused on entering the Indian luxury and niche car market, seeing an opportunity for growth. Ford established a subsidiary, Ford India, and initially invested 1.4 billion Indian rupees. The document concludes by noting that Ford entered the Indian market to take advantage of the growing premium automobile sector in India, which was around 1.3% of the market but growing rapidly.
This document discusses vehicle testing at proving grounds. It begins by defining a proving ground as an area where vehicle performance is tested, often over hundreds of acres with various road conditions. It then describes different types of test tracks at proving grounds for evaluating vehicles at high speeds, slow speeds, off-road, and custom conditions. Specific tests are outlined for each track type to gather data on braking, engine performance, durability, and more. Sensors are used to record data which is analyzed to assess the vehicle. Finally, a general layout of a proving ground is shown along with facilities commonly available.
This document discusses three Honda products - the Activa scooter, Unicorn motorcycle, and CB 1000R motorcycle. It provides details on each product like launch year, key features, pricing strategy used, and promotional activities. For the Activa, it mentions the first scooter launched by Honda in India in 2001. For the Unicorn, it highlights the mono-suspension design. And for the CB 1000R, it focuses on the powerful engine and transmission system.
The document discusses the manufacturing process of ball bearings and tapered roller bearings. It begins by describing the raw materials used, which is typically steel alloyed with carbon and chromium. It then outlines the major steps in ball bearing manufacturing, which are: cutting the outer and inner races to rough size from steel tubing, heat treating the races to harden them, finishing the races to precise sizes after heat treating, producing steel balls from wire in a cold heading process, assembling the balls and races along with a steel or plastic cage. The document also provides details on the manufacturing processes for individual parts of tapered roller bearings.
Aastik Chawla completed an industrial training at Honda Cars India Ltd from December 2014 to January 2015 to fulfill requirements for a Bachelor's degree in Mechanical Engineering. The training provided practical experience in design, production, administration and technical discussions. It aimed to develop leadership, innovation and management skills. Chawla acknowledges the support received from Honda officers and staff during the informative and disciplined training. A certificate confirms the successful completion of the training under guidance of the Head of Painting Department.
Volvo Eicher Commercial Vehicles (VECV) is a joint venture between Volvo Group and Eicher Motors that manufactures commercial vehicles. The intern completed a two-week time study of non-automotive engine peripherals production at VECV. The time study involved direct observation using a stopwatch to measure cycle times and identify value-added versus non-value added activities. Key findings were that the cycle time for a CPCB 1 engine was 52 minutes with 88% for value-added activities, and the cycle time for a CPCB 2 engine was 58 minutes with 88% for value-added activities. The time study aims to improve efficiency and reduce costs.
This document provides a training report submitted by Atish Kumar to fulfill the requirements for a Bachelor of Technology degree in Mechanical Engineering. The 6-month industrial training took place at SML ISUZU Ltd. in the Quality department. The report includes sections on the objectives of the training, acknowledgements, contents, and an introduction to the Indian automobile industry with statistics on production levels and key players.
A project report on orgnoziation study of tata motorsBabasab Patil
The automobile industry in India has grown significantly over the past few decades. It is now the 11th largest in the world, with annual production of around 2 million vehicles. India has a large market potential given its population of over 1.1 billion and low vehicle ownership rate. The industry employs over 13 million people and contributes around 3% to India's GDP. Motorcycles dominate the two-wheeler segment, while cars make up 79% of passenger vehicle sales. Tata Motors has over 60% market share in commercial vehicles. The industry has attracted many global automakers and is an important part of the Indian economy.
Organizational Design for Effective Software DevelopmentDev9Com
The document discusses organizational design for effective software development. It outlines problems with traditional matrix organizations and introduces team-based structures that can address these. Specifically, it advocates for cross-functional teams that are responsible for entire projects or products, rather than individuals being assigned to multiple projects. This allows teams to be accountable for delivery and improves collaboration, quality and outcomes.
This document provides information about vocational training opportunities at Indo Danish Tool Room (IDTR) in Jamshedpur, India. IDTR was established in 1991 by the Government of India and Denmark to provide tooling and manufacturing training. It offers both long-term and short-term training programs in tool and die making as well as other engineering trades using latest technologies. IDTR also provides consultancy services, designs and manufactures molds, tools and dies, and provides machining and heat treatment services for small industries.
This document provides information about Federal Mogul Bearing India Ltd., including:
1. Federal Mogul Bearing India Ltd. was established in 1979 and set up an engine bearing division in collaboration with Federal Mogul Corporation, USA to manufacture thin-wall engine bearings.
2. The company's mission is to provide superior products on time to delight customers and provide better than market returns to delight shareholders.
3. The quality policy commits to meeting or exceeding customer requirements by maintaining a quality management system focused on customer satisfaction, continual improvement, and safety.
Project report on navjivan automobiles (hero motocorp)Govind14
This report consists all the details related to all the functions of Management of NAVJIVAN AUTOMOBILES i.e. Marketing, Production, Finance and Human Resource
Project summary report on tata motors by bharat goyalbharatgoyal44
This document provides an overview of the automobile industry in India. It discusses the history and development of the industry, including key milestones from the 18th century to modern times. Major automobile companies operating in India are listed. The industry has grown significantly in recent decades and is projected to continue expanding rapidly. India has become an important market and manufacturing hub for automobiles globally. Key statistics on production, exports, and segment growth rates are presented.
The document provides an agenda and overview of Renault-Nissan's external audit group presentation. The presentation covers: an introduction of Carlos Ghosn and his leadership of the companies; the objectives and goals of the Renault-Nissan alliance through SWOT and PESTEL analyses; current and past business models including value chain and Porter's 5 forces analyses; and current company performance. Key points include outlining Carlos Ghosn's career and role in turning around Nissan, the strategic benefits and objectives of the Renault-Nissan alliance, and analyses of the companies' business models and external environments.
The document discusses Honda's supply chain management practices. Honda focuses on close relationships with suppliers, involving them in product development. Honda also uses its scale to purchase materials in bulk from suppliers. It emphasizes quality and efficiency throughout the supply chain, including just-in-time production and continuous improvement methods. Foreign automakers generally share a similar customer-focused philosophy and supply chain approach.
The document discusses various sheet metalworking processes including cutting, bending, and drawing. Cutting operations like shearing, blanking, and punching are used to cut sheet metal. Bending involves straining sheet metal around a straight axis using methods like V-bending and edge bending. Drawing forms sheet metal into convex or concave shapes. Key considerations in sheet metalworking are clearance, bending allowances, springback, and forces required for cutting.
The Indian automotive industry has experienced significant growth over the past decade. Exports of automobiles from India surged 57% in 2008-2009, led by major exporters Hyundai and Maruti Suzuki shipping more vehicles to Europe. However, domestic sales were impacted by the economic slowdown and high lending rates. Passenger vehicle sales grew only 0.13% while commercial vehicle sales declined sharply. Two-wheeler sales also grew modestly at 2.6% due to financing issues. Going forward, demand from Europe may soften and domestic sales will depend on availability of financing and new model launches.
The document provides an overview of the Indian automobile industry, which manufactures over 11 million vehicles per year. It discusses key statistics such as production and export figures as well as segmentation of the market into segments like passenger vehicles, commercial vehicles, and two-wheelers. The automobile supply chain in India is also examined, with details provided on the roles of tier 1, 2, and 3 suppliers in delivering components to automakers.
The document is an industrial training report submitted by V.Hema Bhargava Reddy to SRM University. It provides an overview of Reddy's training at the Allison Transmission manufacturing facility. The report describes the key components and manufacturing processes for gears and transmissions. It also covers quality inspection and testing procedures in the metrology, CMM, and chemical labs. The transmission assembly flow process and repair area work are outlined as well.
Mid term presentation kartikey kr guptakartik dogra
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.
Arpit Kumar completed a summer training project at Tata Motors in Lucknow from June 21st to July 19th. The project involved process validation of critical and major processes on Trim Line 2. Trim Line 2 assembles cowls and cabs before passing them to assembly lines. Arpit analyzed processes like steering fitment and torque validation to ensure quality and safety. He concluded that the experience provided valuable lessons in teamwork, problem solving, and industry experience to support his future career.
The document discusses production scheduling and operations at a Toyota assembly plant. It describes the key stages in vehicle production from stamping body parts to painting and assembly. Production scheduling allocates resources and sequences tasks to produce goods according to the monthly sales order and forecast. A unique reference number is assigned to each vehicle, which is then scheduled for production using a heijunka or leveling process to smooth workload and balance resource usage throughout the supply chain. The daily production sequence is also important to ensure smooth operations and balanced work across assembly teams.
The document provides details about the various processes involved in the manufacturing of motorcycles at a factory, including operations at the press shop, die and tool shop, welding shop, paint shop, buffing shop, hub and panel shop, engine assembly shop, and frame assembly shop. It lists the machines used at each area and describes the specific processes, parts manufactured, and quality checks performed. In total, 48 parts are manufactured for various motorcycle models through these production steps.
1) Toyota Kirloskar Motor Private Limited (TKM) is an Indian joint venture between Toyota Motor Corporation and Kirloskar Group established in 1997 to manufacture and sell Toyota vehicles in India.
2) TKM's manufacturing plant is spread across 432 acres in Bidadi, Karnataka with a total annual production capacity of 310,000 vehicles between two plants.
3) The plant has various departments including press shop, weld shop, paint shop, assembly shop, and final inspection that work together in the vehicle manufacturing process.
Industrial training at general motors by VIVEK NIRWALvivek nirwal
this ppt enclose all important details which i got to learn in during my industrial training with general motors.hope this will help you guys to get more exposure in automobile industry.it will mainly help you in knowing the necessary aspects in manufacturing of a car.General motors is among top 10 automobiles industries of world. so it was a great experience having training with such a high profile industry.
BSM Group Ltd. was founded in 1992 and is located in Shenzhen, China. With our 20 years of experience we have become a reliable strategic partner of fortune 100 companies worldwide.
The BSM Group is comprised of seven domestic companies including Fareast Precision Mold&Molding Engineering Ltd.,Bluestar Technology(shenzhen)Co.,Ltd., Globalsocial Technology(shenzhen)Co.,Ltd.
The BSM Group is stable with growth in proven industries, manufacturing, processing, and R&D for the markets of Automotive, Electronics and Health Care. Diversification in developing industries include hotel operating, smart appliances, communication and IT technology.
BSM Group Ltd. covers an area of 20,000 square meters, consisted of office buildings, large-scale tooling shop, precision mold manufacturing workshop, injection workshop, screen printing workshop, assembly line, together with specialized, advanced manufacturing technique and equipment to trial and support production. The total staff is more than 550 people.
In an increasingly competitive international situation, BSM Group Ltd. always adhere to the development strategy from the "Made in China" to "Innovated in China” , focus on new high-tech technology and new product development, design, manufacture and export. As of 2006 the BSM Group has successively passed ISO9001, ISO14001, ROHS and TS16949 quality management system certification.
Email: Dickens@bluestar-mould.com
This document provides information about Govind Sharma's training at Honda Motorcycle & Scooter India Pvt. Ltd. in Manesar, Haryana. It discusses that Honda was established in India in 1999 and is a major motorcycle manufacturer. Govind trained in frame assembly, specifically for the Honda Unicorn 160 model. The document outlines the inspection processes used and details several defects identified for the Unicorn 160 at launch, along with the root causes found and countermeasures implemented to reduce defects per vehicle and increase direct pass ratio.
This document discusses various methods for inspecting spot welds in automotive manufacturing to identify improper welds. It describes laser inspection methods using spatial augmented reality to project inspection instructions onto vehicle bodies. It also discusses ultrasonic inspection techniques that analyze echo signals to identify flaws. Automated computer-assisted systems are able to rapidly inspect many spot welds and document results. Additional methods explored include electromagnetic acoustic transducers and studies of non-destructive testing techniques commonly used in various industries.
Sunil H is seeking a position in industrial automation or as a PLC programmer. He has over 4 years of experience programming PLCs from manufacturers like Siemens, Omron, B&R, and Messung. His experience includes commissioning machines, developing control systems, process optimization, and achieving productivity targets. Previously he has worked on projects involving engine assembly lines, nut runners, gauging machines, pressing machines, and leak testing machines. He is proficient in PLC programming and HMI configuration.
- Prince Industries pursues excellence in developing its global team and providing exceptional value for customers and ownership. It was founded in 1959 and has expanded its operations and capabilities over the decades.
- It now has facilities in Chicago, Batavia, Illinois, and Shanghai China, serving a wide range of industries through machining, fabrication, assembly, and engineering services.
- Prince Industries aims to be the premier domestic integrator of globally supplied products, employing advanced manufacturing technologies and a commitment to continuous improvement.
MANUFACTURING OF CNC MACHINES- TRAINING REPORT AT JYOTI CNCBhaumik Sheth
This document provides information on the industrial training program at Jyoti CNC Automation Pvt. Ltd. It describes the various production processes used at their facility including the foundry, machining, assembly, sheet metal, and paint shops. The foundry uses processes like pattern making, core making, and molding to produce castings. The machining department then machines the castings using CNC machines. Components are assembled in the assembly shop and sheet metal parts are made in the sheet metal shop before final painting and quality control.
Summer Training Report - Gaurab Pant(1)Gaurab Pant
The document summarizes a summer training report submitted by Gaurab Pant to Rishabh Gupta. It describes the operations of the TATA AutoComp Systems composites division plant in Pantnagar, Uttarakhand. The plant produces automotive parts using various molding and assembly processes. It analyzes defects in TATA Ace front lift panels and methods to reduce rejection rates, such as changing fixtures and handling procedures to address cracking issues. Modifications resulted in lower defect rates for Ace lift panels from over 15% on average to under 4%.
This document provides an overview of Authentic Engineers, an automation solutions company. It discusses the company's history and services, including special purpose machines, vision applications, and control panels. It highlights project portfolios and financials. The presentation agenda is introduced and the company's mission is to become a respected automation partner and achieve 30 crore revenue by 2020 through new opportunities and expanded facilities.
Twin Engineers Pvt. Ltd. is an ISO 9001-2008 certified Indian company established in 1993 that designs and manufactures automated dispensing equipment for sealants and liquids. It has over 80 employees and serves over 100 customers in automotive and other industries. The company has a state-of-the-art R&D facility and has been awarded three patents for its products.
The document provides information about Amrut Engineering Pvt Ltd, including:
- It is a medium-scale private company that manufactures and exports submersible pumps.
- The company believes in quality, customer satisfaction, and implementing latest technologies.
- It has established a quality management system and manufactures various pump products.
1. Tata Motors produces a range of commercial and passenger vehicles under the Tata brand. This includes the Tata Nano, the cheapest car in the world priced at 100,000 rupees.
2. The manufacturing process for vehicles involves several steps from pressing body panels to assembly and painting. Parts are sourced from a network of tier 1, 2 and 3 suppliers.
3. Finished vehicles are distributed nationwide using rail and container transport networks before reaching dealerships and showrooms for sale to customers.
Similar to RENAULT NISSAN AUTOMOTIVE INDIA PRIVATE LIMITED (20)
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
EV Charging at MFH Properties by Whitaker JamiesonForth
Whitaker Jamieson, Senior Specialist at Forth, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
Awareness: Increase your awareness about catalytic converter theft and its impact on vehicle owners.
Practical Tips: Gain actionable insights and tips to effectively prevent catalytic converter theft.
Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
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Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
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2. Objectives of Internship
General objective
• As partial fulfillment of the requirements of the B.Tech. program at XXX
University
Specific Objectives
• To get exposed to functions, structures and operational activities of the organization.
• To learn about various manufacturing & managerial concepts, tools and techniques
that are theoretically and applied in an industry.
• To learn the manufacturing and assembly process of an automobile.
• To experience the working process of an industry.
• To contribute my effort to industry.
3. About RNAIPL
The first dedicated Alliance facility in which Nissans and Renaults are made side-by-side – is a modern and
highly efficient plant producing top quality cars. But there’s more. It’s now officially one of India’s safest and
most environmentally-friendly factories, too. That’s according to the Confederation of Indian Industry (CII),
which has given the plant its top award for excellence in Environmental Health and Safety.
In February 2008, the Renault-Nissan Alliance signed a MOU with Government of Tamil Nadu to set up a
manufacturing plant at Oragadam, near Chennai with a minimum investment of Rs. 4500 Crore over a period
of 7 years. On March 17, 2010, the Renault-Nissan alliance plant was inaugurated in a record time of 21
months since its groundbreaking ceremony in June 2008.
RNAIPL thus achieved the unique milestone of starting operations in record time of 21 months from the date
of signing of MOU. The Plant has an initial capacity of 2, 00,000 units per year and planned to reach
4, 00,000 units per year in full capacity. Nissan’s first locally manufactured global compact hatchback –The
Nissan Micra is manufactured at the plant and commercial production for the same began in May 2010.It
represents 1500 employs.
4. Vision –Enriching People’s Lives
Mission – It provide unique and innovative automotive product
and services that deliver superior measurable values to all stack
holders.
8. Hydraulics
All the shops of RNAIPL are automated. In each shop hydraulic and pneumatic machines
are installed. Most of the manufacturing work are done by robots. So for operating, and
maintaining these machines and robots with accuracy, good knowledge of hydraulic,
pneumatics and robotics is necessary.
Principle (Pascal Law)
Pressure applied to a confined fluid at any point is transmitted undiminished and
equally throughout the fluid in all directions and acts upon every part of the
confining vessel at right angles to its interior surfaces.
9. Pumps
Cont.
A pump is a mechanical device that moves fluids (liquids and gases) or
sometimes slurries, by mechanical action.
Pumps
Positive Displacement Pump
Gear Pump
Vane
Piston
External
Non Positive Displacement Pump
Centrifugal
Internal
Axial
Axial Piston
Radial
10. Control Valves
A mechanical device that is used to control the flow of a fluid.
Valves
Direction Control
Valve (DCV)
Flow Control
Valve (FCV)
Pressure Control
Valve (PCV)
11. Mechanical Utility System
There are five components of mechanical utility system.
1.
2.
3.
4.
5.
Compressors
Driers
Heat Exchangers
Pumps
Cooling Towers
15. BMS (Building Management system)
In BMS all the mechanical utilities are controlled and monitored. All the information about utilities
(driers, compressors etc.) like operating status, present conditions (pressure, temperature, and flow rate)
is transmitted through sensors to BMS. In BMS five displays are using that display the operating status
of the all utilities. One main display is used for main control. All the utilities can be controlled from the
BMS. For safety automatic alarm system is there. If any problem occurs in any utility system then
alarm rings and displays show the place where problem occurs. It also display that what is the problem.
Alarm rings in all the areas. It is very fast and time saving system because where is the problem, it is
already known so only specific person go there and solve the problem so checking of all utilities is not
required.
In design of plant every system is designed according to specific industrial standards.
In firefighting system the circular distance between each fire extinguisher should be 30 meters. But here
at every 15 meters fire extinguisher is placed for more safety. For every danger and safety sign photo
luminescent material is used.
16. PROJECT STRUCTURE (PHASE – I)
PROCESS TEAM
INPUT
TECHNICAL
ALIGNMENT MEETING
PROJECT
ENGINEERING TEAM
NO
YES
FINAL BOQ
(Technically aligned
BOQ)
VALIDATE & CHECK
YES
RNPO
DESIGN OF SYSTEMS
NO
YES
TENDER FLOATING
VALIDATE & CHECK &
PREPARE BOQ
PURCHASE TEAM
TENDER FLOATING TO
CONTRACTORS
TECHNICAL
ALIGNMENT MEETING
RESEND QUOTATION
NEGOTIATION BY
RNPO
SUPPLIER FINALISATION
17. PROJECT STRUCTURE PHASE-2
SCHEDULE
MODE OF WORKING
WORK METHOD
RULES &
REGULATIONS
KICK OF
MEETING
START OF
PROJECT
PROJECT
COMPLETION
QC
&
PREPARING
SNAG LIST
SAFETY AUDIT
(PRIMARY &
SECONDARY)
PREPARE
REPORT
CLOSING OF
SNAG LIST
HAND OVER TO
MAINTANENCE
DRAWING APPROVAL
DESIGN APPROVAL
PROGRESS REVIEW MEET
SCHEDULE MONITORING
19. Stamping Shop
In stamping shop body parts of car are manufactured using steel
plate.
1. Blanking
2. Pressing and Piercing
3. Quality checking
20. Blanking Process
1.
2.
3.
4.
5.
6.
7.
8.
Coil-Car: Coil of steel plate is pick up by crane and transferred to coil-car that transfer the coil to
uncoiler.
Uncoiler and advance correction machine: It sets the inner diameter of coil to the center of the line
by holding device that remove rolling habit of the tip of the coil.
Washing: The device that removes the foreign material that has adhered to the coil.
Leveler: Device that corrects the shape of the steel plate and makes it smooth. It consist a
combination of rollers that level the plate.
Looping: In this process steel plate is stretched into the pit and all the bends are removed..
Feeder: Device that adjusts the coil material to press cycle and set the cutting length and sends it to
piler.
Press: It press the steel plate and cut the steel. Press can be rotated at required angle to cut the steel
plate at any angle.
Piler: The device that piles the cut material with accuracy. From here cut material are transferred to
pressing line. There are Two Piler zone here.
21. Pressing and piercing Line
Here are three pressing lines.
Pressing Lines
XL-Line (5400 ton)
For pressing of larger parts
L-Line (2400 ton)
For pressing of small parts
Line-3 (5400 ton)
For pressing of larger parts
22. Pressing and piercing Line
Cont.
Each line have 4 presses.
PB: By this press shape is given to steel plate by using specific die
according to drawing.
PC: By this press side or extra material is removed.
PD: By this press Piercing is done.
PE: By this press specific holes is made.
L-LINE
XL LINE AND LINE-3
PB
2400 ton
1200 ton
PB
PC
PD
1000 ton
1000 ton
1000 ton
400 ton
PC
400 ton
PD
400 ton
PE
PE
23. Stamping Shop
In stamping shop body parts of car are manufactured using steel
plate.
1. Blanking
2. Pressing and Piercing
3. Quality checking
After the pressing quality inspection is manually done. If there is no fault then
part is transferred to body shop.
24. Body Shop
Stamped parts are transferred using fork lifter from stamping shop to body shop. Here various stamped
parts are welded to make various components of main body like doors, engine compartments and
mounting points, chassis, hood, front cabin, rare cabin etc.
• Spot welding and MAG welding is done for making the components.
• Manually some parts are welded and by robot some other parts are welded.
• Almost all the doors are made by robots like ABB, FANUC using various
mechanical operations (bending, compression) at the edges of parts.
• There are two main lines and six sub lines (three each). Both are same lines. At
present time at Line -1 Sunny and Duster are being manufactured and at Line-2
Micra is being manufactured. Production rate of the body shop is 40JPH (jobs per
hour).
27. Cont.
• In the first sub line the engine compartment, the front cabin and the rear cabin are
assembled using spot welding manually.
• In the second sub line nearby parts of engine, doors, hoods are assembled using
welding and nuts.
• In main assembly line side doors, back doors, hood is assembled using automatic
nut runner machine. Finally quality checking is done of car body.
• Each car is given with the serial number which corresponds to the paint colour.
• The car body is sent to the metal line, where bumps or the dent or spots are
inspected. If any defect is found the body is sent to the sideways where it is tested
for the faults and solutions.
• Finally car body is transferred to paint shop.
28. Paint shop
• In paint shop there are two lines i.e. Line: 1 and Line: 2. both lines are
same.
• Car body comes here from body shop.
• At Line: 1 bodies of sunny and duster are painted and at line: 2 Micra
body is painted.
In paint shop car body passes through following lines:
1. Pre-treatment line (PT-line)
2. Electro Deposit Line (ED-Line)
3. ED-Oven
4. Sealer Zone
5. ED sanding zone
6. Body arranging zone
7. Dust off zone
8. TOPCOAT zone
From the paint shop car body is transferred to Trim & Chassis shop.
29. Pre-Treatment Line.
Cont.
It has 8 stages.
1. Pre-Degreaser-Washing using chemicals and safely removal of oils, greases, fats and carbon deposited on the
car body.
2. Degreaser-2 (D/P).- Final washing with chemicals of car’s body.
3. Pre-Raw water Rinse. -Here, car body is washed using raw water of specific ph.
4. Raw water Rinse (D/P).- Again washed with raw water of specific ph. (final raw water washing).
5. Conditioner- It is used to make the car body surface rough. Because at rough surfaces coating more adheres.
6. Phosphate treatment zone- car body is coated with phosphate for providing metal cleanliness and corrosion
protection to the surface of the car body.
7. Pre-DI (Deionized) water Rinse zone- DI water bath is given to car body. For DI Water rinse Fresh deionized water is used that is cleaner than drinking water. If any contamination remains on the surface before
the ED coating, it will cause the application issue and raise the potential for product failure.
8. DI water Rinse (D/P). -Final DI water bath is given to car body.
Here Pre-Treatment line ends.
30. Electro Deposit Line (ED-Line)
Cont.
It has 3 stages.
1. ED-Bath-At this stage car body is covered with ED Paint. ED (Electro-deposition)
paint (cationic) is used as a primer for car bodies. It imparts rust resistance and
chipping resistance to the car body.
2. UF-(Ultra Filtrate)-1-The paint bath can be contaminated with pre-treatment
chemicals like e.g. phosphates, chlorides, and chromates. So, a part of ultra-filtrate
has to be leaded out to avoid contamination of the paint bath with these chemicals.
3. Fresh water and Tilting stage-After UF stage car body is washed with fresh water.
After washing the car body is tilted to remove all the water and waste paint from the
car body. Then car is tilted back to its initial position.
Here ED Line ends.
31. ED-OVEN
Cont.
Car body passes through the ED Oven for drying the ED paint. First, air is
heated and passed through oven chamber then car body passes through the
chamber. Thus ED paint is dried by hot air.
Sealer-Zone
Sealant is applied at every exterior edge of the car. Sealant is used to resist
the leakage through the car body. Then car body passes through the Sealer
Oven for drying the sealant.
ED sanding zone
Then car body passes through the ED Sanding Zone. Here, extra paint is removed to make
ED paint layer uniform. This process is completely manual. First workers check the ED
paint layer and then remove extra paint using Sanding paper.
32. Body arranging zone
Cont.
•
•
•
It has 3 lines.
Side line
Main Line
Repair Line
When car body enters at storage are then barcode of car body is scanned and data sent to the CCR
(central control room) panel. Bodies of the same color are arranged in the main line. In main line
bodies are arranged on the basis of color such that same color bodies are together. If any car body
of different color comes in that line then it will be shifted to side line till it groups with another
bodies of same color. It is fully automated process according to the color car bodies are arranged
automatically in their respective line.
If after the ED Sanding stage body paint is not uniform or if some other faults are found in ED
paint then car body is transferred to repair line. From here body is sent to repair zone for repairing.
33. Dust Off zone
Dust from the body is removed before painting. So that dust doesn’t
contaminate the paint. Feathers of Emu bird are used as dust remover
Cont.
TOPCOAT Zone
In this zone car is painted through following zone.
•
•
•
•
•
•
•
ACC (Anti corrosion Coating)
Primer coat (Sprayed by robots)
Primer Paint (Manually for more accuracy)
Primer flash off zone (Drying of primer paint)
Base Zone (For main paint, first sprayed by robots ,then manually)
Base flash off zone (Drying of base paint)
Clear Zone (For clearing car surface for shining, First by robots then manually for
more shining purpose.)
Car body is transferred to Trim & Chassis shop
34. Plastic Shop
• In this shop bumpers are manufactured by Injection Molding Process.
• Small pieces of Poly Propylene are used as raw material.
• Two Mechanical Injection Molding machine (MIMM) and one Electrical Injection Molding machine
(EIMM) are here.
• Mechanical Injection Molding Machine is controlled by hydraulic cylinders and Electrical Injection
Molding machine is controlled by Servo motors.
• Electrical molding machine is preferable because it requires less maintenance and works with good
accuracy. In both types of machines hydraulic forces are applied.
• For changing the mold for different units QMC (Quick Mold Change) System is used. It is completely
automated.
• QMC system is controlled by PLC. For changing a one mold it takes 8.2 minutes.
• PLC has all the specification about all the molds. For each mold a number is given. So for changing a
mold, corresponding number is given to PLC.
• Then according to the size and shape of mold, QMC automatically adjusts its process for change the die
• Die also has heater for maintaining the die temperature. It takes 45 minutes for heating the die. So die is
pre heated before the installation for saving the time.
• For both mechanical molding machines there is common QMC unit and electrical molding machine has its
own QMC unit
• Weight of a die is about 28-30 ton. From here bumpers are forward to bumper paint shop for painting and
piercing
35. Bumper Paint Shop
In this process Rare and Front bumpers, and finishers are painted. Finishing process of bumpers
and finishers is also done in this shop. Here, punching and drilling operation are done for
generating holes in bumpers
In this zone bumper is painted through following zone.
• Heating Zone (Low speed conveyor) (bumper is heated. For heating fire is applied by the two
robots. Fire flame length is 250 mm)
• Dust off zone (air is applied to bumper surface for clean the dust.)
• Primer coat (Sprayed by robots)
• Primer Paint (Manually for more accuracy)
• Primer flash off zone (Drying of primer paint)
• Base Zone (For main paint, first sprayed by robots ,then manually)
• Base flash off zone (Drying of base paint)
• Clear Zone (For clearing car surface for shining, First by robots then manually for more
shining purpose.)
• Backing Zone 1 & 2- (High Speed Conveyor) Both backing zones are maintained at 120
degree Celsius temperature. By passing hot air in banking chamber paint is dried. Then bumper
is shifted from high speed conveyor to low speed conveyor
36. Bumper Paint Shop
Cont.
• Quality checking-Here, quality inspection is done. If any fault found in
bumper then it is sent for repair. If no fault is found then bumper is
unloaded from low speed conveyor and sent to vehicle chain.
For finisher painting same process is followed but at dust off zone there is no
need of finisher heating.
After final painting process piercing robot is used to generate holes in
bumper
Robots generate small holes in bumper by drilling operation. Holes are used for placing small sensors in
bumper.
Rare punching machine: It is used to generate big holes in bumper. These holes are used for placing little
big sensors, lights and other components.
Front punching machine: It is used for generate big holes in rare bumper and Front punching machine is
used for generate big holes in front bumper
37. Trim and Chassis shop
• Here all the components of car are assembled
• There are two main lines Line-1 and Line-2. Both lines
are same
• At each line total 31 stations are there.
• At each station 3-4 parts are assembled in car body.
• There are six sub lines in each main line:
Primary line
Trim Line
Chassis Trim line
Engine assembly
Pre final
Tester Line
38. Cont.
Primary line- Car body comes from paint shop. Doors are separated.
Trim Line- Interior components are assembled manually. Ex. Seat belt, floor cover ,Front and
rear glass ,CMM (Speedometer, Tachometer etc.). CCR controls the assembly.
Chassis and Engine Assembly line – Exterior parts are assembled. Ex. engine, suspension
system, exhaust system, fuel tank, exhaust heat observer, brake system
Chassis and Trim line- All assembled components are checked. front and rear wheels.
Pre-final line- pre final line brake oil, fuel and coolant are filled using combo filling machine.
Final Line- Doors are assembled.
Tester Line- wheel alignment, Speed, braking system, Leakage are tested.
Test Drive and Sale
44. Power Train Line
Three Lines are here
• JXX gear box assembly line
• Engine Line:1
• Engine Line:2
45. Gear box assembly Line Process
Cont.
1.
2.
3.
4.
5.
6.
7.
8.
Gear box Scanning
Assembly of gears.
Gear shifter (for 1st and 2nd gear) attached to secondary shaft
Primary shaft, secondary shaft with gear shifter and differential are
assembled in clutch housing
Gear shifters for 3rd, 4th and reverse gear are assembled with both
shafts.
Differential housing is assembled with clutch housing
By using mechanical housing tire side of the gear box is closed
In gear box a magnet is placed
46. Gear box assembly Line Process
Cont.
9. Primary shaft thickness measurement
10. Sealant Deposition
11. Then mechanical and clutch gear boxes are fixed and closed using
nut
12. Gear Box leakage testing by pressurized air.
13. Final Testing of gear box by assemble it with engine.
14. First gear box is scanned.
15. All tests are control by a PC.
16. maximum speed at different gears, Noise level (Manually) Speed at
different torques, power required at different slops at different
speed are tested. It is a one time process.
17. unloaded at gearbox area.
18. Testing of machine by blue and red gear box.
19. All blocks for gear box are imported from Renault France
47. Engine Shop Line
Cont.
• At line-1 K9K (Diesel) engine is manufactured.
• At line-2 XH (petrol) engine is manufactured Gear
Box leakage testing by pressurized air.
48. Process
Cont.
1. Cylinder block scanning.
2. Oil jet is fixed in cylinder by Oil jet press (2 Hydraulic and 4
Pneumatic)
3. Marking of engine code on cylinder block.
4. Oil level indicator assembly.
5. metal pieces are assembled in cylinder block support the crank
shaft. These metal pieces work as a bearing.
6. Then D dimension machine measure the height between bottom
dead center and top dead center for selecting the proper piston.
7. then crankshaft, piston, connecting rod are assembled in cylinder
block
8. oil filter, oil pump and oil pan is fixed
9. In H dimension machine piston is inspected that the piston is
perfect or not for the corresponding bore.
49. Process
Cont.
10.
11.
12.
13.
cylinder head is fixed on the cylinder block using nut bolt.
Then Cam shaft is fixed. Then fuel injector and high pressure fuel pump is fixed.
Timing Pulley and Timing belt is fixed.
Timing belt and gear transfer the power or motion from crank shaft to other engine accessories like cam
shaft, high pressure fuel pump. Fuel pump, cam shaft and other accessories are synchronized with crank
shaft.
14. Flywheel, vacuum pump ,Fuel pipe line, EGI harness cable, Intake manifold, exhaust manifold , Then
EGR (exhaust gas recycle) unit stabilizer, exhaust air intake ,exhaust air filter, Clutch kit (clutch plate
and disk), friction plate are assembled.
15. Engine Testing
16. Then quality of engine is checked and visual inspection of engine is done. If any fault is found then
engine is sent for repair. Then finally engine is sent to the SCM (supply chain management).
50. Casting Shop
In casting shop cylinder head and cylinder blocks are manufactured by casting
process.
In this shop two casting machines are here.
1 HPDC (High Pressure Die casting): Cylinder blocks are
manufactured by High Pressure Die Casting because they are heavy in
weight.
2 LPDC (Low Pressure Die Casting): Cylinder heads are
manufactured by Low Pressure Die Casting Process.
HDPC process is same as LDPC. Only difference is that pressure and die
moving velocity is higher in HDPC i.e. 60-70 Mpa and 308 m/s.
51. LPDC (Low Pressure Die Casting)
Cont.
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Total 16 machines (3 LPDC) are here.
Raw material (ACD 12 Al alloy Rectangular rods)is poured into Melting Furnace where it melts.
Then molten material is transferred to holding zone to maintain the molten material temperature.
Temperature of Holding Zone is maintained at 700 degree Celsius.
Melting rate is 1.5 ton/hr.
LPG (fuel for combustion) furnace is used for melting where burner melt the raw material.
LPG is supplied at 1bar and air is supplied by blower.
Melting and Holding zone individual air blower is used.
At degreasing zone unwanted trapped gasses are removed from the molten material.
Then molten material is poured into LPDC machine
Using LPG die is pre heated before install in LPDC machine
Then casting is done in LPDC.
The temperature of molten material is maintained by electrical heaters in LPDC machine.
Removing the sand from casting surface.
Finishing operation of casting.
Hardening of casting.
Quality checking for cracks.
Visual inspection.
Air leakage checking
52. Conclusion
On the whole, this internship was a very useful experience. I have gained new knowledge, skills
and met many new people. I achieved several of my learning goals, however for some the
conditions did not permit. I got insight into professional practice. I learned the different facets of
working. I experienced that work management, is an important factor for the progress of projects.
Related to my study I learned more about the casting, stamping, machining, and welding. The
safety arrangements are very effective. I really very impressed with safety arrangements. I have
seen that all the employees are very aware of safety.
It is a very important aspect of the conservation of energy. Energy saving arrangements is also
very effective. The internship was also good to find out what my strengths and weaknesses are.
This helped me to define what skills and knowledge I have to improve in the coming time. At last
this internship has given me new insights and motivation to pursue a career in automotive field.