The summer training project report on the material feeding system at Tata Motors' Pantnagar plant documents the industrial training experience of Puneet Kakkar, a mechanical engineering student. It provides insights into Tata Motors' history, operations, and the plant's role in manufacturing vehicles, including its advanced material management systems. The report emphasizes the importance of effective inventory management and workflow processes in ensuring timely production and delivery of vehicles.

1. Summer Training Project
Report on
Material Feeding System
Tata Motors Limited
[Pantnagar Plant]
(1st
June – 30th
June, 2018)
Project Guide- Mr. Uday Pratap Yadav
Manager, TCF-1C (SCM)
CVBU, Tata Motors, Pantnagar
Submitted by- Puneet Kakkar
Mechanical Engineering (3rd
year)
College of Technology, Pantnagar

2. Bonafide Certificate
This is to certify that the project titled “Material Feeding System in Assembly
Shop-1C” is a record of the bonafide work done by Mr. Puneet Kakkar submitted
in partial fulfillment of the requirement for the degree of B. Tech (ME) during
academic year 2018-2019. During the industrial training done at TATA
MOTORS Ltd., Pantnagar, this is the original work carried out by the student
under my supervision and this work is found satisfactory.
SIGNATURE SIGNATURE
UDAY PRATAP YADAV BRIJLAL ARORA
(MANAGER), TCF-1C (HR)
TATA MOTORS LIMITED TATA MOTORS LIMITED
PANTNAGAR PANTNAGAR

3. Acknowledgement
Every project big or small is successful largely due to the effort of a number of
wonderful people who have always given their valuable advice or lent a helping
hand. I sincerely appreciate the inspiration, support and guidance of all those
people who have been instrumental in making this project a success.
I, Puneet Kakkar, student of College of Technology, GBPUAT, Pantnagar
(Mechanical Engineering), am extremely grateful to “Tata Motors Limited,
Pantnagar” for the confidence bestowed in me and entrusting my project.
At this juncture I feel deeply honoured in expressing my sincere thanks to
Mr.Uday Pratap Rana, Manager and Mr. Sanjeev Chauhan, Supervisor,
TCF-1C (Commercial Vehicle Business Unit) for making the resources
available at the right time and providing valuable insights leading to the
successful completion of my project.
I express my gratitude to the entire Material Handling team, for patiently
teaching me the office procedures and guided me through the entire project.
I am very grateful to the HR Department, especially Mr. Brijlal Arora for
providing me this opportunity to work in this prestigious organization.
Last but not the least, I place a deep sense of gratitude to my fellow trainees
who gave me insights into the working of all the departments in the plant and
therefore helped me better understand the ways of the company.

4. Contents
 Bonafide Certificate
 Acknowledgement
 About the Company
 History
 Pantnagar Plant
 Assembly Shop (TCF-1C)
 Department Profile
 Inventory Management
 Project on Material Feeding System
 Conclusion

5. About the Company
Tata Group
Tata Group is an Indian multinational conglomerate holding
company headquartered in Mumbai, Maharashtra, India. Founded in 1868
by Jamshedji Tata, the company gained international recognition after
purchasing several global companies, beginning with Tetley in 2000, recorded
as "the biggest acquisition in Indian corporate history. One of India's largest
conglomerates, Tata Group is owned by Tata Sons, a registered charity.
Each Tata company operates independently under the guidance and supervision
of its own board of directors and shareholders. There are 29 publicly listed Tata
enterprises with a combined market capitalisation of about $151.62 billion as of
March 1, 2018. Significant Tata companies and subsidiaries include Tata
Steel, Tata Motors including Jaguar Land Rover, Tata Consultancy Services, Tata
Power, Tata Chemicals, Tata Global Beverages, Tata Coffee, Tata Swach, Tata
Teleservices, Titan, Tata Communications, and The Indian Hotels Company
Limited (Taj Hotels)
Tata Motors Limited
Tata Motors Limited is a leading global automobile manufacturer of cars,
utility vehicles, buses, trucks and defence vehicles. As India’s largest
automobile company and part of the USD 100 billion Tata group, Tata Motors
has operations in the UK, South Korea, Thailand, South Africa, and Indonesia
through a strong global network of 76 subsidiary and associate companies,
including Jaguar Land Rover in the UK and Tata Daewoo in South Korea. In
India, Tata Motors is a market leader in commercial vehicles and among the
top passenger vehicles manufacturers with 9 million vehicles on Indian roads.
The company’s manufacturing plants are situated at Jamshedpur (Jharkhand),
Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand),
Dharwad (Karnataka) and Sanand (Gujarat). Abroad, Tata cars, buses, and
trucks are being marketed in Europe, Africa, the Middle East, South Asia,
South East Asia, South America, Australia, CIS and Russia.

6. Product of Tata Motors:-

7. History
Tata Motors Ltd was incorporated in the year 1945 with the name Tata
Engineering and Locomotive Co Ltd for manufacturing locomotives and other
engineering products. Tata entered the commercial vehicle sector in 1954 after
forming a joint venture with Daimler-Benz of Germany.
After years of dominating the commercial vehicle market in India, Tata Motors
entered the passenger vehicle market in 1991 by launching the Tata Sierra, a
multi utility vehicle, becoming the first Indian manufacturer to achieve the
capability of developing a competitive indigenous automobile. In 1998, Tata
launched the first fully indigenous Indian passenger car, the Indica, and in 2008
launched the Tata Nano, the world's cheapest car. Tata Motors acquired the
South Korean truck manufacturer Daewoo Commercial Vehicles Company in
2004 and purchased Jaguar Land Rover from Ford in 2008.
Tata Motors is listed on the (BSE) Bombay Stock Exchange, where it is a
constituent of the BSE SENSEX index, the National Stock Exchange of India,
and the New York Stock Exchange. The company is ranked 226th on
the Fortune Global 500 list of the world's biggest corporations as of 2016.

8. Pantnagar Plant
The Tata Motors' plant at Pantnagar is the site where the best-selling Tata Ace -
the mini one-tonne truck, and its variants are manufactured. The plant is a
world-class project that is spread across 1,000 acres in Uttarakhand's State
Industrial Development Corporation.
The Pantnagar plant has been built with state-of-the-art facilities and is a key
enabler of Tata Motors' leadership in the mini-truck segment. It also produces a
few SUV models as well as medium and heavy vehicles.
The plant has been designed to enhance speed and efficiency in manufacturing.
It is the company's first plant with an integrated vendor park, which occupies
337 acres of the plant's total area. This helps keep inventory low and ensures
'just-in-time' (JIT) supplies. The 73 vendors based here account for nearly 75
percent of the items supplied to the plant.
The general office at Pantnagar is a gold-rated green building, a testament to the
unit's efforts to reduce energy consumption and boost energy efficiency. The
plant has an Integrated Management System (IMS) certification.

9. Fact File
 Fourth Tata Motors plant to come up, after Jamshedpur, Pune and
Lucknow
 Spread over 1,000 acres
 Began commercial production in 2007
 Facilities include weld shops, paint shops, engine and gear box shops,
and assembly lines
 Over 5,000 employees and 2,500+ contractual workforce (including
vendors and service providers)
 First plant of TML to house an integrated vendor park
 Production started in record time after acquisition of land (in just 11
months)
 Achieved the 1 million ACE milestone in FY12 and aims to achieve the 2
million milestone in FY19

10. Layout of Pantnagar Plant

11. Main Shops:
1. ASSEMBLY SHOP -Assembly shop is also known as TCF Shop (TRIM CHASSIS
FINAL). In this shop all the assembly works like the assembly of trims, seats, ccb,
window glass, doors engine, and Suspension, Tyres, Headlamps, Tail lamps, and
Dashboard etc. fittings is carried out. This shop can be thought of as the organ fitting
shop in to the skeleton body of the car. Car enters this shop as a skeleton chassis cab
and the final product of the shop is fully completed vehicle. There are presently 4
assembly shops – TCF 1A, TCF 1B, TCF 1C AND TCF 1D.
2. WELD SHOP –Weld shop is also known as BIW Shop (BODY IN WHITE).Here
different parts are welded together and the whole structure of the car is built including
the chassis frame. This shop plays critical role in maintaining the dimensional accuracy
which would otherwise lead to major assembly-line problems and major downtimes in
their correction. It is divided into 5 sections namely, BIW 1A, 1B, 1C, 1D, 1E.
3. PAINT SHOP – The TAIKISHA paint shop is the beauty parlors of the car plant.
This shop paints the car in various shades. This is the most sophisticated shop of the
plant. It uses world class technology for painting the vehicles. The most interesting
point of this shop is that all vehicles, no matter which type, are all painted under the
same shop together. Thus the paint shop has to work 4 times faster than the TCF, so
that body reaches each of the assembly shops. It takes 18 steps spread over less than 10
hours to accomplish the task. Tata Motors Pantnagar boasts to have the biggest
atomized Paint shop in whole of Asia.
4. POWER TRAIN SHOP – This shop is divided into Gear Train and Engine shop.
This shop takes care of the assembly of the engine and the assembly of the gear box.
The engine and the gear box are assembled separately but are coupled at the end of the
line. Various testing related to engine performance and qualities are checked here. The
final product of this shop is engine and transmission subassembly which is supplied to
the assembly shop.

12. Product introduced from Pantnagar Plant

13. TCF SHOP
(Trim Chassis Fitment)
It is the biggest of all the shops in TML, Pantnagar.
Here the painted chassis delivered from the Point shop is accessorized from
scratch to a finish car ready for dispatch and also tested.
The car delivered by the TCF shop is completely checked with reference to
product’s utility quality and manufacturing quality. After several inspections
made by line operators for operational conformance and ethical looks the Car is
permitted to be dispatch from TCF shop by the assurance of Line supervisors
and operators.
The cart dispatched from the TCF shop is delivered, through drive test to the
PDI (Pre-Delivery Inspection) shop where final touching to looks is given and
the conformance of working of all the accessories is done.

14. TCF -1C
Mechanical Line
Underbody Trim Line
(Simplified Layout of TCF-1C)
Dock-
5
Trolley
parts
Water
cooler
Trolley
parts
Dock
-4
Racks
Maintenance
office
Material
office
Kitting-3
Dock
-2
Dock
-3
Rejectionarea
Water
cooler
Trolley
parts
Mechanical
Point
Fuel Tank
Assembly
Trolley
parts
High
Racks
Kitting-2
Trim Sub
Assembly
War
Room
Steering
gearbox
assembly
Engine Receiving
area
Engine Sub
assembly area
Toilet
Water
cooler
LeafSpring
fitment
RearAxle
fitment
FrontAxleSub-
assembly
Silencer
Assembly
Tire
Fitment
Dock
-7
Kitting-4
Tests
FrontPanel
Sub-Assembly
BumperSub-
Assembly
LeafspringSub-
Assembly
Pre- Canopy Tire
Assembly
Area
Wheel
Alignment
Test
Roller &
Brake test
Smoke
Test
Racks
Racks
OfficeArea

15. Material Department
Materials Department deals with planning and building design for the
movement of materials, or with logistics that deal with the tangible
components of a supply chain. Specifically, this covers the acquisition of
spare parts and replacements, quality control of purchasing and ordering such
parts, and the standards involved in ordering, shipping, and warehousing the
said parts. Materials management is the function responsible for the
coordination of planning, sourcing, purchasing, moving, storing and
controlling materials in an optimum manner in order to provide a pre decided
service to the customer at a minimum cost.
Goals
 The goal of materials management is to provide an unbroken chain of
components for production to manufacture goods on time for the
customer base.
 The materials department is charged with releasing materials to a
supply base, ensuring that the materials are delivered on time to the
company using the correct carrier.
 Materials is generally measured by accomplishing on time delivery to
the customer, on time delivery from the supply base, attaining a
freight, budget, inventory shrink management, and inventory
accuracy.
 The materials department is also charged with the responsibility of
managing new launches.

16. Standards
 Tata motors limited use ERP systems such as SAP systems to manage
materials control.
 TML sees the importance level as managing at the plant level by
hiring an inventory manager or materials manager, and also employ
the concept that the supervisors in the plant are responsible
accompanied by a planners.
Functions of Material Management:
Material management covers all aspects of material costs, supply and
utilization. The functional areas involved in material management usually
include purchasing, production control, shipping, receiving and stores.
The following functions are assigned for material department:
1. Production and Material Control:
Production manager prepares schedules of production to be carried in future.
The requirements of parts and materials are determined as per production
schedules. Production schedules are prepared on the basis of orders received
or anticipated demand for goods. It is ensured that every type or part of
material is made available so that production is carried on smoothly.
2. Purchasing:
Purchasing department is authorized to make buying arrangements on the
basis of requisitions issued by other departments. This department keeps
contracts with suppliers and collects quotations etc. at regular intervals. The
effort by this department is to purchase proper quality goods at reasonable
prices. Purchasing is a managerial activity that goes beyond the simple act of
buying and includes the planning and policy activities covering a wide range
of related and complementary activities.

17. 3. Non-Production Stores:
Non-production materials like office supplies, perishable tools and
maintenance, repair and operating supplies are maintained as per the needs of
the business. These stores may not be required daily but their availability in
stores is essential. The non-availability of such stores may lead to stoppage
of work.
4. Transportation:
The transporting of materials from suppliers is an important function of
materials management. The traffic department is responsible for arranging
transportation service. The vehicles may be purchased for the business or
these may be chartered from outside. It all depends upon the quantity and
frequency of buying materials. The purpose is to arrange cheap and quick
transport facilities for incoming materials.
5. Materials Handling:
It is concerned with the movement of materials within a manufacturing
establishment and the cost of handling materials is kept under control. It is
also seen that there are no wastages or losses of materials during their
movement. Special equipment’s may be acquired for material handling.
6. Receiving:
The receiving department is responsible for the unloading of materials,
counting the units, determining their quality and sending them to stores etc.
The purchasing department is also informed about the receipt of various
materials.

18. Material Management Workflow
A workflow diagram (also known as a workflow) provides a graphic overview
of the business process. Using standardized symbols and shapes, the workflow
shows step by step how your work is completed from start to finish. It also
shows who is responsible for work at what point in the process. Designing a
workflow involves first conducting a thorough workflow analysis, which can
expose potential weaknesses. A workflow analysis can help you define,
standardize and identify critical areas of your process.
Workflows are also useful to help employees understand their roles and the
order in which work is completed, and to create more unity within different
departments. Originating from the manufacturing industry, workflows are now
used by a variety of industries—from government to finance to commerce—and
are easier than ever to create.

19. SAP Based Supply Chain Management
1. Material Stock list- This is basically a list of parts required for production of
a vehicle. It includes opening stock of each day, stock available, minimum
stock, maximum stock etc. This list is then sent to the Pre-delivery Inspection
(PDI) Department where they analyse the list and place orders to the vendor.
2. Goods receipt (GR) Tag- This is issued by Central Receiving and
Documentation Office (CRDO) to the driver of the goods loaded truck, after
checking the invoice provided by the vendor and counting the challan quantity
of goods. A LECI code (Register Means of Transport/Visitor) is also provided,
which is a unique code for a transport vehicle.

21. Inventory Management
Inventory management is the function of understanding the stock mix of a
company and the different demands on that stock. The demands are
influenced by both external and internal factors and are balanced by the
creation of purchase order requests to keep supplies at a reasonable or
prescribed level. Inventory management is important for every other business
enterprise.
Retail supply chain
Inventory management in the retail supply chain follows the following
sequence:
1. Request for new stock from stores to head office
2. Head office issues purchase orders to the vendor
3. Vendor ships the goods
4. Warehouse receives the goods
5. Warehouse stores and distributes to the stores
6. Shops and/or consumers (e.g. wholesale shops) receive the goods
7. Goods are sold to customers at the shops.
The management of the inventory in the supply chain involves managing the
physical quantities as well as the costing of the goods as it flows through the
supply chain.
In managing the cost prices of the goods throughout the supply chain, several
costing methods are employed:
1. Retail method
2. Weighted Average Price method
3. FIFO (First In First Out) method
4. LIFO (Last In First Out) method
5. LPP (Last Purchase Price) method
6. BNM (Bottle neck method)
Note: Tata motors, Pantnagar employs FIFO method of Inventory
accounting

22. FIFO Method
The first in, first out (FIFO) method of inventory valuation is a cost flow
assumption that the first goods purchased are also the first goods sold. The
FIFO flow concept is a logical one for a business to follow, since selling off
the oldest goods first reduces the risk of obsolescence.
Under the FIFO method, the earliest goods purchased are the first ones
removed from the inventory account. This results in the remaining items in
inventory being accounted for at the most recently incurred costs, so that the
inventory asset recorded on the balance sheet contains costs quite close to
the most recent costs that could be obtained in the marketplace. Conversely,
this method also results in older historical costs being matched against
current revenues and recorded in the cost of goods sold; this means that
the gross margin does not necessarily reflect a proper matching of revenues
and costs.

23. FIFO at Tata motors, Pantnagar

24. Material Feeding System
Materials feeding mainly concern what principle to use for feeding the materials
to a workstation or an assembly line. Johansson (1991) describe and analyses
three different principles of feeding materials to an assembly station, namely
continuously, Sequential Supply, and kitting.
Applications:
 Forecasting
 Resource allocation
 Production planning
 Flow and process management
 Inventory management and control
 Customer delivery
 After-sales support and service
Aims:
 Improve customer service
 Reduce inventory
 Shorten delivery time
 Lower overall handling costs in manufacturing, distribution and
transportation.
Main Components of MFS at TML
Kitting System Continuous
Supply by two
bin system
Sequential Supply
In-house
Sequencing
Supplier
Sequencing

25. Kitting System
Kitting is the gathering of components and parts needed for the manufacture of
a particular assembly or product. Individual components are gathered together,
as a kit, and issued to the point of use.
The practice of feeding components and subassemblies to the assembly line in
predetermined quantities that are placed together in specific containers is known
as kitting in the industry.
Steps Involved:
 The production team, often in conjunction with the manufacturing leads,
define the kit of parts. These are often runner repeater parts that would
currently take up substantial processing time.
 Stock will be reviewed and where shortages exist purchase orders
raised.
 A method for the issuing of the kit is defined.
 In line with the requirement generated by ERP the stores team will pick
parts and load a trolley with the kit of parts and issue for use.
Advantages of Kitting:
 Saves manufacturing or assembly space. 
 Reduces assembly operators walking and searching times.
 Kitting can reduce or make better control over WIP at the workstations
by storing primary components and subassemblies at a central storage
area. 
 Since the majority of components and subassemblies are not staged at
the workstations, it increases the flexibility of the workstation or
assembly line; product changeover is accomplished with relative ease. 
 Reduces or facilitates material delivery to workstations by eliminating
the need to supply individual component containers. 
 Offers potential in increasing product quality, due to the possibility to
have quality checks earlier in the value chain and the possibility of
reducing the frequency of wrong parts in the end product or missing
parts in the end product. 


26. Limitations:
 Making the kits (i.e. Kit assembly) consumes time and effort with little or
no direct value added to the product.
 Is likely to increase storage (not line side) space requirements especially
when kits are being prepared in advances.
 Temporary shortage of parts may force the user to kit short; doing so will
reduce the overall efficiency of the operation.
 Defective parts that are inadvertently used in certain kits will lead to parts
shortages at the workstations.
Types of Kitting
Kitting Locations
Stationary Travelling
Centralised
Picking store
Decentralised
Picking store

27. KITTING PROCESS FLOW CHART
OKNOT
OK
Start
Pick empty trolley
from trolley parking
area.
Read VC
description, model
VC and ASN on
display.
Go to respective
locations model
wise to pick parts.
Pick parts from the
storage bin.
Pick correct quantity
as per validity
mentioned.
Pick floor parts at
last
Check trolley and
bin cleanliness
Grab ASN sticker &
scan with scanner
and extra ASN put
in kitting trolley.
Ensure correct route
has been followed
while picking.
Check parts visually
for damage.
Park completed
trolley in parking
area.
Supervisor
inspection
Deliver Trolley on
the line
Correct error and
deliver to line side
End

28. IT enabled Kitting (Pick to Light)
Display Screen in the kitting area with
Information about model number, model
name and ASN of the vehicle
Scan-enabled ASN sticker printed
from kitting machine
ASN sticker being scanned
LED display and light starts to blink, indicating the part
to be picked with its quantity.
Kits are being prepared with ASN sticker
Kits delivered at assembly station

29. Proposed Improvement in Kitting
(Automated Kitting)
Manual kitting can often be a space-hogging operation. A Kitting process using
low-density static shelving waste an excessive amount of floor space and
require operators to travel among multiple storage aisles seeking specific items
or kits – working against the time savings you are trying to achieve in the first
place.
Utilizing an Automated Kitting System that incorporates an automated storage
and retrieval machine — such as vertical carousels, horizontal
carousels, vertical lift modules (VLMs) or vertical buffer modules (VBM) — to
store individual parts and completed kits creates a high-density, space-saving
kitting operation.
How an Automated Kitting System Works:
 Individual items are organized and stored individually in totes, bins or sub-
divided trays and stored within an automated storage and retrieval system.
For maximum picking efficiency, the system’s internal Power Pick Global
inventory management software automatically stores items for the same kit
close together.
 When it is time to assemble the items into specific kits, the operator uses the
automated storage and retrieval system as an order picking system, batch
picking multiple kits into totes located on a conveyor or batch station.
 After the operator assembles the kits from the selected parts, the completed
kits can be re-stored in the same storage device using a unique part number
or transferred to another zone.
 When kits are needed, an operator accesses the storage location and
retrieves the kit(s) and routes them to the next destination (assembly line,
order consolidation, packing, etc.) quickly and easily using AGVs.

30. Benefits to Expect by Automating your Kitting Process:
 Fast and efficient system for storage and picking of parts and kits
 Eliminates operator travel time
 Limited access ensures security of contents
 Uses 1/3 the energy of mini-loads and multi-shuttle systems
 Kits are delivered in sequence to the assembly area to support just-in-time
manufacturing
Employment of Automated
guided Vehicle (AGV) to
deliver Kit

31. Two- Bin System
Two-bin inventory control is an inventory control system used to determine
when items or materials used in production should be replenished. The two-bin
inventory control method is mainly used for small or low-value items. For
example, when items in the first bin (working stock) have been depleted, an
order is placed to refill or replace these items. The second bin is supposed to
have enough items to last until the placed order arrives. The first bin has a
minimum of working stock and the second bin keeps reserve stock or remaining
material. Bin cards and store ledger cards are used to record the inventory.
The two-bin inventory control system is used for quantity control of material to
help minimize costs on the production floor. Small or low-value items are
mainly part of a two-bin inventory control system, as opposed to higher value
items subject to the perpetual inventory system. Depending on historical
patterns of variance in the depletion rate of the working stock (bin no. 1), the
amount ordered for the reserve stock (bin no. 2) can be adjusted. The two-bin
inventory control system is broadly employed across different industries
with manufacturing operations. The system is also effective for hospital
inventory control.
This method is also sometimes referred to as kanban, which is strongly
associated with the just-in-time (JIT) method of a manufacturing process.

32. A simple representation of Kanban 2-Bin system
Proposed Improvements:
1. Colour Coding - Use different coloured bins for different areas of your site.
For example, if there are 5 screws that look the same but are very different, put
each type in a different coloured bin for easy identification. Colour code critical
or fast moving parts, yellow for slower and green for slowest.
2. Installing Stock Indicators - They work by have two or sometimes three
settings, in stock, out of stock and pending refill. These means the stock
controller can easily see what products need refilling and what is already down
for re stocking.

33. Sequential Supply
Sequential supply is a supply method that part number needed for a specific
number of assembly objects are displayed at the assembly stations, sorted by
object.
The main motivation for sequential supply is the fact that if the product is
assembled on a serial line where only a few components are assembled at each
station, kitting is less advantageous since it will require a lot of extra materials
handling to prepare different kits for each station. The sequencing process can
be located within or outside the assembly plant which means that the
materials feeding principle can differ between the assembly station and the
supply chain.
Advantage of Sequential Supply-
1. The sequencing reduces the inventory levels since only selected articles
sorted by assembly object is displayed hence increasing the control and limiting
the articles exposed to theft, damage etc.
2. Increased quality in assembly work is facilitated by sequencing compared to
continuous supply since the choice of which article to pick has been removed
from the assembler and hence letting the assembler focus on his/her core
activity, namely to assemble.

34. 3. Increased control over the material flow is achieved sequencing. Since,
continuous supply displays all of the part numbers sorted by part number at the
assembly station a huge inventory is created.
4. If materials are fed traditionally with continuous supply to the assembly
station, many packages have to be displayed at the station. But if sequencing is
used instead, only one package containing different specific part numbers
belonging to the same component group has to be displayed at the assembly
station. The packages which part numbers are transported in are often specially
designed for the specific component groups. Sequencing has thus made it
possible to produce customized cars with variety of parts such as seats, wheels,
mirrors, safety equipment and electronic devices etc. while still maintaining
economy of scale.
Steps Involved:
Bar Code Scan for BIW
number and colour
Generation of
Assembly Sequence
number (ASN)
Communication of
generated ASN to
kitting area and
Supplier
Vehicle dropping and
Integration with kitting
trolley and Supplier
parts sequencing.

35. 1.
2.
3.
4.

36. Sequential Supply
A simple representation of In-house sequencing and
supplier sequencing
In-house Sequencing
In such type of sequencing,
bulky parts which require sub-
assembly are sequenced inside
the shop floor by sticking
ASN sticker.
Examples- Fuel tank,
Radiator, Dashboard, FCM,
Booster, Head liner etc.
Supplier Sequencing
In this type of sequencing, the
supplier supply the bulky part
just in sequence according to
the BIW ASN information
conveyed to them.
Examples- Bumper, Seat,
Steering, Front panel,
silencer, Rear axle etc.
In house sequencing
Supplier sequencing
Kitting and direct
line feeding

37. Sequential Supply Parts
A. In-house Sequential supply Parts
1. Heating, ventilation and air
conditioning (HVAC)
system
2. Fuel Tank
3. Brake Booster

38. B. Supplier Sequential Supply Parts
4. Radiator
Note: Other in-house sequenced parts include- FCM, Door Trim, Head
liner, ORVM, Cross-member
1. Silencer
5. Dashboard
2. Rear Axle

39. [Grab your reader’s attention with a
great quote from the document or
use this space to emphasize a key
point. To place this text box
anywhere on the page, just drag it.]
3. Seat
4. Front Panel
Seat
5. Bumper
Seat
Supplier sequence sticker

40. Conclusion
In a big organization such as Tata Motor Limited there was lot to learn in the
span of 1 month. I sincerely feel privileged to be part of such a big mechanical
firm. I had the opportunity to learn and understand the process of Material
handling and feeding and also how work is organised in such field. Being a
mechanical engineer I had opportunity to learn about the whole manufacturing
process of the LCV how all the parts assembled and I have also learned that
how the assembly of the engine is done.
It has helped me to remove the gap between the theoretical and practical
knowledge, and to have a better understanding of the stages involved in
assembling processes of an automobile.
Fortunately I was given Basic problem solving project associated with Material
feeding system to assembly along with sequential supply in the vehicle. I’ve
tried my level best to successfully apply my engineering knowledge to suggest
some improvement in this project.
Overall this internship in the Tata Motor has been the most interesting
experience of my life so far.
.