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PROJECT REPORT

ON

REDUCTION OF HUB PLAY COMPLAIN IN


ASSEMBLY LINE
OF
HVAL, TATA MOTORS (JAMSHEDPUR)

SUBMITED BY:-

SANTPRASAD TYAGI
DIPLOMA IN ENGINEERING (Mechanical)
2
ND
YEAR, DAYALBAGH EDUCATIONAL INSTITUTE,
DEEMED UNIVERSITY
AGRA (U.P.)
HV AX LES LIM ITED
C/ O TATA MO TORS LIM ITED
Telco Campus, Jamshedpur 831 010

CERTIFICATE

This is to certify that the project report entitled REDUCTION OF


HUB PLAY IN REAR AXLE ASSEMBLY LINE is done by Mr.
SANTPRASAD TYAGI, second year student of DAYALBAGH
EDUCATIONAL INSTITUTE, AGRA (U.P.) pursuing Diploma in
Mechanical Engineering during the summer of 2009 for the partial
fulfillment of the project as a Vocational Trainee at HV AL,
TATA MOTORS , Jams he dp ur.

Mr. SURANJAN CHATTERGEE


( Asst. General Manager)
H.V. AXLE Ltd.
TATA MOTORS
JAMSHEDPUR (JHK.)
ACKNOWLDGEMENT

Whenever I start a new work from the grass root level,to make that work a
huge success there is involvement of many other people whose
encouragement works as strength to complete the new work.
Similarly I have started my project and many people played a vital
role in its fulfillment. So I would like to acknowledgment my sincere
thanks to all the people whose support made my project a success.
First of all I would like to thanks Mr. SURANJAN CHATTERGEE
(AGM) who gave us this opportunity to carry out this project and had been
a constant source of inspiration. Without his support this project would
have been an impossible task.
I also extend my gratitude and thanks to Mr.SAGAR MAHAJAN
(Manager in SQA Dept.) & Mr. Satish Gupta (Technical officer) for there
constant support and guidance throughout the tenure of this project.
I would also like to pay the words of thanks to the all line managers
who took out time from their hectic schedule to give the skill matrix & for
their suggestions, which enable me to come out with a conclusion.
I would like to thanks all the people of H.V.A.L. who helped me
directly or indirectly in completion of my project.

THANKING YOU:

SANTPRASAD TYAGI
Contents

 Acknowledgement

 TATA Motors

 Heavy Vehicle Axles Ltd.

 Supplier Quality Assurance

 Hub Play

 Reduction of Hub Play

 Conclusion

 Photo Gallery
SALIENT STATISTICS

TATA MOTORS, JAMSHEDPUR


 TOTAL AREA OF JAMSHEDPUR: 1780 ACRES

 TOTAL AREA OF WORKS: 580 ACRES

 COVERED AREA OF WORKS: 217 ACRES

 LENGTH OF ROADS INSIDE WORKS: 30 MILES

 AREA OF COLONEY: 1200 ACRES

 POPULATION OF COLONEY: 35000(APPROX.)

 TEMPERATURE: 45.5-DEGREE CEL. (MAX)


6.7-DEGREE CEL. (MIN)
 AVERAGE RAINFALL: 99 CM

 LONGITUDE: 86.12-DEGREE EAST

 LATITUDE: 22.47-DEGREE NORTH

 ALTITUDE: 159m.ABOVE SEA LEVEL


(TATANAGAR)

 GEOGRAPHICAL LOCATION: JHARKHAND


(EAST SINGHBHUM)
ORGANISATIONAL STRUCTURE OF TATA MOTORS LIMITED
(JSR)

TATA MOTORS LIMITED

CVBU PCBU

PUNE JSR LKU PUNE

HVAL TML HVTL TTL TCL

HRD ERC APPC PL-I PL-II PL-III VD AM

 CVBU : Commercial Vehicle Business Unit


 PCBU : Public Carrier Business Unit
 TML : Tata Motors Limited
 HVAL : Heavy Vehicle Axle Limited
 HVTL : Heavy Vehicle Transmission Limited
 TTL : Tata Technologies Limited
 TELCON : Tata Constructions
 HRD : Human Resource Department
 ERC : Engineering and Research Center
 APPC : Auto Production Planning and Control
 PL-I : Plant-1(Vehicle assembly line)
 PL-II : Plant-2(Engine division)
 PL-III : Plant-3(Cab/Cowl manufacturing unit)
 VD : Vehicle Dispatch
 AM : Auto Manufacturing
Tata Motors Limited

Tata Motors Limited is India's largest automobile company, with standalone revenues
of Rs. 25,660.79 crores (USD 5.5 billion) in 2008-09. It is the leader in commercial
vehicles in each segment, and among the top three in passenger vehicles with
winning products in the compact, midsize car and utility vehicle segments. The
company is the world's fourth largest truck manufacturer, and the world's second
largest bus manufacturer.

The company's 23,000 employees are guided by the vision to be "best in the manner
in which we operate, best in the products we deliver, and best in our value system
and ethics."

Established in 1945, Tata Motors' presence indeed cuts across the length and breadth
of India. Over 4 million Tata vehicles ply on Indian roads, since the first rolled out in
1954. The company's manufacturing base in India is spread across Jamshedpur
(Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand)
and Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set
up an industrial joint venture with Fiat Group Automobiles at Ranjangaon
(Maharashtra) to produce both Fiat and Tata cars and Fiat powertrains. The company
is establishing a new plant at Sanand (Gujarat). The company's dealership, sales,
services and spare parts network comprises over 3500 touch points; Tata Motors also
distributes and markets Fiat branded cars in India.

Tata Motors, the first company from India's engineering sector to be listed in the
New York Stock Exchange (September 2004), has also emerged as an international
automobile company. Through subsidiaries and associate companies, Tata Motors has
operations in the UK, South Korea, Thailand and Spain. Among them is Jaguar Land
Rover, a business comprising the two iconic British brands that was acquired in
2008. In 2004, it acquired the Daewoo Commercial Vehicles Company, South
Korea's second largest truck maker. The rechristened Tata Daewoo Commercial
Vehicles Company has launched several new products in the Korean market, while
also exporting these products to several international markets. Today two-thirds of
heavy commercial vehicle exports out of South Korea are from Tata Daewoo. In
2005, Tata Motors acquired a 21% stake in Hispano Carrocera, a reputed Spanish bus
and coach manufacturer, with an option to acquire the remaining stake as well.
Hispano's presence is being expanded in other markets. In 2006, it formed a joint
venture with the Brazil-based Marcopolo, a global leader in body-building for buses
and coaches to manufacture fully-built buses and coaches for India and select
international markets. In 2006, Tata Motors entered into joint venture with Thonburi
Automotive Assembly Plant Company of Thailand to manufacture and market the
company's pickup vehicles in Thailand. The new plant of Tata Motors (Thailand) has
begun production of the Xenon pickup truck, with the Xenon having been launched
in Thailand at the Bangkok Motor Show 2008.

Tata Motors is also expanding its international footprint, established through exports
since 1961. The company's commercial and passenger vehicles are already being
marketed in several countries in Europe, Africa, the Middle East, South East Asia,
South Asia and South America. It has franchisee/joint venture assembly operations in
Kenya, Bangladesh, Ukraine, Russia and Senegal.

The foundation of the company's growth over the last 50 years is a deep
understanding of economic stimuli and customer needs, and the ability to translate
them into customer-desired offerings through leading edge R&D. With over 2,000
engineers and scientists, the company's Engineering Research Centre, established in
1966, has enabled pioneering technologies and products. The company today has
R&D centres in Pune, Jamshedpur, Lucknow, in India, and in South Korea, Spain,
and the UK. It was Tata Motors, which developed the first indigenously developed
Light Commercial Vehicle, India's first Sports Utility Vehicle and, in 1998, the Tata
Indica, India's first fully indigenous passenger car. Within two years of launch, Tata
Indica became India's largest selling car in its segment. In 2005, Tata Motors created
a new segment by launching the Tata Ace, India's first indigenously developed mini-
truck.

In January 2008, Tata Motors unveiled its People's Car, the Tata Nano, which India
and the world have been looking forward to. The Tata Nano has been subsequently
launched, as planned, in India in March 2009. A development, which signifies a first
for the global automobile industry, the Nano brings the comfort and safety of a car
within the reach of thousands of families. The standard version has been priced at
Rs.100,000 (excluding VAT and transportation cost).

Designed with a family in mind, it has a roomy passenger compartment with


generous leg space and head room. It can comfortably seat four persons. Its mono-
volume design will set a new benchmark among small cars. Its safety performance
exceeds regulatory requirements in India. Its tailpipe emission performance too
exceeds regulatory requirements. In terms of overall pollutants, it has a lower
pollution level than two-wheelers being manufactured in India today. The lean design
strategy has helped minimise weight, which helps maximise performance per unit of
energy consumed and delivers high fuel efficiency. The high fuel efficiency also
ensures that the car has low carbon dioxide emissions, thereby providing the twin
benefits of an affordable transportation solution with a low carbon footprint.

In May 2009, Tata Motors ushered in a new era in the Indian automobile industry, in
keeping with its pioneering tradition, by unveiling its new range of world standard
trucks. In their power, speed, carrying capacity, operating economy and trims, they
will introduce new benchmarks in India and match the best in the world in
performance at a lower life-cycle cost.

The years to come will see the introduction of several other innovative vehicles, all
rooted in emerging customer needs. Besides product development, R&D is also
focussing on environment-friendly technologies in emissions and alternative fuels.

Through its subsidiaries, the company is engaged in engineering and automotive


solutions, construction equipment manufacturing, automotive vehicle components
manufacturing and supply chain activities, machine tools and factory automation
solutions, high-precision tooling and plastic and electronic components for
automotive and computer applications, and automotive retailing and service
operations.
Company Profile
It has been a long and accelerated journey for Tata Motors, India's leading
automobile manufacturer. Some significant milestones in the company's
journey towards excellence and leadership.
Milestones
1 • Tata Engineering and Locomotive Co. Ltd. was established to manufacture
945 locomotives and other engineering products.

1 • Steam road roller introduced in collaboration with Marshall Sons (UK).


948

1 • Collaboration with Daimler Benz AG, West Germany, for manufacture of


954 medium commercial vehicles. The first vehicle rolled out within 6 months of
the contract.

1 • Research and Development Centre set up at Jamshedpur.


959

1 • Exports begin with the first truck being shipped to Ceylon, now Sri Lanka.
961

1 • Setting up of the Engineering Research Centre at Pune to provide impetus to


966 automobile Research and Development.

1 • Introduction of DI engines.
971

1 • First commercial vehicle manufactured in Pune.


977

1 • Manufacture of Heavy Commercial Vehicle commences.


983

1 • First hydraulic excavator produced with Hitachi collaboration.


985

1 • Production of first light commercial vehicle, Tata 407, indigenously designed,


986 followed by Tata 608.

1 • Introduction of the Tatamobile 206 - 3rd LCV model.


989

1 • Launch of the 1st indigenous passenger car Tata Sierra.


991 • TAC 20 crane produced.
• One millionth vehicle rolled out.

1 • Launch of the Tata Estate.


992

1 • Joint venture agreement signed with Cummins Engine Co. Inc. for the
993 manufacture of high horsepower and emission friendly diesel engines.

1 • Launch of Tata Sumo - the multi utility vehicle.


994 • Launch of LPT 709 - a full forward control, light commercial vehicle.
• Joint venture agreement signed with M/s Daimler - Benz / Mercedes - Benz for
manufacture of Mercedes Benz passenger cars in India.
• Joint venture agreement signed with Tata Holset Ltd., UK for manufacturing
turbochargers to be used on Cummins engines.

1 • Mercedes Benz car E220 launched.


995

1 • Tata Sumo deluxe launched.


1 • Tata Sierra Turbo launched.
997 • 100,000th Tata Sumo rolled out.

1 • Tata Safari - India's first sports utility vehicle launched.


998 • 2 millionth vehicle rolled out.
• Indica, India's first fully indigenous passenger car launched.

1 • 115,000 bookings for Indica registered against full payment within a week.
999 • Commercial production of Indica commences in full swing.

2 • First consignment of 160 Indicas shipped to Malta.


000 • Indica with Bharat Stage 2 (Euro II) compliant diesel engine launched.
• Utility vehicles with Bharat 2 (Euro II) compliant engine launched.
• Indica 2000 (Euro II) with multi point fuel injection petrol engine launched.
• Launch of CNG buses.
• Launch of 1109 vehicle - Intermediate commercial vehicle.

2 • Indica V2 launched - 2nd generation Indica.


001 • 100,000th Indica wheeled out.
• Launch of CNG Indica.
• Launch of the Tata Safari EX
• Indica V2 becomes India's number one car in its segment.
• Exits joint venture with Daimler Chrysler.

2
002
Tata Motors has several joint venture, subsidiary and
• Unveiling of the Tata Sedan at Auto Expo 2002.
• Petrol version of Indica V2 launched.
associate
• Launch ofcompanies:
the EX series in Commercial vehicles.
• Launch of the Tata 207 DI.
• 2,00,000th Indica rolled out.
• 5,00,000th
Jaguar Landpassenger
Rover vehicle rolled out.
• Launch of the Tata Sumo'+' Series
• Launch of the Tata Indigo.
• TataEngineering
Tata Technologies
signedLtd. (TTL)
a product and itswith
agreement subsidiaries
MG Rover of the UK.

2 •
 Launch
Telco of the Tata SafariEquipment
Construction Limited Edition.
Co. Ltd. (Telcon)
003 • The Tata Indigo Station Wagon unveiled at the Geneva Motor Show.
• On 29th July, J. R. D. Tata's birth anniversary, Tata Engineering becomes Tata
 HV Axles
Motors Ltd. (HVAL)
Limited.
• 3 millionth vehicle produced.
• First CityRover rolled out


HV Transmissions Ltd. (HVTL)
135 PS Tata Safari EXi Petrol launched
• Tata SFC 407 EX Turbo launched
 TAL Manufacturing Solutions Ltd. (TAL)
2 • Tata Motors unveils new product range at Auto Expo '04.
004 • New Tata Indica V2 launched
• Sheba
Tata Properties
Motors and DaewooLtd.Commercial
(Sheba) Vehicle Co. Ltd. sign investment
agreement
• Indigo AdventMotors
Concorde unveiled(India)
at Geneva Motor
Ltd. Show
(Concorde)
• Tata Motors completes acquisition of Daewoo Commercial Vehicle Company
• Tata LPT 909 EX launched
• TataDaewoo
Tata Daewoo Commercial
Commercial VehicleVehicle Company
Co. Ltd. (TDCV) Ltd (TDWCV)
launches the heavy duty
truck 'NOVUS' , in Korea
• Sumo VictaCarrocera
Hispano launched S. A. (HC)
• Indigo Marina launched
• Tata Motors lists on the NYSE

2 • Tata Motors rolls out the 500,000th Passenger Car from its Car Plant Facility in
005 Pune
• The Tata Xover unveiled at the 75th Geneva Motor Show
• Tata Motors acquires 21% stake in Hispano Carrocera SA, Spanish bus
manufacturing Company
• Tata Ace, India's first mini truck launched
TataMotors
• Tata Motors winsInsurance
JRD QV award Broking & Advisory
for business Services Ltd
excellence. (TMIBASL)
• The power packed Safari Dicor is launched
• Introduction of Indigo SX series - luxury variant of Tata Indigo
 Tata Motors European Technical Centre plc
• Tata Motors launches Indica V2 Turbo Diesel.
• One millionth passenger car produced and sold
Tata Motors
• Inauguration Finance
of new factoryLimited
at Jamshedpur for Novus
• Tata TL 4X4, India's first Sports Utility Truck (SUT) is launched
• Launch of Tata Novus
Tata Motors
• Launch of NovusThailand
range of medium trucks in Korea, by Tata Daewoo
Commercial
Tata Marco
 Vehicle polo Motors Ltd (TMML)
Co. (TDCV)

2 • Tata Motors vehicle sales in India cross four million mark


006 • TataMotors
Tata Motors(SA) Proprietary
unveils new Ltd premium
long wheel base (TMSA)Indigo & X-over concept at
Auto Expo 2006
• Indica
TMLV2 Xeta launched
Distribution Company Ltd (TDCL)
• Passenger Vehicle sales in India cross one-million mark
• Tata Motors and Marcopolo, Brazil, announce joint venture to manufacture
fully built buses & coaches for India & markets abroad
• Tata Motors first plant for small car to come up in West Bengal
• Tata Motors extends CNG options on its hatchback and estate range
M.L. Bapna
• TDCV develops South Korea's first LNG-Powered Tractor-
CEO (HVALTrailer
& HVTL)
• Tata Motors and Fiat Group announce three additional cooperation agreements
• Tata Motors introduces a new Indigo range
Ashesh Jamaiyar
2
007
• Construction COO
of Small
PROFILE OF
Car plant at Singur, West Bengal, begins on January 21
(HVAL)
• New 2007 Indica V2 range is launched

limousine
A K Panda
HV AXLES LIMITED
• Tata Motors launches the longwheel base Indigo XL, India's first stretch
R R Mishra
AGM (Rear Axle Fctory) AGM (FABU) to Indigo sedan and estate range
• Common rail diesel (DICOR) engine extended
• Tata Motors and Thonburi Automotive Assembly Plant Co. (Thonburi),
announce formation of a joint venture company in Thailand to manufacture,
S Mohanty Suranjan Chatterjee
assemble and market pickup trucks.
AGM (Central Materials)
• Roll out of 100,000th Ace AGM (Central Quality)
• Tata-Fiat plant at Ranjangaon inaugurated
• Launch of a new Upgraded range of its entry level utility vehicle offering, the
R P Singh
Tata Spacio. D N Tripathi
AGM (PPC) AGM – (P&A & IR)
• CRM-DMS initiative crosses the 1000th location milestone
• Launch of Magic, a comfortable, safe, four-wheeler public transportation mode,
developed on the Ace platform Dipan Sengupta
P K Sinha
• Launch of Winger, India’s only maxi-van
Div Mngr
Div Mngr (HR & PSD)
• Fiat Group and Tata Motors announce ) of Joint Venture in India
establishment
(Central Maintenance
• Launch of the Sumo Victa Turbo DI, the new upgraded range of its entry-level
utility vehicle, the Sumo Spacio
U Macwana
• Tata Motors launches Indica V2 Turbo with dual airbags and ABS
AGM (Logistics & Stores)
• Launch of new Safari DICOR 2.2 VTT range, powered by a new 2.2 L Direct
Injection Common Rail (DICOR) engine.
• Rollout of the one millionth passenger car off the Indica platform. P K Choudhury
AGM (Planning, PE,NPI,ERC,
Ext Business,
2 • Ace plant at Pantnagar (Uttarakhand) begins production.
008 • Indica Vista – the new generation Indica, is launched.
• Tata Motors' new plant for Nano to come up in Gujarat. Tarun Gupta
• Latest common rail diesel offering- the Indica V2 DICOR, launched.AGM (Finance & Excise)
• Indigo CS (Compact Sedan), world’s first sub four-metre sedan, launched.
• Launch of the new Sumo -- Sumo Grande, which combines the looks of an
SUV with the comforts of a family car. S. Aich
• Tata Motors unveils its People's Car, Nano, at the ninth Auto Expo. AGM (Projects, IDM
• Tata Motors signs definitive agreement with Ford Motor Company to purchase
Jaguar and Land Rover.
• Tata Motors completes acquisition of Jaguar Land Rover.
• Tata Motors introduces new Super Milo range of buses.
• Tata Motors is Official Vehicle Provider to Youth Baton Relay for The III
Commonwealth Youth Games Pune 2008.
• Indica Vista – the second generation Indica, is launched.

PROFILE OF HV AXLES LTD.

H V Axles Ltd., a subsidiary of Tata Motors, was formed in March 2000. Earlier it
used to be the Axle Division of Telco (Tata Engineering), Jamshedpur,

The manufacturing facilities of HVAL are located in the industrial belt of Jamshedpur
in the state of Jharkhand, 250 kms from Kolkata, India's leading metro city and is
well connected by air, road and rail to major cities/ locations.
Starting operations in 1954 (creation of Telco), today HVAL is the market leader in
medium & heavy commercial vehicle axles in India with an installed capacity of over
3.6 lakh axles per annum. The company’s product range includes Front Steer Axles
(both Live and Normal), Rear Drive Axles and Dummy / Trailer Axles. It is currently
the sole supplier of M & HCV Axles to the Jamshedpur and Lucknow plants of Tata
Motors.

VISION OF HV AXLES LTD.

To be a benchmark stand alone M & HCV Axles manufacturer, rated as number one
in the CV Industry in India & among the recognized top five globally in terms of
Volume, Durability, Reliability, Revenues, Cost & Product range, with lowest
ownership cost of products, offering a first overhaul life of more than three lakh
kilometers and achieving 10% revenue from an expanded customer base by 2010-
2011.

MISSION OF HV AXLES LTD.

To provide superior value for money to customers through quality and cost effective
Axles and related Products & Services

To achieve sustainable growth by continuously seeking new business


opportunities/challenges, employing contemporary technologies and maintaining a
high performance work culture.

CORE VALUE OF HV AXLES LTD.

Integrity, Customer Focus, Corporate Citizenship, Passion for Engineering

Product of HVAL

Live Front Axle


All dimensions are in mm.
DRG NO. DRG NO.
SL.NO. DIMENSION
HVA – 610 HVA - 1210
1 SPRING C / C DISTANCE 840 840
SPRING SADDLE
2 17 DIA 17 DIA
- HOLE SIZE
DISTANCE FROM
ANCHORPLATE
3 (BRAKE) FACE TO17 DIA HOLE 430 430
ON
SPRINGSADDLE
HOLES ON SPRING SADDLE
4 23 23
FOR U BOLT MOUNTING :
HOLE DIA 153 153
SPACE BETWEEN BOLTS
89 89
U BOLT CENTRE
125 X 85.72 & 133.274 125 X 85.72 & 133.274
5 HUB BEARINGS SIZE (OD X ID ):
X 70 X 70
6 HUB LUBRICATION GREASE GREASE
7 WEIGHT OF AXLE (Kg) 415 435
GROUND CLEARANCE
8 281 281
(With 9 X 20 Tyres)
CIRCULAR - OD : CIRCULAR - OD : 120
9 TUBE SEC. & SIZE 120 , ,
ID : 87 ID : 87
405 DIA X 100 WIDE 405 DIA X 100 WIDE
10 BRAKES : DUAL AIR OVER DUAL AIR OVER
HYDRAULIC HYDRAULIC
11 DRUM / WHEEL PCD : 275 275
12 WHEEL RIM FIXING DIA :(mm) 218.7 218.7
13 WHEEL BOLTS : M 20 X 2.5 ( 8 N0S. ) M 22 X 2.5 ( 8 N0S. )
14 TRACK 1760 1991
15 RATED LOAD ( Kg ) 4060 4060
16 TOE IN 0-3 0-3
RATED OUTPUT TORQUE IN
17 FORWARD DIRECTION ( mKg ) 670 / 200 670 / 200
PEAK / CONTINUOUS:
RATIO & DIA OF CROWN 37 / 7 , 41 / 6 , 41 / 7 41 / 6 , 41 / 7
18
WHEEL & PINION ( 345 mm DIA ) ( 345 mm DIA )
19 QTY / SPEC. OF OIL: 3.5 Litre ( 85 W 140 ) 4.35 Litre ( 85 W 140 )
NOTE: Specifications are subject to change without notice.
Supplier Quality Assurance

Quality Policy
HV Axles Ltd. is committed to maximizing customer satisfaction and striving
to achieve the goal of excellence by continual improvement through
manufacture and sale of reliable, safe, cost effective and quality products as
well as services of international standards, by using environmentally
sustainable technologies for improving levels of efficiency and productivity
within its plant & ancillaries. HV Axles Ltd. also has a commitment towards
improving the quality of life of its employees, both within and outside its plant
and offices, through improved work practices and social welfare schemes.

1 Environmental Policy
HV Axles Ltd. is committed to minimize the adverse impact of its products,
operations and services on the environment.
Towards this end it shall strive to: (i) Establish sound environmental
objectives and targets and a process of reviewing them. (ii) Comply with all
applicable legal / regulatory and other environmental requirements.
(iii) Use of environmentally sustainable technologies and practices for
prevention of pollution and the continual improvement in environmental
performance (iv) Conserve natural resources and energy by minimizing their
consumption and wastage. (v) Minimizing waste generation, maximizing
resource efficiency, recycling of material & preventing pollution.
(vi) Building awareness across all sections of the workforce on environmental
issues.

Supplier Quality system requirements


General Requirements
The ISO / TS 16949:2002 Standard is the foundation for the development of
this manual. All automotive material suppliers to HV Axles Ltd. must comply
with this standard and their related documents.
A minimum of ISO 9000 certification is required by all suppliers. All calibration
Labs and test sources must be accredited to NABL (National Accreditation
Board for Laboratories) or certified by TML/HV Axles Ltd. Third party
registration to the applicable quality standard is evidence of conformance. HV
Axles Ltd. also reserves the right to require self-assessment or assessment
by an HV Axles Ltd. representative. Formal corrective actions in the
standardized 8D are required from the supplier for any
deficiencies / defect observed during inspection or assembly. The same has
to be submitted within 15 days. These requirements of manual are part of the
purchase order or contract issued by HV Axles Ltd. Acceptance of the
purchase order/contract constitutes acceptance of the requirements of this
manual. Additional quality requirements for parts, material and services
specified on the purchase order, contract, drawings or specifications must be
satisfied and take precedence over the requirements of this manual.
Prior approval in writing from HV Axles Ltd. would be mandatory for suppliers
for any hange in their approved process. Failure to comply with quality
system requirements may result in suspension of supply and will require
objection clearance from HV Axles Quality department before restoring
the supplies HV Axles Ltd. reserves the right to revise this manual at any
time without prior notice.
Supplier Selection
Selection of a new supplier is done based on the assessment of supplier’s
infrastructure, financial position, machine & tools, inspection facilities,
availability of technical persons etc.
Third Party Certification
HV Axles Ltd. shall perform supplier quality management system
development with the goal of supplier conformity with ISO/TS 16949:2002.
Conformity with ISO 9001: 2000 is the first step in achieving this goal.
2009, Hv Axles Ltd. Jamshedpur All rights reserved, Reproduction prohibited
without written approval Unless otherwise specified by HV Axles Ltd., the
suppliers to HV Axles Ltd. shall be third party registered to ISO 9001: 2000
by an accredited third party certification body. A roadmap for moving to
ISO/TS16949:2002 is expected from each supplier.
Approved Raw Material Source
All suppliers must procure raw materials from sources approved by HV Axles
Ltd. / Tata Motors. For approved source see Appendix B
Control of Inspection, Measuring and Test Equipment
The suppliers must have established and documented procedures to control,
calibrate and maintain inspection, measuring and test equipment and devices
used to demonstrate the conformance of product to the specified
requirements. Inspection, measuring and test equipment should be used in a
manner that ensures that the measurement uncertainty is known and is
consistent with the required measurement
capability.
Sub-Contractor Control
The supplier shall be responsible for any sub-contracted (outsourced or
alternate) process and will have final approvals or inspection in place to
ensure that all subcontracted components conform to specifications dictated
by the drawings. Prior to any sub-contracting activity the supplier shall
communicate to HV Axles Ltd. in writing & thereafter carry out fresh PPAP.
Declaration of Responsible Person by supplier
It is the responsibility of the Supplier to report to HV Axles Ltd. the names of
key individuals who are responsible for delivering a quality product to HV
Axles Ltd.. There must be someone available with authority to make
necessary decisions. Such person(s) of the supplier shall be responsible for
signing minutes of meetings, giving authorization for lifting / scrapping non-
conforming material etc. Any change in this responsibility shall be reported to
HV Axles Ltd. immediately.

Sample Acceptance process


Supplier’s business initiation takes place with the submission of the sample
(2-5 nos) with all related documents. The sample is accepted or rejected
based on its conformance to drawing and other requirements conformance
as mentioned in 2.11 A sample checking report is made and a copy is made
available to the vendor. All suppliers of production part materials are required
to submit a PPAP to HV Axles Ltd. & receive approval prior to beginning of
regular dispatches
PHOTO GALLERY OF H.V.A.L.

PRODUCT
ASSEMBLY LINE
CONCLUSION
The project assigned to me during my summer training in HV Axles Ltd was
“REDUCTION OF HUB PLAY COMPLAIN IN ASSEMBLY LINE” At the time
of starting of project rejection of axle due to hub play had increased from 5
axle per day to approx 20 axles per day out of 350 axles manufactured.
To understand and reduce this complain I was given formal training of 10
days at Metrology lab to understand checking procedure and after that
attached to supplier quality assurance group to analyze complain through
Fish Bone diagram and to reduce the complain by finding root cause and
closing it through effective CAPA.

Main finding of my project was as follows:


 Process followed in assembly at HV Axles were ok
 Spacer tube quality was not ok and variations were found in some
parameter which was critical from assembly and functional point of view.

After controlling the variation it was observed that there was 80% reduction in
hub play complain.

This project had not been completed with such a great output if I have not got
technical and functional support from Supplier Quality assurance group and
other related departments.