Industrial Training Report

Machine Related Operations

SONA BLW PRECISION FORGING LTD.

Sona Enclave Village,
Begumpur Khatola ,Sector 35
Gurugram - 122004
Haryana, India
In Partial fulfilment of the requirements for the degree of B.Tech. In
Mechanical Engineering

Submitted by
ROHIT VATS
15ME23

Submitted to

Department of Mechanical Engineering

Shree Guru Gobind Singh Tercentenary Institute of Engineering
& Technology
Gurugram- 122505
 CANDIDATE’S DECLARATION

I, ROHIT VATS, a student of B. Tech. in Mechanical Engineering Department at Shree Guru Gobind
Singh Tercentenary Institute of Engineering & Technology, Haryana hereby declare that I own full
responsibility for the information, results, conclusions etc. provided in this project/ industrial training
work titled MACHINE RELATED OPERATIONS submitted to SGT Institute of Engineering &
Technology, Gurugram, Haryana, India for the award of B.Tech. (Mechanical Engineering) degree. I have
completely taken care in acknowledging the contribution of others in this academic work. I further declare
that in case of any infringement of intellectual property rights or copyrights found at any stage, I, as the
candidate will be solely responsible for the same.

Date Name Rohit Vats

Place Haryana
COMPANY CERTIFICATE
 CERTIFICATE

This is to certify that this project/ industrial training report entitled “MACHINE RELATED
OPERATIONS” submitted by Mr. ROHIT VATS (1512180180) in partial fulfilment of the requirement
for the award of the degree of Bachelors of Technology in Mechanical Engineering to SGT Institute of
Engineering & Technology, Haryana, India is a record of student’s own work carried out under our
supervision and guidance.

To the best knowledge, this project/ industrial training report has not been submitted in part or full
elsewhere in any other University or Institution for the award of any degree or diploma. It is further
understood that by this certificate the undersigned do not endorse or approve any statement made, opinion
expressed or conclusion drawn therein, but approve the thesis only for the purpose for which it is
submitted.

SUPERVISOR

Mr. PARDEEP GUPTA Mrs. SHUBHANGI

MANAGER Assistant Professor
Company Name SONA BLW Department of Mechanical
Engg.
Address Phase 3 IMT MANESAR SGTIET, Gurgaon

COUNTERSIGNED

Dr. Rajan Garg

Professor & Head
Mechanical Engineering Department
SGTIET, Gurgaon

ACKNOWLEDGEMENT

The present work will remain incomplete unless I express my feelings of gratitude towards a number of
persons who delightfully co-operated with me in the process of this work.

This work was carried out under the supervision of Mr. PARDEEP GUPTA, MANAGER, SUZUKI,
Maruti Suzuki India Limited Plot No.1, Phase 3A, IMT Manesar, Gurugram - 122051 Haryana, India and
Mrs. Monika, Assistant professor, Mechanical Engineering Department, SGT Institute of Engineering &
Technology, Gurgaon, India for which I would like to express my deepest appreciation and thank for
guiding me since it was assigned, and sharing their insight, experiences, and endless wisdom. I am
extremely grateful and appreciative for all the knowledge and know-how they have given me.

I express and extend my thanks to Dr. Rajan Garg, Professor & Head, Mechanical Engineering
Department, SGT Institute of Engineering & Technology, Gurgaon for his constant inspiration,
painstaking effort and illuminative guidance during the training period.

My special thanks are due to Mr Pardeep Gupta, Manager, Sona Blw Precision Forging Ltd. ,Sona
Enclave Village, Begumpur Khatola ,Sector 35-Gurugram – 122004 Haryana India who taught me
all about perseverance, moral ethics and provided his specialized technical advice and recommendations,
which is really appreciated.

In addition, I am indeed grateful to my beloved parents for creating a positive working environment,
showing me the ropes, their superior guidance, and always being there for me through the good and bad
times.

Thanks, are also especially to Navdeep for interesting discussions and for being a good and supportive
friend.

Greater thanks are due to my dear friends for their endless support.

Date:
Place: HARYANA Name: APRAJAY SHARMA

ABSTRACT
 CONTENTS

Page no.

CANDIDATES DECLARATION
COMPANY CERTIFICATE
CERTIFICATE
ACKNOWLEDGEMENT
ABSTRACT
CONTENTS
LIST OF FIGURES
LIST OF TABLES
CHAPTER 1 INTRODUCTION
1.1 company’s profile
1.2 company’s policies
CHAPTER 2 INDUSTRIAL TRAINING
2.1 basic engine detail
2.2 difference between engines
2.3 About dent
CHAPTER 3 MANESAR PALNT
3.1 About Manesar plant
3.2 models in Manesar plant
CHAPTER 4 Assembly plant
CHAPTER 5 Project work
CHAPTER 6 Theoretical & technical aspects
CHAPTER 7 One month dent inspection
CHAPTER 8 Instruction sheets
CHAPTER 9 Objective of the project
CHAPTER 10 Software requirements
CHAPTER 11 Testing
CHAPTER 12 Output of the project
CHAPTER 13 Future work improvement
REFRENCES
 LIST OF FIGURES

Figure Title of the figure Page no.

no.
2.1 Seven side location 15
3.1 Manesar plant 17
3.2 Different levels of plant 19
3.3 Blanking 20
3.4 Stamping 21
3.5 Welding 22
3.6 Painting 23
3.7 Assembly 24
3.8 Inspection 25
3.9 S&D 26
3.10 SPD 27
4.1 Assembly plant 29
4.2 Structure of plant 30
5.1 Dent 32
5.2 Defects in vehicle inspection 37
6.1 Checking method of dent 39
6.2 Audit sheet 40
6.3 Invoiced vehicle audit sheet 41
7.1 One month dent inspection 43
7.2 Corrosive spring 44
7.3 New replaced spring 45
8.1 WIS 46
8.2 SIS 47
12.1 Pie chart 50
12.2 Slope chart 51
LIST OF TABLES
 CHAPTER 1: INTRODUCTION

I have got a great opportunity of 6 months training in SONA BLW PRECISION FORGINGLTD.
The training successfully done in the Gurgaon plant in which the allotment of the assembly plant one
of the exciting study of my life. This plant was full of the last touch-up.

My work was to see every operator when they are working in which I have to see all the
operations on machine done by the operator to make the products.

Some sheets are given to me in whom I was asked to mention ok and not ok of the every operator
doing their work.

The awareness among all of the operator by asking them not to cause defects and do work
carefully is done by me

1.1 COMPANY PROFILE - MARUTI SUZUKI

Maruti Suzuki is one of India's leading automobile manufacturers and the market leader in the car
segment, both in terms of volume of vehicles sold and revenue earned. Maruti Udyog Limited
(MUL) was established in February 1981, though the actual production commenced in 1983 with
the Maruti 800, based on the Suzuki Alto Kei car which at the time was the only modern car
available in India. It’s only competitors- the Hindustan Ambassador and Premier Padmini were
both around 25 years out of date at that point. Through 2004, Maruti has produced over 5 Million
vehicles.

The company annually exports more than 125,000 cars and has an extremely large domestic
market in India selling over 1,700,000 cars annually .Maruti 800, till 2004, was the India's largest
selling compact car ever since it was launched in 1983. More than a million units of this car have
been sold worldwide so far. Currently, Maruti Alto tops the sales charts and Maruti Swift is the
largest selling in A2 segment.

Due to the large number of Maruti 800s sold in the Indian market, the term "Maruti" is commonly
used to refer to this compact car model. Till recently the term "Maruti", in popular Indian culture,
was associated to the Maruti 800 model.

Maruti Suzuki India Limited, a subsidiary of Suzuki Motor Corporation of Japan, has been the
leader of the Indian car market for over two decades .More than half the cars sold in India are
Maruti cars.

Suzuki Motor Corporation, the parent company, has been a global leader in mini and

Compact cars over three decades. Suzuki’s technical superiority lies in its ability to pack power
and performance into a compact, lightweight engine that is clean and fuel efficient.

Maruti is clearly an “employer of choice” for automotive engineers and young managers from
across the country. Nearly 75,000 people are employed directly by Maruti and its partners.

The company vouches for customer satisfaction. For its sincere efforts it has been rated (by
customers) first in customer satisfaction among all car makers in India for 17 years in a row (as of
2016), in annual survey done by J D Power Asia Pacific.

Maruti Suzuki was born as a government company, with Suzuki as a minor partner to make a
people's car for middle class India. Over the years, the product range has widened, ownership has
changed hands. What remains unchanged, then and now, is Maruti’s mission to motorize India.

1.1.1 COMPANY’S MISSION

When Maruti entered the Indian car market, it sought to fill what it perceived as two very glaring
needs. Primarily, to provide fuel efficient, low-cost vehicles, which are reliable and of high
quality; secondly, to offer customers value for money and complete customer satisfaction.
Additionally, the absence of an efficient public transportation system was leading to a growing
demand for passenger cars. A burgeoning work force and growing middle class population meant
that personal transport had become a necessity. To attract good managerial talent, the corporate
world had started to offer cars even to junior executives. Since the cars that Maruti manufactured
were mainly entry level cars, the company successfully fulfilled this demand in the market.

The main objectives of setting up the Maruti plant were to fulfil the following needs.

1. Modernization and upliftment of Indian Automobile Industry from its current dishevelled
situation.
2. Production of fuel-efficient vehicles to conserve the scarce resources of petroleum.
3. Production of large number of motor vehicles, which are necessary for the economic
growth of any country.
1.2. COMPANY POLICIES

5S

These come under the Work Place Management.

1. SEIRI - Proper Selection

2. SEITION- Systematic Arrangement

Colour Coding.

Outline Marking.

Sign boards.

Labels.

3. SEISO- Cleaning

CLITA Rule.
C - Cleaning
L - Lubrication
I - Inspection
T - Tightening
A - Adjustment

4. SEIKETSU- Standardization

5. SHITSUKE- Discipline
 3G – 3GEN

This is handy in Problem Solving.3G means, “In case of an abnormality, all concerned members
should actually go to the place where the problem has occurred, see the actual thing and take
Realistic action to solve the problem”. In the Japanese language this point is compiled in 3 words:
-
GENCHI – Go To The Actual Place

GENBUTSU – See the Actual Thing

GENJITSU – Take The Appropriate Action

3K

This refers to the Standardization in an organization.

KIMERA ARETA KOTO GA - What has been decided

KIHON DORI NI - Exactly as per standard

KICHIN TO MAMO RU - Must be followed

3M

In a plant, various problems occur which hamper production and adversely affect the quality of
products. Most of these problems occur due to 3M: -
MURI – Unnecessary extra load on man and machine.

MUDA – Wastage

Overproduction

Unnecessary motion

Transportation

Over Processing

Inventory and Unnecessary WIP

Scrap/Repair/Rework

Waiting for work and material

Intellectual Waste

MURA – Inconsistency, Unevenness

KAIZEN

• Changing for better.

• Continual or on-going improvement in work process usually without any large capital
outlay and involving the entire workplace of an organisation.
• Thriving for innovation and evolution.

• Reduces human work and makes production efficient.

 CHAPTER 2: 7 SIDE LOCATIONS IN ENGINE

1. Front side (Pulley side)

2. Rear side (Flywheel side)
3. Right side (Exhaust side)
4. Left side (Intake manifold)
5. Top side (Cylinder head)
6. Middle and biggest side (Cylinder block)
7. Bottom Side (Oil sump)

Figure 2.1 Seven Side Location

 2.1. DIFFERENCE IN PETROL AND DIESEL ENGINE

FACTORS PETROL DIESEL

MILEAGE Less More

POLLUTION Less More

NOISE Less More

VIBRATION Less More

DRIVING Smooth Less smooth

PICK UP More Less

TORQUE Less More

PRICE Less More

RATE OF COST Less More

RUNNING COST Less More

LIFE More Less

SIZE/WEIGHT Less More

CNG FIT Yes No

Table 2.1 difference

btw petrol and diesel
 CHAPTER 3: MANESAR PLANT

The Manesar manufacturing plant was inaugurated in February 2007 and is spread over 600 acres (2.4 km2).]

Initially it had a production capacity of 100,000 vehicles annually but this was increased to 300,000 vehicles
annually in October 2008.

The production capacity was further increased by 250,000 vehicles taking total production capacity to 800,000
vehicles annually. The Manesar Plant produces the Alto 800, Alto K10, Swift, Ciaz, Baleno, Baleno RS and
Celerio. On 25 June 2012, Haryana State Industries and Infrastructure Development Corporation demanded
Maruti Suzuki to pay an additional Rs 235 crore for enhanced land acquisition for its Haryana plant expansion.

The agency reminded Maruti that failure to pay the amount would lead to further proceedings and vacating the
enhanced land acquisition.

The launch of the Dzire happened in the month of May 2017 and the variant is said to have good mileage

Figure 3.1 Manesar Plant

3.1 VEHICLE MODELS IN PRODUCTION:

Sl. No. Models Vehicle Code Engine Series

1 Omni Y88 K
2 Alto – 800 YE3 F
3 Gypsy King E19 G
4 Swift YP8 K/D
5 Dzire YSD K/D
6 Eeco YG8 G
7 WagonR YR9 K
8 Ertiga YL8 K/D
9 Alto K-10 YE3 K
10 Celerio YL7 K
11 Ciaz YL1 K/D
12 Baleno new YRA/YRC K/D
13 S – Cross YAD D
14 Vitara Brezza YBA D
15 Super Carry Y9T E
16 Ignis YJC K/D
17 Dzire Tour (Taxi) YN4 K/D

Table 3.1 vehicle

models

Gurgaon Plant Manesar Plant Gujarat Plant

Omni Dzire Swift
Alto – 800 Alto K-10 Baleno New
Gypsy King Celerio – Petrol
Eeco Ciaz
WagonR Baleno New
Ertiga Swift Dzire Tour (Taxi)
S – Cross
Vitara Brezza
Super Carry
Ignis
Table 3.2 plant wise vehicle
models
3.2. DIFFERENT LEVELS OF PLANT

PRESS SHOP

WELD SHOP

PAINT SHOP

ASSEMBLY SHOP

VEHICLE INSPECTION

S&D

Figure 3.2 Different Levels of Plant

3.3. PROCESSES USED IN MANESAR PLANT

BLANKING

It is the process used to make as a blank which is often termed as a piece of the bundles of rolled
sheet metal. These sheets are packed in the form of gripping them with the defined boxes which
are able to store the sheet metal and these sheets are used further for the next step of production
after loading into the trolleys.

Figure 3.3 Blanking

 STAMPING
This stamping is done by the press shop which is having many dies and many automated
machines to transfer the sheets from one side to another. In this process the press exerts the
pressure and this press leads to develop the shape of die as the die is beneath the press so that the
required set of stamped things can be made such as the doors, hood, panel and many more things
can be made.

Figure 3.4 Stamping

 WELDING

It is the process of joining two materials so that a reasonable product can be seen. The main types
of welding used in Maruti Suzuki are the MIG and the Spot welding. These are used as 1% MIG
welding and 99% of Spot welding. 2500 Spot welds in a vehicle are used. Three main things that
are used for welding are air, water and electricity.

Figure 3.5 Welding

 PAINTING

Figure 3.6 Painting

After coming from the weld shop the vehicle is protected from the outside environment impact as
well as the other factors affecting the vehicle material. The paint is done so that the good quality
of the steel is maintained in which the metal can be prevented from the external corrosion as well
as an external environmental impact on the vehicle the events of the paying is maintained so that
the vehicle can be seen from anywhere.
 ASSEMBLY

In this the assemble of all the parts from which the vehicle is made is done in which the various
parts such as perking brakes, tires, wires, chassis as well as all the work to made a vehicle is done
which gives the finish touch-up for the vehicle made. This process is used in a manner to give the
last product that is ready for the inspection purpose. In this the checking is also done for the
vehicle which is ready to out as a product. But the large part of checking is done only in the
inspection.

An assembly line is a manufacturing process in which parts (usually interchangeable parts) are
added as the semi-finished assembly moves from workstation to workstation where the parts are
added in sequence until the final assembly is produced. By mechanically moving the parts to the
assembly work and moving the semi-finished assembly from work station to work station, a
finished product can be assembled faster and with less labour than by having workers carry parts
to a stationary piece for assembly.

Assembly lines are common methods of assembling complex items such as automobiles.

Similarly, MARUTI has 3 assembly lines in Manesar plant which carries out all the assembly
work.

Figure 3.7 Assembly

 INSPECTION

In this process the vehicle is examine at every point of misbehave that can be occur by the other
processes. In this the many of the tests of the vehicle are taken so that it can be send to the
aftermarket for the sale purpose. The sale of the vehicle only can be done if the clear chit from the
inspection is done. This is the one of the major part of the processes.
For this process many workers specially trained to inspect car for any type of dent, scratches or
any kind on defect if there, then to mark and report it are assigned at almost every station of the
assembly line.

Figure 3.8 Inspection

 S&D

This department also called as the sales and dispatch department in which the vehicles in
A large space after completion of the production and check resides for supplying the
Vehicles to the dealers connected with the MARUTI SUZUKI INDIA
LIMITED (MSIL). The dispatch process is done after checking it properly in the V.I.
Department also called as the vehicle inspection department. The dispatch is done by the
Big trucks which are used as a transport media. Here are approx. 35,000 vehicles can
Come in that space.

Figure 3.9 Sales and Dispatch (S&D)

 SPD

This department is also called as the spare parts dispatch in which all the spare parts are
transported to the sellers after proper arrangement of spare parts. These spare parts are supplied
by the vendors to MSIL which gets departed after the labelling on the spare parts. As per the
government policies MSIL supplies the spare parts for petrol cars 15 years and for diesel cars 10
years.

Figure 3.10 SPD (Spare Parts Department)

 CHAPTER 4: ASSEMBLY PLANT

This plant is the plant associated with the assembling of the vehicle overall parts with the frame.
After coming from the press shop, weld shop, paint shop vehicle comes to the assembly plant in
which all the parts are assembled to make the vehicle complete. This plant is having the three
main lines called as:

• Trim line

• Chassis

• Final line

TRIM LINE: This line is consisting of the line where after coming from the hot wax area the
unloading of doors takes place and thereafter the whole things such as the accessories as well as
the mounting are placed with the engine itself. It is divided in two lines such as the trim 1-2 and
trim 2-1 lines. This line deals with the overall fitment of the sun visors, airbags, actuators, engine
mountings, ECM, TBM, IP, fuel pipes, hose pipes, glass, A.C. vents etc.

CHASSIS LINE: This is the single line in which all the essential parts of the vehicles are
mounted one by one at this line starting from differentials is done and after that the engine
assembly is done. This gives the overall chassis of the vehicle to be complete structure with the
tightening of the fuels tanks with all the pipes needed. After that it goes to the final line.

FINAL LINE: At this line the final vehicle is completed it is also divided in two sub lines called
as the final 1-2 and final 2-1. This line comes after the coming from the chassis line. The final line
consists of the assembly of the last touch-up parts and gives the rise to a new vehicle to be
produced. In this essential parts such as the steering wheel, steering shaft. Tires, petrol 5 litre
approx. to every vehicle with the filling of the break oil, engine oil, coolant and many more.
4.1. ASSEMBLY PLANT MAP

Figure 4.1 Assembly Plant

Here at the plant we can see that the many of the lines such as we have explained about the all lines
are shown where the lines such as the trim, final, chassis, steering, door is shown which are the lines
or the heart of the plant. The whole assembly plant is shown where the assembly of the whole vehicle
is done which leads to give the whole vehicle to be turned out as a great activity.
4.2. STRUCTURE OF PLANT

DPM

SECTION
MANAGER

QUALITY PRODUCTION PROGRESS MATERIAL

LINE
INCHARGE

LINE
SUPERVISOR

LINE
OPERATOR

Figure 4.2 Structure of Plant

 CHAPTER 5: PROJECT WORK

5.1. INTRODUCTION OF THE PROJECT

The project is based on the controlling of dents in which the dents are controlled on the basis of
the fact that the system is followed by each and every steps of production as well as on the other
levels of the plant.

My work was to see every operator when they are working in which I have to see all the dents
done by them because of their mistakes such as by gun hitting, knee hitting, Extra force in
inspection time ,taking support of vehicle and many more.

Some sheets are given to me in whom I have to mention ok and not ok of the every operator doing
their work.

The awareness among the all of the operator by asking them not to do dent and do work carefully
is done by me in which the all the work assembly of the vehicle is done where assemble parts are
made from the other shops.

Firstly blanking is done after which the press shop works well which leads to go through the
gentry to its next step which is welding in which most of the welds are of spot welds and other
welds of MIG welding. After the welding process completes then the paint is done.

Afterwards the assembly and inspection at last is used to make the whole vehicle.
WHAT IS DENT?

A slight hollow in even surface made by blow or by the exertion of pressure. Dents can be
commonly seen in vehicles due to any of the reasons such as in MSIL dents occurs due to many
of the reason from the tool touching to the at last support of a body of the vehicles. The dents are
usually made on the vehicles by the man fault.

This usually done by the operators working in the organization but the effect of it is that the
vehicle gets rejected for some time and after removal of the dent it gets dispatch to the next level.

Figure 5.1 Dent

5.2. CAUSES OF DENTS IN VEHICLES
1. At the time of loading.

2. Chances of gun and limit wrench hitting.

3. Chances of jig hitting.

4. Torque and marking of bolts.

5. Nut tightening chances of dent.

6. Possibility of operator knee hitting.

7. Possibility of thumb dent on doors while opening of doors.

8. Possibility of gun slip.

9. Taking support of the body.

10. Mobile phone at the pent.

11. Due to the button of the pent if the safety belt is not wear.

12. Hammer hitting or tool hitting.

13. Fuel filling gun hitting.

14. Pipes may hit the vehicles.

15. Material bin may fall of the rack and hit the body.

16. Tool may hit the vehicle.

5.3. DISADVANTAGES OF DENTS:

1. Cost of repairing the dent.

2. Production failure.

3. Lead time increases,

4. Defects in vehicle increases.

5. Company cannot achieve zero defect policy.

6. Productivity decreases.

7. Surplus of the vehicles.

8. Holding cost increases.

9. Paint quality decreases.

10. Vehicle looks decreases.

11. Customer satisfaction cannot be achieved.

12. Company gets its reputation down.

13. Supply will get decrease.

5.4. MOTIVATION BEHIND PROJECT

To do this project our motivation was the dents which were increasing day by day this leads to
decrease the trust of the company with the consumer and customer which was not a good sign for
the company.

Our mentor Mr. Ghansham motivated us to do this project so as to give the learning behind the
project which was really as good as sugar. In their opinion this is the one of the major things
which is really having the potential to grow further in this field. Today in every abnormalities of
the vehicle one of the major tasks are to control the dents. The dents are greater as compared to
other abnormalities. So as to increase the length of feet we were able to do the project on the
vision of the mentor.

We were only focusing to decrease the dents by awareness and by understanding them. The
whole project is one of the most demanding projects which really worth because of the dents the
whole vehicle gets rejected which leads to increase the cost, time, work flow and other key
factors which affect the vehicle most.

It is a major problem in the field of automobile where a vehicle gets rejected by mainly due to
dents and not only by other key factors. We have seen many of the data last year and month
which was really seems to be the increment of dents during the period where we thought to
decrease them by controlling it. The whole data after analysis we find that it should need
improvement so we took the project to deal with it and finally we were able to do by their efforts
for us to do the project.

In our six months of project we have got the opportunity to control the dents that are coming in
the vehicles of MSIL for that we have followed on regular basis that the effect of dents on the
vehicles are various which can be explain later.

Project plays a key role in the vehicle manufacturing process and any other automobile industry.
My project is based on the vehicle inspection process which is done in every automobile industry
to ensure that every vehicle produced by the industry meets the quality and grade the promise to
offer to the customer.

Vehicle inspection consist of various processes and checks at almost every level of vehicle
manufacturing in every station of paint and assembly station My supervisor is stationed for
proper checking of the vehicle manufacturing.

The job of a V.I inspector is to check that when the vehicle assembly is complete, to check

1) All the electronics works properly

2) All the mechanical systems are running perfectly
3) To check that the car is dent and scratch less

During my project research, I found that the most defects due to which the vehicle doesn’t get
clearance were many but the main three defects due to which the vehicle doesn’t get clearance
were

1) Dents
2) Scratches
3) Press shop defects

There are many other small defects which results to the not clearance of vehicles which are like
shortage of parts from the vendor, improper fitments of bolts and many other delays.

So we selected to work on dent inspection as a project

Under dent inspection the main area of inspections were weld repair area and the paint shop

The basic process for the vehicle inspection was to check every corner of the body were dents
could be possible to occur either by manufacturing process by the different press in the plant or
by the workers who encounters the vehicle body while working on it.

Defects occur during vehicle inspection

8%
8%
Dents
9% Scratches
Press defects
54%
Product shortage
Others
21%

Figure 5.2 Defects Occur During Vehicle Inspection

5.5. SCOPE OF THE PROJECT

The project is having the potential to grow further up to next level in which in future the project
gives the information about to decrease the Dents in any of the organization.

The project is mainly focusing on the automobile companies where it is having the large
possibility to improve in which we can apply it to the industries to get the results of the less dents
by providing the quality data and enhance the level of understanding among the operators as well
as the supervisors.

The whole project is having the potential to increase the automotive industry by the simple
application of it in plants. The whole project is focused on the removal or the control of the dent
so that it cannot be occur. It can be increase its application by the continues application of it as
well as the likeminded people should do the brain storming which will definitely give the results
as we want and the targets would be achieved in less time.

The whole automobile industry gets losses and pending orders due to the dents occurred in them.
The whole can be easily removed by the complete elimination of it in zero defect policy. The zero
defects can be achieved only by the enhancement of the project as well as the application of it in
large manner.

The controlling of dents having the wide use of it in the automotive industries because of the
reality behind money loss, time loss and the main which is companies image loss is one of the
major points to be focused while working to improve the overall system by the generation of
good quality projects.
 CHAPTER 6: THEORITICAL AND TECHNICAL ASPECTS

6.1. CHECKING METHODS OF DENTS:

1. CHECK SHEET: A check sheet is a document in which the overall vehicle checking is done
at every station with their stamp of OK and not OK of the vehicle. This sheet is consisting of
the all the views of the vehicle such as the front view, top view, side views. The check sheets
are separate for every vehicle in which the detailed checking at every step from first to last
step is done. The overall check sheet is stamped by the operators to show that the condition is
OK or not.
The dent is analysed by the check sheet and the views on it show that the dents at point
located by the help of the monitoring process at the last of final line.

The picture of a check sheet is shown:

Figure 6.1 Checking Methods of Dent (Check sheet)

2. AUDIT SHEET: This sheet is used for the purpose of getting the number of operations
which are the directly or indirectly affecting the dents in a vehicle. This is also called as the
dent audit sheet which leads to give the checking the operators that whether they are
mistaking or not in any operation which can cause dent in the vehicle overall structure. The
audit sheet consists of the causes, processes etc. to check that the possibility of dent can be
there. The dent supervisor can check easily by locating the mark of N.G. (not good) and
O.K.in the audit sheet.
The audit sheet is shown in the picture as:

Figure 6.2 Checking Methods of Dent (Audit Sheet)

3 INVOICED VEHICLES AUDIT SHEET (ONE WEEK TASK)
This sheet gives the overall detail about the vehicles which are having the introduction about the
vehicle where we have to find among the 35,000 vehicles. These were the vehicles model called
Celerio. This was the 1-week work for me and my team and we have cleared the result given.

Total no. of vehicles =38

N.G. = 15

OK = 10

NOT FOUND = 13

Figure 6.3 Invoiced Vehicle Audit Sheets

 CHAPTER 7: ONE MONTH DENT INSPECTION

PROBLEM: To determine the cause of dent on the door of the vehicle and determine the location
of the station where the dents are suspected.

SOLUTION: I have assigned a task to deal with in which I have watched out every station where
the left side rear door has chances to get a dent in accordance to the mentor we have find out the
station where we have thought out that this might be the cause of dent.

Figure 7.1 One Month Dent Inspection

Here the lever of the door hanger was seems to be the main reason of getting the dent so we have
inspected it thoroughly and got that the spring of the lever was in wear condition and corrosive
itself.

Figure 7.2 Corrosive Spring

This was inspected and found by us and what we have found that there were many other hangers
which were infected by the corrosion so that because of that the operator was unable to pull out
the lever gently which causes the dent. The whole process was affected due to it.
Here are some numbers of hangers we founded during the inspection which are at right hand side
so R is used.

R-129

R-120

R-031

R-076

R-122

R-099

R-075

R-145

R-148

R-153

R-122

These were found after the inspection of the vehicles where in assembly plant the assembling of
485 vehicles per day occurs.

Now after getting the main cause what we have done is to get a solution so the concerned
department is contacted where the information is given to them about the dent.

Here supervisor of the station get disappointment about the dents and the solution is done after
replacing the springs of these hangers and the marks are putted so that operator can understand the
limit about the door and some instructions were giving to the operator as well to holding of the
hanger lever as well as how to do the work properly.
 Figure 7.3 New Replaced Spring

Here in the figure we can see the change in the spring of the hanger which were same as for other
hangers which were mentioned above. Other than this the hangers get the marking on it so that it
can be easy to them to put the door on the hanger which was almost 1 day work for the worker.
 CHAPTER 8: INSTRUCTION SHEETS

Sheets that are used for the purpose of giving the right directions for the work to the operator are
called as the instruction sheets.

Here the instruction sheets can be read out at the starting time of the work, at lunch or the tea breaks
given by the company.

Two types of the instruction sheets commonly found in the company.

1. WORK INSTRUCTION SHEET:

Figure 8.1 Instruction Sheets (WIS)

Work instruction sheet short called WIS is the bunch of sheets used for the purpose of in case of
any unknown wants to know or any labour want to know about the process of machine then he
can easily get to know about it

Which is beneficial for others to know that how a machine is working and what are the main role
of the skilled labour.

The main focus of the WIS is on the safety as well as the skill of the worker.
The overall skill of the worker is depends upon how they are doing a work.
In this the measurement of the every machine is written as well as the steps of the machine
working are also be given by them. Every machine has allotted a WIS which gives the basic
knowledge about the overall operations in every machine.

2. SAFETY INSTRUCTION SHEET:

Figure 8.2 Instruction Sheets (SIS)

These bundles of sheets we can find at every station as the station has its own safety standards so
to deal with it we have to use the instruction sheets
Which is having the details to deals with the procedure of safety, key points as well as the right part
to be picked out by the PIKA PIKA system. This system is having the support to deal with the parts
to be picking up is a right one and it is going at right place. Generally it includes the pictures as well
which is having the right way of doing it.

CHPTER 9: OBJECTIVE OF THE PROJECT

The objective of the project is to control the dents in the industry by the application of the
systematic adjustment plans as well as the development of the awareness among the whole
employees. When we were doing this project we were focusing too aware the workers about the
dents because of the reason that in every 7 months they have to change the workers so the
awareness was necessary.

Other than awareness which was really a big challenge to us we were focusing on the
systematically working of the Workers in a manner that they should follow the system in order to
do the work properly. This was a big task for us to deal with it and watching out at every step that
who is doing work in a wrong way. Our objective was to achieve the quality standards by
systematically.

The efficiency of the workers should be proper at every station of the every line which can be
either trim line, final line. We were focusing on their holding of the tools, putting the tool at its
position where it should be at place. To reduce the time we have did the efforts by checking at
every possible points where the dents can occur and always following the system. Our objective
was to achieve the quality standards in a manner that the quality at every point should be
constant.

Our objective was mainly focusing on the abnormal activities should not be possible during the
running of the plant by any of the person such as workers in the plant. Here at the back end we
were also focusing to develop the good relationship among the workers as well as us so that they
will be unable to do any abnormal things knowingly. So the
Relationship management was one of the main focusing area of us which was our objective.

CHAPTER10: SOFTWARE REQUIREMENTS

We were having the requirements of the software such as the Microsoft Excel, Microsoft office
word, PowerPoint as well as the notepad were used to make sheets as well as to make the data
which was analysed. Whole software’s were used to improve the report as well for writing it. The
excel was used by the company to deal with the every sheet to be made on it. They were
protected as well as

CHAPTER 11: TESTING

The testing of the project is done in MSIL where it is used as the one of the precious application of the
project. In which the use of it gives the controlling of dents and these dents were able to enhance the
quality as well as the quantity of the production day by day. During our testing what we have found
that the application of the project leads to continues improvement in case of dents.

The testing phase of the project is done with the help of our mentor who had done a great job in
controlling the dents. The dents were decreased with the help of him as well as the management
performed activities.

We have tested it out and the results are very true which really worth to an organization to the
controlling of dents in any automobile industry.
CHAPTER 12: OUTPUT OF THE PROJECT

dent

5%

20%

60%

30%

40%

january february march april may

Figure 12.1 Pie Chart

It was really quite easy after applying our efforts.

As the above provided data is given from January to May we can see that the effect of the dents were
increasing day by day so we thought that this should be brought down by the effective application of
the project now at the column chart it can be seen.

The dents and months relationship charts can be seen in the column chart where the decrement can be
seen.

At the above Pie chart the effectively analysis of the dents is shown which we called as an output.
This output really needs to be applied again and again in an organization.
 DENT CHART

70%

60%

50%

40%
DENT
30%

20%

10%

0%
JANUARY FEBRUARY MARCH APRIL MAY

Figure 12.2 Slope Chart

At the above dent chart we can see that the continuous decrease in the slope of the dents can be seen
where from the month by month the dents are decreasing itself. The whole efforts are done by the
whole team as well as with the effort of the mentor itself.

It can be seen that in the graph from 6 dents to 1 dent in months we have achieved with our hard work
at all the station from final line to trim line as well as the paint shop was considered.

All the proofs we have seen in the technical aspects as well as in theoretical aspects. The output is the
combination of the charts as shown.
 CHAPTER 13: FUTURE WORK/IMPROVEMENT

The future work on it is to make it very simple which can be one with the effective brain storming as
well as the organizational efforts which is very relevant to company in order to make the future very
bright in case of the dents.
Proper R&D is required in the field of dents where the dents should be analysed deeply with the help
of the big team as well as with the tie ups of the big organizations. Every organization should think
about it so that the problem will be zero defects.
Now all the organizations are going towards the zero dents policy where the dents are being the
obsolete day by day so we have to focus only on it which is also doing the MSIL.
They have the zero defect policy where they are thinking to enhance the working environment day by
day.
In which the workers are the biggest challenge which are gets changed in every 7 months which
causes to give cost on training as well as the lack of skill among them causes to give many dents due
to it.
So it can be done by the organizational efforts and the efforts of the individual with dedication to its
organization.
REFERENCES
www.google.com/quora/marutisuzuki

www.wikipedia.com

www.marutisuzuki.com/Maruti_Suzuki

Trainer: Mr. JS Sethi, Maruti Suzuki Training Academy

Mentor: Mr. Ghansham, Supervisor