Professional Documents
Culture Documents
PREFACE
Summer training is an integral part of our academic curriculum. During the training a student gets an opportunity to set the practical aspects of theory. I feel great pleasure in submitting this piece of work as my summer training project. I hope that this work will create a will to read and learn from this project. It is expected that creation of this study shall benefit reader in all aspects regarding Production of Automobile Switch and method to control rejections. I have used my best efforts to cover nearly all the aspects related to Rejection Control and Increase in Productivity in MRPL, Pune. The working title of the project is Rejection Control and Increase in Productivity used by Mindarika Pvt. Ltd. for making Tata Nano Lever Combination Switch. It was conducted in a very cordial manner. This research is an attempt to present a report based on practical knowledge acquired during my training. In my opinion, the readers will be satisfied with the project and its application. I assure that this work is my original work and its authenticity it true to the best of my knowledge and believe.
ACKNOWLEDGEMENT
A journey is easier when we travel together. Interdependence is certainly more important than independence. It will always be my pleasure to thank those who have helped me generating this project, a lifetime experience for me. I would like to express my heartiest gratitude to AIT School of Management, Greater Noida, for providing me an opportunity to accomplish this summer training in Mindarika Pvt. Ltd., Pune in the Department of Production. The important persons associated with this study did add value to this study and without their guidance and my hard work it would have never been possible to avail a real life experience of working with N. K. Minda Group, an original equipment supplier for TATA Motors having a national importance. The major objective of the study was to understand the problems related to rejection and searching a reason and method of rejection control. I feel pleasure to extend my gratitude to Mr. D. N. Bajpai (Director of AITSchool of Management, Greater Noida) for providing me an opportunity to work with Mindarika Pvt. Ltd. And learn various aspects of the Rejection Reduction process and Increase the Productivity of the organization. It is my privilege to thank Mr. Sunil Kulkarni (Manager, Assembly Dept., Mindarika Pvt. Ltd., Pune) and Mr. Anurag Bharadwaj (Asst. Prof, AITSchool of Management, Gr. Noida) whose guidance have enabled me to learn and understand the finer and complicated aspects of Production, in general and of Rejection Control and Increase in Productivity, in particular. The help and guidance which he has extended to me has made me feel as being an integral part of the continuous learning. The greatest credit goes to the blessings bestowed upon me by Almighty God without whose yearning; I could not have even moved a step forward and to my parents who are always a constant source of inspiration in all my endeavors. ABHIJEET CHANDEL Roll No M2011001
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CERTIFICATE
This is to certify that the project "Rejection Control and Increase in Productivity used by Mindarika Pvt. Ltd. for making Tata Nano Lever Combination Switch is the bonafide project work done by Abhijeet Chandel student of Apeejay Institute of Technology- School of Management, Greater Noida during the Summer Internship Training, in partial fulfillment of the requirements for the award of the Degree of Post Graduate Diploma in Management and that the project has not formed the basis for the award previously of any degree, diploma, fellowship or any similar title. To the best of my knowledge and belief the project represents independent and original work on the part of candidate under my guidance.
DECLARATION
This is to declare that the facts and figures used in this report have been true to the best of my knowledge. All the data provided has been authentic as far as their sources are concerned.
TABLE OF CONTENTS
1. INDRODUCTION (A) About the UNO MINDA-where the study was conducted..08 (B) About the Mindarika Pvt. Ltd., Pune...................................20 (C) About the Tata Nano30 (D) About the Tata Nano Lever Combination Switch..................................................................................32 2. Research Objective...52 3. Research Methodology.....54
Introduction
This identity manual defines the corporate identify of the N K Minda Group and determines the various areas of the application. The main aspect in this is that of correct logo usage. These guidelines are to be strictly followed in all communication. Deviations from this, where absolutely necessary, have also been explained. The manual also attempts at simple application and an easy understanding. These guidelines and design specification have a binding effect on all custodians of the UNO MINDA brand and shall as a general rule apply to the companys internal and external communication. Only if these specification are consistently complied with, will the desired uniform appearance of the brand UNO MINDA can be achieved.
Think
We are a thinking entity. We accord value to applying thought in all aspects of operation. We appreciate bold and loud thinking; we place a premium on original thought. We encourage it. We celebrate it. For, we truly believe that it is the quality of our collective thought that makes us who we are.
Inspire
Inspiration is the key to our being. A cornerstone in our belief and value systems. We inspire and in turn are inspired. We aim to inspire trust, confidence, convocation and commitment in all who come in our contract. In turn, we are inspired by the higher ideals of growth, of value creation, of contribution and of the possibility of being the best we can be. Always
Flourish
Our destination is beyond mere growth; for we believe the quality of growth is an important as the growth itself. So while at heart we are a business, our soul beats for responsible and inclusive growth. Growth in human capital. Growth with professional values. Growth in the happiness quotient all around. We believe that when everyone grows, all stakeholders flourish
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Mission
To continually enhance stakeholders value through global competitive while contributing to society.
Values
The N K Minda Group has identified 5 core values and works towards inculcating these in its day-to-day working.
Customer is supreme
We understand and anticipate customer need and exceed their expectations. We aggressively pursue new business, determined to add value for our customer with ingenuity, determination and a positive approach to every task, a can-do sprit We always ask How can we serve our customer best?
Live Quality
We nature quality as an attitude at UNO Minda We are quality driven and Apply a Quality Minded Approach to everything we do. We are passionate about quality and its continuous improvement through teamwork.
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Registered Office:
B-64/1, Wazirpur Industrial Area Delhi 110052
Chief Executive of UNO MINDA : Mr. N K Minda - Chairman and Managing Director
UNO Minda Group Companies Minda Industries Limited Minda Industries Limited (Battery Division) Mindarika Pvt. Limited Minda Acoustic Limited Minda Autogas Limited Minda Emer Technologies Limited Tokairika Minda India Private Limited Minda International Limited Minda Auto Components Limited Minda Autocare Limited PT Minda Automotive Asean Minda Vietnam Company Limited
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Achievements of UNO MINDA 2011 2010 2010 2010 2010 2010 2010 2010 2010 2010 2009 2009 2009 2008 MRPL Manesar received ACMA Bronze Trophy for Excellence in Technology in the Non SME Category MRPL Manesar received ACMA Gold Award for Manufacturing Excellence BAL TPM EXCELLENCE AWARD to Minda Switch Pune Plant MINDA Acoustic received Outstanding Performance Award - 2010 from Mahindra Automotive & Farm Equipment Sectors MIL Blow Molding received Best Localization Award from Toyota Kirloskar Motor, Bangalore MRPL Manesar received Gold Trophy in Good Green Governance Award MRPL Manesar Received Gold Award from Quality Circle Forum Delhi Chapter MRPL Manesar received Energy Conservation Award from Government of India Grand Development Award 2010-11 to MIL Switch Div. from HMSI TAFE has awarded Minda-Lighting Sonepat as a SELF CERTIFIED SUPPLIER ACMA Silver Trophy for Excellence in Technology in the NON SME Category this year. (MIL 2wh Switch - Gurgaon) ACMA Gold Trophy for Recognition under Manufacturing excellence this year (MINDARIKA PVT. LTD) ACMA Gold Trophy for Recognition under Quality & Productivity excellence this year. (MIL 2wh Switch Pantnagar) "Excellence in Quality" award from TATA Motors. The award was conferred on 16th Oct 2008 during Tatas Annual Suppliers Meet 2008 held in Mumbai.
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2007 2007 -
Minda launches Automotive batteries for OEM and Aftermarket Minda Industries Limited wins the National R&D Award 2007 by Department of Scientific & Industrial Research, Ministry of Science & Technology Bajaj Award for Excellence to Minda Industries Limited Achievement Award from Honda for quality & delivery to Minda Industries Limited Received TKML cost achievement award for Mindarika NABL accreditation for Minda Industries Limited labs Received TS 16949 certification for Lighting Division Received TS 16949 & ISO 14001 certification for Horn Division Received ISO 14001 and OHSAS 18001 certification for Switch Division Received TS 16949 and ISO 14001 certification for Mindarika Received Maruti's Manufacturing Excellence Award for Mindarika Received FORD Q1 award for Mindarika Implemented ERP-BAAN in Mindarika Won 1 st prize in Honda Supplier Quality Circle Competition for 2nd time in Mindarika Won 1
st
2005 2005 -
2004 2004 2003 2003 2003 2003 2003 2003 2001 2001 -
Received QS 9000 certification for Horn Division Implemented ERP-BAAN in Mindarika Started BEST (Business Excellence through Simple Techniques) journey in association with CII Won 1st prize in Honda Supplier Quality Circle Competition in Mindarika Won Runners Up trophy in CII North Region Quality Circle Competition Won Safety & Environment Award from Haryana State Labour Department in Mindarika Received Maruti's Best Performance Award 2 Received QS 9000 certification for Mindarika Received Maruti's Best Performance Vendor Award in Mindarika Received ISO 9001 certification for Switch Division other switches Received ISO 9001 certification at Mindarika Got approval as R&D Centre for Ministry of Science and Technology
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time in Mindarika
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4 Wheelers Switchers
Mindarika is consistently winning accolades across categories of products in the automotive switches segment. The belief is to offer innovative solutions for clients problems and to serve them better through customer-centric solutions. The range of products includes: Lever Combination Switches Signal Switch Light Switch Dimmer & Passing Switch Wiper Switch Washer Switch Hazard Switch Besides these, on offer are additional features like: Intermittent Time Control RR Washer / Wiper Switches Horn Switch
Panel Switches
Hazard Warning Switch RR Defog Switch FR Fog Lamp Switch RR Fog Lamp Switch RR Wiper Washer Switch Blower & A/C Switch A/C Switch
4 Wheelers Horns
Minda Acoustics Limited prides itself on its development skills and capabilities. It has developed horns right from fundamental horn design stage. HN9 ( 90mm dia Disc horn) - 12V / 24V ( High Tone & Low Tone) Trumpet Horn - 12V / 24 V (High Tone & Low Tone) K-95 (95mm dia Disc horn) - 12V / 24V ( High Tone & Low Tone)
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4 Wheelers
Off Road
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International Customers
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Mindarika Pvt. Limited, with Rs. 1.30 billion (USD 32.12 million) in revenue, is India 's largest four wheeler automotive switch manufacturer. Mindarika Pvt. Limited has consciously evolved into a complete design and development centre for four wheeler automotive switches. It offers customised solutions to the automotive industry in the realm of product improvisation and new product development and has very strong localization capabilities. The core strengths at Mindarika are skilled manpower, adherence to the highest quality standards and providing cost effective solutions. Milestones: 1992 Ist TAA with Tokairika Japan for OPS & others. 1994 2nd TAA with Tokairika Japan for Combination Switches. 1995 Certified for ISO-9002. Established Joint Venture company Mindarika Limited. 1996 Received ISO 9001 certification. 1996 Start of Production at Gurgaon Plant Received Maruti's Best Performance Vendor Award 1998 Achieved QS 9000 (Design Responsible) certification Received Maruti's Best Performance Vendor Award 2000 Started Exports to Japan 2001 Implemented BaaN IV ERP package Received Safety and Environmental Awards from Haryana Labour Department 2002 Started Exports to USA 2003 Achieved TS 16949 & ISO 14001 Received Maruti's Manufacturing Excellence Award Recommended for Ford Q1 Award 2004 2005 2006 Received award for BEST COST PERFORMANCE (INNOVA Program) from TKML Runners up award for "Supplier Of The Year" from Toyota Kirloskar Motors Limited Received awards for Tier 2 Vendor upgradation and Kaizen & MPS from Maruti Suzuki 20
Major Products
Switches
Mirrors
Seat Belts
Air Bags
Emblems
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Mindarika Products
Lever Combination Switch Power Window Switch Head Lamp Leveling (HLL) Switch Stop lamp Switch Door Lamp Switch Clutch Switch Reserve Light Switch Heater Ventilation Air Condition (HVAC) Switch Blower Switch Cigarette Lighter Switch Hazard Warning Switch Panel Switch Mirror Switch
Door Switch
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3. Fiat
5. Ford
6. Honda
7. Maruti Suzuki
8. Volkswagen(VW)
9. Toyota
10. Hyundai
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Mindarika has two design studios located at Manesar & Pune with top-of-the-line CAD-CAM software with 68 dedicated CAD seats, with more than 100 experienced and technically competent product designers and well-developed facilities to create the latest innovative designs for the customers. The company has 50 Workstations of PRO-E Wildfire 2 and is the largest user of the same among Tier-1 suppliers in India. It also has 13 Workstations of I-DEAS 10 NX. Some of the finest design softwares like PRO Engineer Wildfire II, I-DEAS Simulation NX 12, Alias, Rhinoceros, Adobe Photoshop, Adobe Illustrator and Image ware are used by the designers to produce the designs best suited to customer requirements. This softwares are extensively used for 3D styling and to check the surface details, assembly, mating parts and seamless movements.
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2. Quality Circles
Quarterly Inter-unit competition Sending teams to QCFI, CII Quality Circle meets.
3. 5S Activities Special emphasis is paid to 1S & 2S 1S- Seiri (Sorting Out) 2S- Seiton (Organising) 3S- Seiso (Cleaning) 4S- Seiketsu (Standardization) 5S- Shitsuke (Disciline)
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4. Visual Control
Helps in Information sharing, monitoring & control. Easy accessibility of relevant information.
5. Morning Meeting Morning meetings (lasting 5-10 minutes) are held everyday in all departments. This is for Information sharing and action on most critical issues of the day.
6. Morning Exercise Light Exercises are conducted everyday morning. It sheds all traces of fatigue and laziness after the journey to the plant.
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7. Monthly Unit Address Important Information & monthly Company results are shared by Management with all members of the organization. Awards for significant achievements are distributed to employees.
8. Birthday Meeting All employees with birthday in a given month celebrate. The occasion is also used to take feedback and suggestions from employees. Action is taken by the management on these suggestions for implementation.
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The Tata Nano is a city car manufactured by Tata Motors. One of the smallest as well as lowest powered (35 PS (26 kW)) cars in the world, it was designed to be the cheapest car in India aimed mainly at the lowest price segment in the Indian domestic market.[5] The Nano sold in India is a 624cc, rear-engine (for a less complex and hence cheaper transmission), manual transmission, four-passenger, four-door car. The car lacks power steering and safety features like air-bags and ABS. The car was launched in the Indian market in March, 2009. With a pre-launch price offer of 100,000 (US$ 2100). Among other reasons, new emission regulation forced Tata to refine the engine with a higher price tag.
Expectation of Tata Nano In 2008 the Financial Times reported: "If ever there were a symbol of Indias ambitions to become a modern nation, it would surely be the Nano, the tiny car with the even tinier price-tag. A triumph of homegrown engineering, the Nano encapsulates the dream of millions of Indians groping for a shot at urban prosperity. Homegrown engineering" is a relative term here as many of the systems and parts used in the Nano may not have been developed or produced in India. 30
Many have had great expectations for this small car, some perhaps going a bit too far. One study, by Indian rating agency CRISIL, thought the Nano would expand the nation's car market by 65%. It was also anticipated that the 2009 launch of the car would greatly affect the used-car market, with prices dropping 25-30% in the lead up to the launch. However, due to limited supply (customers had a waiting period of up to one year) used-car prices reverted to their former figures. Sales of new Suzuki Alto-based Maruti 800s (considered the Nano's nearest competitor) dropped by 20%, and used ones by 30% immediately following the unveiling of the Nano. As Autocar journalist Mark Rainford summarizes: People are asking themselvesand uswhy they should pay, say, 250,000 Rupees for a Maruti Alto, when they can wait and get a brand new Nano for less in a few months time, a car that is actually bigger.
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MRPL is one of the leading manufacturers and suppliers offering a wide range of precision engineered Combination Switches to the valued clients. These switches are widely used in electrical & automobile industries for their various applications. Moreover, this switch is produced in compliance with the set industry norms and standards. MRPL holds expertise in offering a wide range of combination switch to the Tata Group. This switch is manufactured using quality raw material, which is obtained from vendors of the market and also some material are manufactured in MRPL. MRPL switch is extensively demanded in the automobile industry for Tata Nano. These products have gained immense appreciation from Tata Group for the following featuresAccurate Finish Optimum Performance High Efficiency
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Material Name used for making Tata Nano Lever Combination Switch Body CP and Body Mounting and Cancel Clip Cancel Cam Spring Horn Pin and Spring Retainer Plate Screw, Clamp Screw and Screw Tapping Traplight-A Lighting Body Cover Return Cancellation Slide, Lifter, Slide Spring, Lifter Spring and Cam Light Lever Holder Spring Moving Contract Knob Light Lower RH Cord CP RR Wiper Knob Wiper Light Detent Piece Spring Wiper Detent Knob Wiper Light Piece and Lever Light Pin Slotted 6 Pole Connector Terminal A, B, C, D, E and F Cam Dimmer Contract Point Plunger Washer Hazard Contract Holder Push ROD Knob Hazard Sticker Grease Marutemp-D, Pamarabu-JH-10 Solder Wiper Contract Terminal Rivet
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Production Process of Tata Nano Lever Combination Switch Process of Light Module
Insulator Soldering Cord CP RR Wiper Low Version Soldering Contract Soldering Wiper and Fog Testing Doubling Becket Holding Terminal Reverting CAM Dimmer Wiper and Contract Holder Hazards Contract Holder Sub Assembly
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Body Cover Sub Assembly Light Model Locking Assembly Light Model Triaging Final Testing Process of Wiper Module
Insulator Soldering Cord CP RR Wiper Low Version Soldering Contract Soldering Wiper and Fog Testing Doubling Becket Holding
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Terminal Reverting Cam Dimmer Lower Doubling Wiper Contract Holder Doubling Wiper Lever Contract Holder Doubling Wiper Contract Holder Sub Assembly Washer Sub Assembly Wiper Body Batch Making Wiper Sub Assembly Wiper Screwing Final Testing
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Revised A Quality Control Concept is a small group consisting of first-line employees who continually control and improve the quality of their work, products and services. These small services Operate autonomously, utilize quality, control concepts and techniques and other improvement tools, top members creativity and promote self and mutual development.
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Step 12 Follow up
Method Implement evaluation procedure, use Control Chart, have six monthly reports for evaluation. Make modification if necessary.
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Guidelines for conducting Brainstorming in a structured manner Keep the participants, preferably, between six to ten. Give required time for incubation. Make it very clear to all the participants on what subject the Brainstorming is done. Enter the points on Black Broadly Flip Chart or in a Transparency for all to see. Explain the guidelines. One idea only at a time. Contribution in turn. You may pass. Clarify the point but dont explain the ideas. No criticism. If session losses grip, have a break or change. To bring creativity use five Ws and one H (When, Where, What, Who And Why and How) Get maximum number or ideas. Clarify each rule. Agree on an evaluation criteria.
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(2) Guidelines for Data Collection Useful points for Data Collection Be clear in mind about the objective. Prepare the question which will make it clear and precise. Collect data relevant to that. Use data sheet, check sheet and/or check list as per the requirement. Keep them simple and easy. Reduce opportunities for error. Capture data for analysis, reference and traceability. Form should be self explanatory. Analyze the collected data for its creditability and relevance. Present data in a way that clearly answer the questions.
(3) Guidelines of Cause and Effect Diagram How to use Cause and Effect Diagram Preparing itself is an education process. It can be used as a guide for discussion. You can use it to find out reasons behind the causes in a systematic manner. A detailed Cause and Effect Diagram making exercise helps to have an in-depth knowledge about the process. It can be used for any kind of a process. Some Dispersion Analysis Type of Cause and Effect Diagram (a) An arrow with the box made and the defect is written.
Defect in a cricket match
(d) For each sub cause sub cause identified Not enough steamers in India
(4) Guidelines for making Histogram Take some observation and put them in data sheet Find the minimum and maximum in each line and circle them. Make the lowest and highest value. Compute the range. Calculate the approximate width of class intervals based on the formula (R + W)
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(5) Guidelines for making Pareto Diagram These are data of 150 defectives out of 100 fans inspected and to make Pareto Diagram and rearrange data table.
Types of Defect Motor Winding Bend in fans blades Cracks on central rob Capacitor Scratched on Surface Regulator Bend in screws Others No. of Quantity 20 15 14 10 12 40 25 14
Now arrange them in a table showing Types of defect Number of defect Cumulative %age of defect to total Cumulative %age
Types of Defect Regulator Bend in Screws Motor Winding Bend of Winding Cracks in Central Rob Scratches Capacitor Others
No. of Quantity 40 25 20 15 14 12 10 14
Cumulative %age 27% 44% 57% 67% 76% 81% 91% 100%
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160 140 120 100 80 60 40 20 0 Problem Code %age of total Cumulative %age
(6) Guidelines for constructing Control Chart Collect samples at fixed internal and record the measurement. Total the value for each subgroup. Calculate the average for each subgroup (X). Calculate the overall average. This is called X. Determine the range for each subgroup. Calculate the average range. Calculate the control limit for X Determine the scale for the graph and plot the graph.
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100 50 0
Parking Off
1. Parking Not Working Cause and Effect of Lever Combination Switch Machine Preventive maintenance not done. Machine operator at high pressure. Pretesting not available for sub assembly testing. Man Wrong assembly in process. Process Quality Control Sheet(PQCS) and Operator Guidance Sheet(OGS) not followed. Check points not check properly. Unskilled associate. Method Handle of Material improper. Poor checking at Standard Quality Control (SQC) end. Improper Contract.
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Cumu
Material Sequence not followed. Production Control Chart (PCC) not followed. Incorrect inspection at Right Control Chart (RQC).
2. Passing Not Working Cause and Effect of Lever Combination Switch Machine Preventive maintenance not done. Machine operator at high pressure. Man Wrong Assembled. Careless in process. Process Quality Control sheet(PQCS) and Operator Guidance Sheet(OGS) not followed. Unskilled Associate. Method Handling of material improper. Dimensionally material not ok. Poor Checking at Standard Quality Control (SQC) end. Material Sequence not followed. Production Control Chart (PCC) not followed. Check point not check properly. 3. High Speed Wiper Not Working High speed wiper not working Contract not made Extra plastic on contract demand Sample checking in parts production Agreed to take action 100% inspection Standard 48
Changes in Tata Nano Lever Combination Switch by 4Ms Change Sheet to help Rejection Control and Production Increase Man New Operator. Operator resumes work after internal of > 1 month. When required work sequence is changed on assembly line. Machine New Machine/tooling. Setting of Machine is changed. Machine is started against after repair due to failure. Any improvement, modification or replacement due to failure. Material Any change through ECN i.e. source, material gradual etc. Defect occurred the component. Method Change in process. Change in inspection method. Working method change due to quality concerns. Change in layout.
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Research Objective
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Research Objective
Rejection Reduction and Production Increase for making Tata Nano Lever Combination Switch.
Its Action To study how to control the rejection. To study how to increase the production. To study the aspects of better utilization of (3Ms)material, man and machine. To study to take necessary corrective actions to control the rejection and its impact on increasing the production. To study to locate and identify the manufacturing process faults in order to control and minimize scrap and waste.
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RESEARCH METHODOLOGY
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RESEARCH METHODOLOGY
Type of research: Descriptive Descriptive research includes surveys and fact finding enquiries of different kinds. The major purpose of descriptive research is description of the state of affairs as it really exists at present. The main characteristic of this method is that the researcher has no control over the variables; he can only report what has happened or what is happening. Type of data collected: Primary Data as well as Secondary Data
Primary data is facts and information collected specifically for the purpose of the investigation at hand. Data collection method: Survey method.
Data collection technique: Interview and telephonic. Universe of the study: Sampling technique: Pune Convenient Sampling.
The researcher chooses the sample based on who they think would be appropriate for the study. This is used primarily when there are a limited number of people that have expertise in the area being researched. Sample size: 100
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20 - 30 30 40 40 50 50 & Above
40% 35% 30% 25% 20% 15% 10% 5% 0% 20 - 30 30 40 40 50 50 & Above Series1
Interpretation - The above diagram exhibits that 22% of the respondent 20 30 age group, 37% of the respondent 30 40 age group, 27% of the respondent 40 50 age group and 14% of the respondent 50 & above age group to buy Tata Nano.
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Q2. Do you think that Tata Nano should be banned from largely populated city?
Yes No
67% 33%
Yes No
Interpretation - The above diagram exhibits that 67% of the respondents were of the opinion that it should be banned from city and 33% of the respondent agreed to use in city travel.
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Q3. Do you think Tata Nano Lever Combination Switch is easy to handle and convenient in its operation?
Yes No
89% 11%
Yes No
Interpretation - The above diagram exhibits that 89% of the respondents prefer this switch and 11% of the respondent did not prefer.
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Q4. Are you satisfied with quality of Tata Nano Lever Combination Switch?
Yes No
91% 9%
100%
Interpretation - The above diagram exhibits that 91% of the respondent are satisfied this switch and 9% of the respondent are not satisfied this switch.
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Interpretation - The above diagram exhibits that 43% of the respondent improves by works, 32% of the respondent improves by products and 25% of the respondent improves by service.
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Q6- Which module of Tata Nano Lever Combination Switch needs to be improved?
65% 35%
80% 60% 40% 20% 0% Light Module Wiper Module Series1 Series1
Interpretation - The above diagram exhibits that 65% of the respondent light module to be improved and 35% of the respondent wiper module to be improved.
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Light Body Cover Light Lever Holder Lever CP Light RH 6 Pole Connector Others
Series1
Interpretation - The above diagram exhibits that 27% of the respondent light body cover to be improved, 22% of the respondent light lever holder to be improved, 21% of the respondent lever CP light RH to be improved, 17% of the respondent 6 pole connector to be improved and 13% of the respondent others materials to be improved.
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Light Body Cover Light Lever Holder Insulator CP Wiper RH 6 Pole Connector Others
Light Body Cover Light Lever Holder Insulator CP Wiper RH 6 Pole Connector Others
Interpretation - The above diagram exhibits that 30% of the respondent light body cover needs to be improved, 21% of the respondent light lever holder needs to be improved, 21% of the respondent insulator CP wiper RH needs to be improved, 17% of the respondent 6 pole connector needs to be improved and 11% of the respondent others materials needs to be improved.
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Q9. At what stages inspection should take place in manufacturing of Tata Nano Lever Combination Switch?
44% 56%
Interpretation - The above diagram exhibits that 56% of the respondent process flow needs to be improved and 44% of the respondent quality flow needs to be improved.
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Q10. In Process Flow, at what stages inspection should be considered in manufacturing of Tata Nano Lever Combination Switch?
Trial Run Inspection First Off Inspection Inspection by Self-Control Decentralized/Floor/Patrolling Inspection Centralised/Crib Inspection
Interpretation - The above diagram exhibits that 29% of the respondent trail run inspection to be considered, 23% of the respondent first off inspection to be considered, 21% of the respondent inspection by self-control should be considered, 16% of the respondent decentralized/floor/patrolling inspection should considered and 11% of the respondent centralized/crib inspection should be considered.
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Q11. In Quality Flow, at what stages inspection should be considered in manufacturing of Tata Nano Lever Combination Switch?
Average Out Going Quality(AOQ) Accepted Quality Level(AQL) Rejected Quality Level(RQL) Operation Characteristic Curve(OCCurve)
Interpretation - The above diagram exhibits that 32% of the respondent average out going quality (AOQ) should be considered, 27% of the respondent accepted quality level (AQL) should be considered, 23% of the respondent rejected quality level (RQL) should be considered and 18% of the respondent operation characteristics curve (OC-Curve) should be considered.
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Finding
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Finding
An old Chinese saying goes: If you don't know where you are going - you will never get there. The Rejection Reduction and Increase in Productivity in Tata Nano Lever Combination Switch is a holistic exercise which starts from the time a prospective borrower walks into the plant and culminates in control the quality and monitoring with the objective of ensuring and maintaining the quality of material and managing production. All the efforts have been made to portray a close picture of the approach of rejection reduction and increase in productivity in switch. The telephony and the interview taken gives a clear indication of a general attitude of individuals towards the credit undertaking and their knowledge regarding the terms and conditions of the plant.
Most of people are satisfied with the quality of Tata Nano Lever Combination Switch that is manufactured in MRPL.
Most of people want to improve light module of Tata Nano Lever Combination Switch because there have single handle in light module.
Most of people want to improve light body cover in light module of Lever Combination Switch.
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Most of people want to improve also light body cover in wiper module of Lever Combination Switch.
Most of people want quality flow inspection should take place in manufacturing of Tata Nano Lever Combination Switch.
Most of people want trail run inspection in process flow should be considered in manufacturing of Tata Nano Lever Combination Switch.
Most of people want average out going quality (AOQ) in quality flow should be considered in manufacturing of Tata Nano Lever Combination Switch.
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There should be review of quality control and increase in productivity based on manufacturing Tata Nano Lever Combination Switch.
It should bring more clarity to the goal and vision of the organization.
It should provide more quality control and increase in productivity by the employees for manufacturing Tata Nano Lever Combination Switch.
New method of quality control and increase in productivity adopted for completing the target of manufacturing of Tata Nano Lever Combination Switch.
Employees and Customer should provide the feedback regarding the products. It will help the organization to improve the weak areas of quality and performance.
Adopt new technology for rejection reduction and increase in productivity for which employees would be motivated to produce quality switch.
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New mechanism should be evolved to reduce the time factor involved in procedure of quality control and increase in productivity.
The frequency for training program for quality control and increase in productivity should be increased and this session should be interactive.
The awareness sessions for the employees should be made more interactive and the views and opinion of the production regarding quality control and increase in productivity should be given due consideration. Assistance should be sought from specialists for framing a proper quality control production system that suits the organization target for manufacturing of switch. Constant monitoring of the quality control and production system should be done through discussions, suggestions and interactions.
Use of modern quality control techniques like Average Out Going Quality (AOQ), Accepted Quality Level (AQL), Rejected Quality Level (RQL) and Operation Characteristics Curve (OC-Curve) which are more effective.
More transparency should be brought in the quality control and production system.
Information regarding the quality control and increase in productivity of the switch should be kept in proper manner.
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LIMITATIONS
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LIMITATIONS
The following are the limitations with this report Limited time available for study. Difficulty in getting data as data provider (staff) where quick busy in their work. The research is confined to a certain parts of Pune and does not necessarily shows a pattern applicable to all of Country. Thus, the study might not produce absolutely accurate results as it was based on small sample taken from the population. Some respondents were reluctant to divulge personal information which can affect the validity of all responses. In a rapidly changing industry, analysis on one day or in one segment can change very quickly. The environmental changes are vital to be considered in order to assimilate the findings.
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BIBLIOGRAHY
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Bibliography
1. Dr. B. S. Goel, Production & Operations Management, Pragati Prakashan, Meerut, Eighteen Edition 2005.
Search engines
1. www.google .com 2. www.unominda.com 3. www.mindarika.com 4. www.wikipedia .com
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QUESTIONNAIRE
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Study on Rejection Control and Increase in Productivity used by Mindarika Pvt. Ltd. for making Tata Nano Lever Combination Switch
I am Abhijeet Chandel, student of PGDM-IV trimester from AIT-School of Management, Greater Noida. I am doing field survey on Rejection Control and Increase in Productivity used by Mindarika Pvt. Ltd. for making Tata Nano Lever Combination Switch. Please cooperate and help me by giving your valuable answer to the Questionnaire given below. Which help me in reaching to my goal? This document will be kept confidential and will not be shared with anyone. The study is purely academic and it is a part of our curriculum of PGDM course. PERSONAL PROFILE NAME _ ---------------------------------------------------------------Age_ -----------------------------------
Questionnaire
Q1. Which age group of people to buy Tata Nano? (1) 20-30 [ ] (3) 40-50 [ ] (2) 30-40 [ ] (4) 50 & above [ ]
Q2. Do you think that Tata Nano should be banned from largely populated city? ? (1) Yes [ ] (2) No [ ]
Q3. Do you think Tata Nano Lever Combination Switch is easy to handle and convenient in its operation? (1) Yes [ ] (2) No [ ]
Q4. Are you satisfied with the quality of Tata Nano Lever Combination Switch? (1) Yes [ ] (2) No [ ]
Q5. If no then how to improve it? (1) Works [ ] (3) Service [ ] Q6. Which module of Tata Nano Lever Combination Switch is to be improving? (1) Light Module [ ] (2) Wiper Module [ ] (2) Products [ ]
Q7. In Light Module, which material to be improves? (1) Light Body Cover [ ] (3) Lever CP Light RH [ ] (5) Others [ ] (2) Light Lever Holder [ ] (4) 6 Pole Connector [ ]
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Q8. In Wiper Module, which material to be improves? (1) Light Body Cover [ ] (2) Light Lever Holder [ ]
Q9. Where inspection should take place in manufacturing of Tata Nano Lever Combination Switch? (1) Process Flow [ ] (2) Quality Flow [ ]
Q10. In Process Flow, where inspection should be considered in manufacturing of Tata Nano Lever Combination Switch? (1) (2) (3) (4) (5) Trail Run Inspection [ ] First Off Inspection [ ] Inspection by Self-Control [ ] Decentralized/Floor/Patrolling Inspection [ ] Centralized/Curb Inspection [ ]
Q11. In Quality Inspection, Where inspection should be considered in manufacturing of Tata Nano Lever Combination Switch? (1) Average Out Going Quality (AOQ) [ ] (2) Accepted Quality Level (AQL) [ ] (3) Rejected Quality Level (RQL) [ ] (4) Operation Characteristics Curve (OC-Curve) [ ]
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