An

INDUSTRIAL REPROT
on
CQA (Central Quality Assurance) Dept
Submitted in the Partial Fulfillment for the requirement of the
award of Degree
!Te"h
In
#e"hani"al Engineering
at
$PIET% #eerut
Submitted To& Submitted '&
Mr. D.D. Johri Ravikant Kumar
!D ".#ech$ %&& 'em
(Mechanical Department) Roll (o. ))*+*,--.*
$P In(titute of Engineering Te"hnolog'
Ra)*ura% #awana Road% #eerut
DE+LARATION
#his trainin/ pro/ram has 0een un1ertaken 1urin/ the summer 0reak *-), as a trainee 0y
me a2ter completion o2 my thir1 year un1er the /ui1ance o2 my mentor Mr. 'an3ay Kumar
(Quality Department).
4urther & 5oul1 like to 1eclare that this pro3ect is my ori/inal 5ork an1 has 0een prepare1
solely 2or aca1emic purpose.
#his pro3ect has not 0een presente1 in any seminar or su0mitte1 else5here 2or the a5ar1
o2 any 1e/ree or 1iploma.
Date6
7lace6 Ravikant Kumar
A+,NO-LED.E#ENT
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TRAININ. DETAILS
NA#E & RA%&KA(# K9MAR
/EAR & *-),
OR.ANI0ATION & MA&(DRA @ MA&(DRA ?t1.$
7A#(A ("&AR)
PLA+E OF TRANIN. & '!(A?& A9#! 7%#. ?#D$
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DESI.NATION OF .UIDE & Mr. 'A(JA= K9MAR
PERIOD & 4R!MA )B J9(: *-), #o C) J9?= *-),.
DURATION & 12 DA='.
FIELD OF TRAININ. & Q9A?&#= D:7AR#M:(#
TALE OF +ONTENTS
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INTRODU+TION OF +O#PON/
3i(tor'&
4e5 /roups can i1enti2y as closely 5ith &n1iaEs 1estiny an1 in1ustrial pro/ress as the
Mahin1ra 8roup. &n 2act$ Mahin1ra is like a microcosm o2 &n1ia. "oth 5ere 0orn aroun1
the same time$ ha1 the same aspirations an1 0oth eFperience1 the inevita0le trou/hs an1
crests in the 3ourney to5ar1s their /oals. An1 0oth continue to march on the path to
pro/ress an1 /lo0al reco/nition.
#he 0irth o2 Mahin1ra @ Mahin1ra 0e/an 5hen K.C. Mahin1ra visite1 the 9nite1 'tates
o2 America as Chairman o2 the &n1ia 'upply Mission. e met "arney Roos$ inventor o2
the ru//e1 E/eneral purpose vehicleE or Jeep an1 ha1 a 2lash o2 inspiration6 5oul1nEt a
vehicle that ha1 prove1 its invinci0ility on the 0attle2iel1s o2 <orl1 <ar && 0e i1eal 2or
&n1iaEs ru//e1 terrain an1 its kut cha rural roa1sG
'5i2t action 2ollo5e1 this thou/ht. #he Mahin1ra 0rothers 3oine1 han1s 5ith a
1istin/uishe1 /entleman calle1 8hulam Mohamme1 @ on !cto0er *n1$ )H,B$
Mahin1ra @ Mohamme1 5as set up as a 2ranchise 2or assem0lin/ Jeeps 2rom <illys$ 9'A.
#5o years later$ &n1ia 0ecame an in1epen1ent nation an1 Mahin1ra @ Mohamme1
chan/e1 its name to Mahin1ra @ Mahin1ra. 8hulam Mohamme1 mi/rate1 to 7akistan
postApartition an1 0ecame the 2irst 4inance Minister o2 7akistan.
'ince then$ Mahin1ra @ Mahin1ra has /ro5n stea1ily in siIe an1 stature an1 evolve1 into
a 8roup that occupies a premier position in almost all key sectors o2 the economy. #he
8roupEs history is stu11e1 5ith milestones. :ach one takin/ the 8roup 2or5ar1. &n2act$
to1ay$ its total turno4er i( about 5!6 billion dollar(!
Mahin1ra is a /roup in a hurry$ en/a/e1 in an am0itious$ sustaine1 an1 prolon/e1
penetration into the /lo0al arena. &ts spirit can 0e encapsulate1 in the 5or1s o2 the poet
Ro0ert 4rost$ a 2avourite o2 &n1iaEs 2irst 7rime Minister$ 7an1it Ja5aharlal (ehru6
J#he 5oo1s are lovely$ 1ark an1 1eep$
"ut & have promises to keep$
An1 miles to /o 0e2ore & sleep$
An1 miles to /o 0e2ore & sleep.J
4or Mahin1ra @ Mahin1ra$ this translates into many more milestones to 0e set up 0e2ore
it rests &2 ever.
The .rou* at a .lan"e
Automoti4e
K Domestic !perations
K &nternational !perations
K Mahin1ra Renault 7rivate ?imite1 (MR7?)
K Mahin1ra (avistar Automotives ?imite1 (M(A?)
K Mahin1ra (avistar :n/ines 7rivate ?imite1 (M(:7?)
After7#ar8et Se"tor
K Mahin1ra 'pares "usiness
K Mahin1ra 4irst Choice
K Mahin1ra 4irst Choice <heels ?t1.
Farm Equi*ment Se"tor
K Domestic !perations
K &nternational !perations
K Mahin1ra 8u3arat #ractor
K Mahin1ra A/ri0usiness
K Mahin1ra 7o5ere1
K Mahin1ra 9'A
K Mahin1ra Australia
K Mahin1ra China #ractors
Finan"ial Ser4i"e( Se"tor
K Mahin1ra @ Mahin1ra 4inancial 'ervices ?t1 (Mahin1ra 4inance)
K Mahin1ra &nsurance "rokers ?t1.
K Mahin1ra Rural ousin/ 4inance ?t1 (MR4?)
Infra(tru"ture De4elo*ment Se"tor
K Mahin1ra oli1ays @ Resorts
K Mahin1ra ?i2e spaces Developers ?imite1
K Mahin1ra <orl1 City
K Mahin1ra &n2rastructure Developers
K Acres Consultin/ :n/ineers
Information Te"hnolog' Se"tor
K #ech Mahin1ra
K "ristlecone
#ahindra 9 -heeler(
#ahindra S'(te"h
K 4or/in/s
Mahin1ra 4or/in/s ?imite1 A &n1ia
Mahin1ra 4or/in/s :urope A A/
A 8'A
A 'chono5eiss @ Co 8M"
A J:C!
A 'tokes 9K
A 4alkenroth
K :n/ineerin/ 'ervices
Mahin1ra :n/ineerin/
:n/ines :n/ineerin/ &taly
Mahin1ra Aerospace
K 'tampin/s
K 'teel
K 4errites
K Contract 'ourcin/
K #elematrices
K Composites
K Castin/s
K 8ears
S*e"ialit' u(ine((e(
K Mum0ai Mantra
K Mahin1ra De2ense 'ystem
#ahindra Partner(
K Mahin1ra !1ys sea
K Mahin1ra &nter tra1e
K Mahin1ra 'teel 'ervice Center
K Mahin1ra Mi11le :ast :lectrical 'teel 'ervice Centre (MM:''C)
K Mahin1ra ?o/istics ?t1.
K Mahin1ra Retail
DEPART#ENTS OF T3E +O#PAN/
#here are many 1epartments in the company 1escri0e1 0elo56
).CQA (Central Quality Assurance) Dept.
*.R @ D (Research @ Development) Dept.
C. ?o/istics Dept.
,. 7ro1uction Dept.
B. &#>' Dept
.. 7D@C (7ro1uct Development @ Control) Dept.
D. Maintenance Dept.
+. 'QA Dept.
+:A ;+entral :ualit' A((uran"e< De*t&
#he /eneral o03ective o2 Luality assurance 1epartment is to enhancement o2 pro1uct an1
service Luality an1 an increase o2 customer satis2action. #o achieve this o03ective$ CQA
shoul1 reach the 2ollo5in/ /oals6
K Continuous an1 consistent 1evelopment$ implementation an1 maintenance o2
Luality assurance mana/ement system.
K 'ta22 trainin/ an1 compliance 5ith the reLuirements o2 the Luality assurance
Mana/ement.
K Quality control over provi1e1 pro1ucts an1 services in accor1ance 5ith #he Rules
an1 'tan1ar1s o2 the company.
K Developin/ an1 makin/ arran/ements 2or enhancin/ the Luality o2 provi1e1
pro1ucts an1 services.
K !r/aniIin/ an1 con1uctin/ internal au1it o2 the Luality assurance mana/ement system.
K !r/aniIin/ an1 controllin/ corrective an1 preventin/ actions o2 Luality
mana/ement.
K Control over eLuipment an1 pro1uction process.
K Control over pro1uct output.
K &nvesti/ation o2 customer claims.
R = D ;Re(ear"h = De4elo*ment< De*t!
#he phrase re(ear"h and de4elo*ment (also R and D or$ more o2ten$ R=D)$ accor1in/
to the !r/aniIation 2or :conomic CoAoperation an1 Development$ re2ers to Jcreative
5ork un1ertaken on a systematic 0asis in or1er to increase the stock o2 kno5le1/e$
inclu1in/ kno5le1/e o2 man$ culture an1 society$ an1 the use o2 this stock !2 kno5le1/e
to 1evise ne5 applicationsJ
(e5 pro1uct 1esi/n an1 1evelopment is more o2ten than not a crucial 2actor in the
survival o2 a company. &n an in1ustry that is 2ast chan/in/$ 2irms must continually revise
their 1esi/n an1 ran/e o2 pro1ucts. #his is necessary 1ue to continuous technolo/y
chan/e an1 1evelopment as 5ell as other competitors an1 the chan/in/ pre2erence o2
customers.
Logi(ti"( De*t&
#he 5ork o2 lo/istics 1epartment is to provi1e the inventory to the company. &t ensures
the 1eman1 o2 a company an1 provi1e su22icient inventory to the company 5hen
reLuire1.
Produ"tion De*t&
#he 5ork o2 pro1uction 1epartment is to ensure the market 1eman1 an1 to pro1uce the
pro1uct accor1in/ to it. 'o the measure concern o2 pro1uction 1epartment is the Luantity
o2 the pro1uct that is 1eman1e1 in market.
IT De*t&
#he 5ork o2 &# 1epartment is to ensure the connectivity o2 server to the computers an1 to
check the 1ata o2 all computers 5ith an au1it. #he au1it takes a2ter a constant perio1 or
su11enly to check unuse1 1ata.
PD=+ ;Produ"t De4elo*ment = +ontrol< De*t&
#he phrase pro1uct 1evelopment @ control$ accor1in/ to the !r/aniIation 2or :conomic
CoAoperation an1 Development$ re2ers to Jcreative 5ork un1ertaken on a systematic 0asis
in or1er to increase the stock o2 kno5le1/e$ inclu1in/ kno5le1/e o2 man$ culture an1
society$ an1 the use o2 this stock o2 kno5le1/e to 1evise ne5 applicationsJ
(e5 pro1uct 1esi/n an1 1evelopment is more o2ten than not a crucial 2actor in the
survival o2 a company. &n an in1ustry that is 2ast chan/in/$ 2irms must continually revise
their 1esi/n an1 ran/e o2 pro1ucts. #his is necessary 1ue to continuous technolo/y
chan/e an1 1evelopment as 5ell as other competitors an1 the chan/in/ pre2erence o2
customers.
#aintenan"e De*t&
#he maintenance 1epartment ensures the 5orkin/ con1ition o2 machines in the company.
Means maintenance 1epartment 5ork on the maintenance o2 machines use1 in
pro1uction. &t also ensures the timin/ o2 plant o2 5hole assem0ly line.
LI#ITATIONS
#he limitations o2 the company are 1escri0e1 in terms o2 Do>s an1 Don>ts in the
!r/aniIation.
Do>( and Don>t( in the Organi?ation&
DoEs an1 Don>ts means 5hat shoul1 0e 1one an1 5hat shoul1 not 0e 1one in the
!r/aniIation.
Do>(&7
K 7unctuality(timeliness)$
K Maintainin/ healthy @ cor1ial relationship 5ith the people in or/aniIation.
K 9n1erstan1in/ the 5ork culture.
K !0eyin/ 1irect or1ers 2rom the seniors.
K 'ho5in/ a sense o2 0elon/in/ 5ith the or/aniIation.
K Maintainin/ proper ?ine an1 'ta22 Relationship 5ith the seniors an1
su0or1inates (&2 Any)
Don>t(&7
K Do not take the trainin/ li/htly an1 casually.
K Do not /ive an impression that you are 1oin/ the trainin/ 3ust 2or the sake
o2 it. 7ut your heart an1 soul.
K Do not involve in internal politics.
K Do not reveal you 5eaknesses.
K Do not lie to your seniors.
K Do not 5aste your time.
K Do not copy any material. "e ori/inal.
K Do not /o 2or leave unless it is in1ispensa0le.
K Do not ask 2or 2avors.
-OR, E@PERIEN+E
& 5orke1 in the company as a trainee in CQA 1epartment an1 & learn many thin/s in the
company. #he eFperience cannot 0e 1escri0e1 in 5or1s. #he eFperience /aine1 0y me in
the company isM
De("ri*tion the de*artment I wor8ed in&
& 5ork in the CQA 1epartment 5hich 1escri0e1 0elo5
+:A ;+entral :ualit' A((uran"e< De*t&
Quality assurance is a part o2 Luality mana/ement 5hich represents a compleF process
2ocuse1 on creation o2 the con2i1ence that the correspon1in/ reLuirement to Luality is
kept$ an1 inclu1es all the 2actors an1 the actions nee1e1 2or achievement o2 the
appropriate Luality level o2 pro1ucts an1 services. Many enterprises have Quality
assurance 1epartments 5hich provi1e$ 1evelop an1 maintain a system o2 Luality
assurance mana/ement. 'uch system covers not only processes o2 samplin/$ 5orkin/
5ith speci2ications an1 or/aniIin/ researches$ 0ut also 1evelopment o2 1ocumentation
an1 techniLues 5hich /uarantee satis2actory Luality o2 pro1ucts an1 services.
#he 5ork o2 CQA is 2ocuse1$ 2irst o2 all$ on preventin/ the claims 2rom customers. &n
case o2 receivin/ such claims on Luality o2 provi1e1 pro1ucts an1 services$ the
1epartment starts searchin/ the reasons an1 e22ects o2 the reveale1 1iscrepancies. Quality
Assurance means the completion o2 a pro3ect in accor1ance 5ith the previously a/ree1
speci2ications an1 2unctionality reLuire1 5ithout 1e2ects an1 possi0le pro0lems.
#he /eneral o03ective o2 Luality assurance 1epartment is to enhancement o2 pro1uct an1
service Luality an1 an increase o2 customer satis2action. #o achieve this o03ective$ CQA
shoul1 reach the 2ollo5in/ /oals6
KContinuous an1 consistent 1evelopment$ implementation an1 maintenance o2
Luality assurance mana/ement system.
K 'ta22 trainin/ an1 compliance 5ith the reLuirements o2 the Luality assurance
Mana/ement.
K Quality control over provi1e1 pro1ucts an1 services in accor1ance 5ith #he Rules an1
'tan1ar1s o2 the company.
K Developin/ an1 makin/ arran/ements 2or enhancin/ the Luality o2 provi1e1
pro1ucts an1 services.
K !r/aniIin/ an1 con1uctin/ internal au1it o2 the Luality assurance mana/ement
system.
K !r/aniIin/ an1 controllin/ corrective an1 preventin/ actions o2 Luality
mana/ement.
K Control over eLuipment an1 pro1uction process.
K Control over pro1uct output.
K &nvesti/ation o2 customer claims.
"ase1 on our 5ish that 2uture /enerations may live in sa2ety an1 com2ort$ 5e are
a1optin/ the user perspective an1 al5ays aim to create an1 1eliver relia0le
pro1ucts that are environmentA2rien1ly an1 that /enerate true customer
satis2action.
&n or1er to ensure the e22ective$ positive operation an1 implementation o2 the
Luality mana/ement systems$ #Q' H--- Au1its are per2orme1$ 5hich also provi1e
2urther opportunities to raise Luality levels. 8ui1ance 2or &nternal Au1its is provi1e1
continuously an1 actions are taken re/ularly to enhance the skills o2 au1itors
so that #Q' H--- assessments lea1 1irectly to Luality improvements.
3uman Re(our"e :ualit'
Fo(tering qualit' awarene(( among em*lo'ee(
CQAEs Luality assurance activities are implemente1 un1er participation o2 the entire sta22.
Juman Resource QualityJ plays a ma3or role in achievin/ Luality that really inspires
customer satis2action.
<hat is reLuire1 o2 all employees$ 5hether they 5ork in research an1 1evelopment$
manu2acturin/$ or a1ministrative 1ivisions$ is maintainin/ a hi/h a5areness o2 Luality.
#his is premise1 on the philosophy o2 5orkin/ a5arenessM 5hat customer satis2action
means to CQA an1 5hat each in1ivi1ual shoul1 1o to achieve it.
&n a11ition to trainin/ an1 e1ucation$ practical implementation tests$ an1 in2ormation
sharin/$ Luality a5areness amon/ all employees is also raise1 throu/h 0est practices an1
JLuality enli/htenmentJ pro/rams. Quality relate1 2ee10ack 2rom the 2iel1 is al5ays
incorporate1 into these activities.
Fo(tering and im*ro4ing the (8ill le4el of qualit' engineer(
Quality en/ineers an1 technicians o2 course play a lea1in/ role in Luality assurance
activities. #heir operations are 1ivi1e1 into three ma3or cate/ories as 1epicte1 0elo5. &n
or1er to consistently create an1 1eliver hi/hALuality pro1ucts$ a 1eepAroote1 company
culture must 0e sustaine1 0y skills that are constantly up1ate1 an1 improve1. <e are
al5ays aimin/ at skill improvement an1 are trainin/ specialists in the respective 2iel1s.
+omment from a qualit' engineer
As a Luality en/ineer$ my 1aily 5ork involves the 1evelopment o2 metho1s 2or evaluatin/
the relia0ility o2 ne5 pro1ucts. #his is aime1 at pro1ucin/ hi/h Luality output an1 tryin/
to prevent pro0lems 0e2ore they happen. & try to /o to actual pro1uction sites as o2ten as
possi0le$ in or1er to see con1itions 2or mysel2 an1 to communicate 5ith the en/ineers an1
sta22 there. & 0elieve that sharin/ in2ormation in this 5ay helps us 1evelop 0etter metho1s.
At the same time$ 5e also apply trial an1 error techniLues in or1er to improve the
e22iciency o2 pro1uct evaluation. & 5ill continue to strive 2or even 0etter an1 more
meanin/2ul evaluation metho1s$ so that 5e can meet the hi/h eFpectations an1 3usti2y the
trust that customers are placin/ in us. #he en1 result is 0oun1 to 0e hi/her customer
satis2action.
Reliabilit' +enter
Reliabilit' +enter Anal'?e( and A((e((e( +:A Produ"t :ualit'% Reliabilit'% and
(afet'&
#he Relia0ility Center$ a su01ivision o2 the Quality Assurance Department$ is in char/e
o2 supportin/ relia0ility testin/ at the time o2 ne5 pro1uct 1evelopment$ assessment o2
ne5 pro1ucts$ an1 analyIin/ 2ailures o2 pro1ucts. &n a11ition to the #echnical Center in
&chika5a City$ Chi0a 7re2ecture$ the Center also has a testin/ site in the Akita re/ion.
#he results o2 analysis an1 assessments per2orme1 at each site are use1 to 1evelop hi/herA
Luality pro1ucts. #he Center also per2orms key research an1 technolo/y 1evelopment
5ork 2rom a lon/Aterm perspective$ inclu1in/ research on the latest electronics
technolo/ies$ to the research in the ne5 2iel1s that 5ill 0e also important to CQA
operations.
&n April *---$ the CQA Relia0ility Center o0taine1 &'!N&:C)D-*B certi2ication$ as the
2irst such site in Japan in the area o2 environmental testin/ o2 electronic components. #he
irasa5a site o2 the CQA Relia0ility Center o0taine1 &'!N&:C)D-*B certi2ication in
January *--D 2or chemical testin/ o2 harm2ul su0stances analysis.
Reliabilit' and Safet' Te(ting
CQA pro1ucts un1er/o ri/orous an1 eFtensive testin/ un1er every conceiva0le con1ition
to ensure that they 1eliver the per2ormance reLuire1 0y customers un1er their respective
use environments an1 con1itions. #hese tests veri2y that the teste1 pro1ucts have the
Luality reLuire1 un1er international an1 in1ustryA5i1e stan1ar1s$ customer stan1ar1s$ as
5ell as CQA internal stan1ar1s.
Failure Anal'(i(
#he Center analyIes 2ailures relatin/ to relia0ility an1 sa2ety$ clari2yin/ the root causes$
an1 provi1in/ the results to the 0usiness /roups 2or improvement.
A**li"ation Te"hnolog' Su**ort
#he Center provi1es support 2or practical application o2 technolo/ies in electronic
components inclu1in/ electro1e 2ormation$ terminal sol1erin/$ protection usin/ resin$ an1
packa/in/.
#ea(urement +ontrol +enter
7erio1ic cali0ration is essential to maintain an1 re/ulate the accuracy o2 measurement
eLuipment. "ase1 on a pro1uct Luality system that con2orms to &'! H--) stan1ar1s$
CQA operates sophisticate1 cali0ration eLuipment an1 hi/hly relia0le cali0ration services
inAhouse.
Measurement re2erence eLuipment meetin/ national an1 international tracea0ility
reLuirements is installe1 at the Measurement Control Center an1 is use1 to maintain an1
re/ulate the accuracy o2 the companyEs measurement 1evices. A company5i1e la0elin/
system 2or measurement 1evices serves 2or i1enti2ication$ an1 in2ormation on the 1evices
is recor1e1 an1 mana/e1 0y computer.
9sin/ a perio1ic sche1ule 0ase1 on accumulate1 past 1ata$ employees o2 the
Measurement Control Center make roun1s in the CQA Measurement #estin/ 'ervice
Car$ provi1in/ testin/ an1 cali0ration services.
&2 testin/ reveals a pro0lem$ the Measurement Control Center in2orms the 1ivision usin/
the measurement 1evice$ 5hich then 1eci1es in the most appropriate course 0ase1 on the
results o2 the tests.
<hen a pro0lem 5ith a measurin/ 1evice is 1etecte1$ environmental testin/ is per2orme1
as reLuire1 to 1etermine the relia0ility o2 the eLuipment an1 the 1e/ree o2 sta0ility.
#estin/ processes are automate1 as much as possi0le$ usin/ the latest stateAo2AtheAart
1evices$ in or1er to minimiIe the risk o2 human error an1 maFimiIe the accuracy o2
measurement 1ata.
An automatic cali0ration system 1evelope1 inA house aims at 2urther improvin/
measurement 1ata accuracy an1 spee1in/ up the cali0ration process.
+S ;+u(tomer Sati(fa"tion< A"ti4itie(
CQA supplies components as a 2la/ship pro1uct line not only to electronic 1evice set
manu2acturers 1irectly linke1 to en1 consumers$ 0ut also to assem0ly manu2acturers an1
component manu2acturers. &n 1oin/ so$ CQA makes every e22ort to ensure customer
satis2action (C')$ throu/h the three avenues as 2ollo5s$ an1 strives to achieve /eneral
satis2action$ encompassin/ Luality$ cost$ 1elivery$ environmental e22orts an1 services$ in
or1er to 0ecome the company o2 choice 2or potential customers.
Su**lier E4aluation Information
CQA o0tains the results o2 supplier evaluations as complete1 0y its customers. #he
evaluation ranks the 1i22erent levels o2 customer satis2action$ 5ith an JAJ in1icatin/ that
the customer is 2ully satis2ie1. CQA keeps track o2 chan/es in the percenta/e re/ar1in/
the A rank$ an1 passes this in2ormation to the relevant 1ivision responsi0le to improve
C'.
Produ"t7Related +om*laint(
CQA maintains a 1ata0ase o2 pro1uctArelate1 complaints 2ile1 0y customers 0oth in &n1ia
an1 overseas. &n2ormation is sent online to the involve1 1epartments 5ithout 1elay$ so
that s5i2t action can 0e taken to improve C'. &n a11ition$ this system is 1esi/ne1 to
automatically sen1 si/ni2icant complaints to top mana/ement.
+S E4aluation
&n or1er to 0ecome the supplier o2 choice 2or our customers$ our sales sta22 mem0ers
make sure that they un1erstan1 the nee1s o2 our customers. CQA makes every e22ort to
improve C' 0y Luickly un1erstan1in/ the 1etails o2 customer complaints$ an1 provi1in/
2ee10ack to the relevant 1ivisions so that they may take necessary reme1ial action. An1
there many su0 1ept. 2or checkin/ Luality o2 the pro1uct.
). 'tan1ar1 Room.
*.4A& (4inal Assurance &n2ection).
C.CA& (customer assurance inspection)
,.<RA7 (<arranty Relate1 Action 7oints).
B.R4& (Rea1y 2or &nspection).
..R4D (Rea1y 2or Dispatch).
D.(!%AAC ((e5 !verall %ehicle Au1itACustomer).
#hese all 1epartments are 2or the customer satis2action.
FOR STOPPIN. T3E E@TRA 3ARD-ARE PROLE#S
A< In the trim lineA 5e shoul1 have cover on the trolley.
9< Tool boBA some time tool 0oF is very 2ar 2rom the 5orkers. 'o &n every sta/e 5e
nee1 the
6< Accor1in/ to me the 0est 5ay to eliminate this type o2 pro0lemA
CFormal announ"ement i( mo(t im*ortant *ro"e((D.
"ecause the 5orkers only the 1epen1 upon their 5ork. #hey are not 1epen1 the ho5
much material is loosin/.
1< At La(t StageA <e can put the Ma/netic "oF.
2< #he eFtra person must 0e there nee1e1. 'ometime 1ue to 2ast 5orkin/ the 5orkers
1oes not concentrate.
5< 7roper person shoul1 0e place1 at their 5ork.
E< #he 8un may 0e ma/netic so 5e can han1le the har15ares easily.
Accor1in/ to checkin/ the 1e2ects 5e have 2oun1 one o2 the most pro0lem 5hich is
kno5n as :Ftra ar15are. 'o 5e shoul1 1o somethin/ to eleminate this pro0lem.
'o no5 & have 2oun1 my pro3ect report on this topicA
To eliminate the *roblem of EBtra 3ardware!
)A Need a eBtra *er(on for thi( wor8A
&t means 5e shoul1 provi1e a eFtra person at the last sta/e.
Accor1in/ to me this is one o2 the most metho1 to eliminate the eFtra ar15are in the
vehicles.
*A #o4able Rod7
<e can a13ust the mova0le ro1 in the tool 0oF.
&t can 0e a13ust into t5o stepsA
CA 3anging tool boB7
4irst o2 all 5e have most pro0a0ility to 2all the eFtra har15are in the vehicles
the neFt metho1 to avoi1 this type o2 pro0lem.
#here are many reasons 1ue to this process can 0e han1le. <e shoul1 concern the 5orker
in1ivi1uallyA
)) #he line inchar/e shoul1 have responsi0ility.
*) #o check the 5orkin/ on the line personally.
C) #ime consumin/ is must.
,) <e can not say 2or any 5orker to 0lame.
B) <orkin/ process is 2ast.
.) #he 5orkers are 1epen1 to each other.
D) 'o they 1o not 2it personally.
+) 8ive the seminar.
H) (ee1 a security.
)-) #ake a action 0y the line inchar/e @ supervisor.
))) <orkers are 2ree 2rom this type o2 kno5le1/e. 'o 5e shoul1 say.
PDI Data
Fehi"le "ha((i( no! Defe"t #odel
"B8CBD,) 7aintN7ress
"B8CB.+C 'cratch
"B8CBD.D !k
"B8CB+C* !k
"B8CB+** ?ock @ Rust 7aint
"B8CB+C) Door settin/
"B8CB+C- "i/ scratchN ?ock ti/ht
"B8CBDB) Rust paintN 0ea1in/
"B8CBDD* 'cratch
"B8CBD.+ Rust paint
"B8CBD.C 'cratch
"B8CB*,, MirrorN Rust paint
"B4C,+B+ 'tickerNscratch on 0onnet
"B4C*+,- ?ock ti/htNRust paint
"B8CB.BC 'cratch
"B8CBB*H ?ock ti/htNRust paint
"B8CB.-, 7aint pro0lem
"B8C,H+H Rust paint
"B8CB.+H !k
"B8CB.-) !k
"B8CBDB* Rust paint
"B4CC--) 'cratch
"B8CBD,, an1le loose
"B8CBDB+ :Ftra ar15are
"B8CBD,- 'cratch
"B8CBDBC ?ock ti/ht
"B8CBDBD Rust paint
"B8CBBB) Rust paint
"B8CBB*) Rust paint
"B8CC-+- Rust paint
"B8CB.D+ Rust paint
"B8CB..) Rust paint
A REIF INTRODU+TION
Mahin1ra 7A#(A 7lant is actually an assem0ly line plant normally involve1 in the
pro1uction o2
). "olero
*. Al2a
C. 8&!
,. Champion
B mo1els o2 "olero are 0ein/ pro1uce1 5hich are
). '?;
*. '?:
C. D&
,. ?on/er((onAAC)
B. ?on/er (AC)
7ro1uction o2 "olero involves assem0lin/ o2 parts at , 1i22erent levels or lines6
). #rim ?ine
*. Chassis ?ine
C. :n/ine ?ine
,. Main ?ine
Trim Line&
#rim line involves the 0o1y an1 its various 2itmentsM
#a)or Ste*(&
). Removal o2 4acia.
*.4itment o2 4elt$ 4ire5all$ 79 2oam$ Roo2 'ealer (i2 a0sent)$ Roo2 Coverin/$ etc.
C.Accelerator ca0le$ 'pee1o Ca0le$ "onnet Ca0le$ Clutch "ea1in/ 2itment.
,."rake "oosterM Accelerator$ Clutch an1 "rake 7e1al 2itment.
B.Com0ination ?amp$ &nstrument Cluster$ "attery 2itment.
..?ock an1 <in1screen 4itment.
D."lo5er 4itment an1 various arness 5ire 2ittin/s.
+ha((i( Line
Ste*( following in&
).Chassis inversion an1 Rear aFle 2itment.
*.'uspension 4itment involvin/ lea2 sprin/ an1 rear shock a0sor0er an1 upper an1
lo5er suspension arms alon/ 5ith sprin/s an1 shock a0sor0ers.
C.7ressure Application 2or 3oinin/ upper an1 lo5er suspension arms.
,.4illin/ 1i22erential oil an1 8" valve 2itment.
B.7o5er steerin/ $'tea1 5ire$ 'ta0iliIin/ 5ire 2itment.
..4uel tank$ 4uel pipe an1 "reather pipe 2itment.
Engine Line
Ste*(&
).7ressure plate an1 Clutch plate mountin/ on :n/ine.
*.Assem0lin/ #ransmission an1 :n/ine an1 mountin/ 0elt connectin/ :n/ine an1
po5er steerin/.
C.7o5er 'teerin/ oil tank an1 "rake 0ooster hose pipe 2itment.
,.:n/ine harness 2itment an1 some o2 its connections like /roun1 connections$
connections to compressor$ alternator$ 2uel in3ector pump an1 transmission system.
#ain Line
Ste*(&
). "rake 0ea1in/ 2itment (inclu1in/ that 2or han10rake) an1 connections to 8" valve an1
2ront an1 0ack 5heels.
*.:n/ine mountin/ on chassis$ propeller sha2t 2itment.
C."o1y mountin/ 2ollo5e1 0y 0asic connections such as "rake "ooster$ connections$
"attery connections$ 7o5er 5in1o5 s5itch connections etc.
,.4ascia preparation involvin/ ea1li/ht 2itment$ coolant tank 2itment etc.
B.Ra1iator 4itment 2ollo5e1 0y 4ascia Mountin/$ "rake an1 Clutch "lee1in/ an1
#ire mountin/.
.. orn an1 "onnet ?ock 2itment$ Air 2ilter mount an1 ea1li/ht an1 AC pipe connections.
D. Ac /as 2illin/ $ 'teerin/ 2itment an1 2inally <iper 4itment.
+ON+LUSION
-hat did I learnG
'ummer trainin/ serves as the only 1irect eFposure to an or/aniIation an1 its 5ays o2
2unctionin/ 1urin/ the entire curriculum. #he summer trainin/ in any technolo/y course
is very important 2or the stu1ents an1 it 5ill help in 2uture 5hen an stu1ent /oes to
company.
CThi( *rogram i( the mo(t effe"ti4e aid in enabling the (tudent( to relate te"hni"al
theor' to *ra"ti"e% and in ma8ing an informed "areer "hoi"e!H
Courses are inten1e1 to provi1e a crossA2unctional orientation in 0asic technical concepts$
Luantitative metho1s an1 analytical skills. 'ince imme1iacy o2 application is not stresse1
at this sta/e$ the person can take his o5n time to re2lect on the su03ects an1 internaliIe the
concepts. !nce this conceptual 2rame5ork is in place$ it nee1s to 0e teste1 un1er real li2e
con1itions. #he technical institutes cannot simulate the real li2e con1itions o2 an en/ineer.
Althou/h innovative tools like case stu1ies 1o attempt to a11ress these limitations$ they
2ail to capture the reality. #here2ore$ 5e nee1 some mechanism 0y 5hich trans2er o2 skills
takes place 2rom the classroom to the 5orkplace. 'ummer trainin/ 0eauti2ully 2ills this
/ap. &t /ives him a chance to eFperiment 0ecause mistakes are not penaliIe1 5hile har1
5ork is 1e2initely re5ar1e1. (ot only 1oes a stu1ent /et an opportunity to implement the
concepts$ 0ut skill learnin/ is 2aster 0ecause o2 the constant an1 imme1iate 2ee10ack 2rom
his peers an1 mana/ers.
'tu1ents$ especially those 5ith little or no 5ork eFperience$ are sli/htly con2use1 a0out
the 1iscipline in 5hich they 5ant to specialiIe an1 pursue their career. 'ummer trainin/
/ives them an opportunity to closely interact 5ith the or/aniIation an1 help i1enti2y the
pros an1 cons o2 various career choices. Arme1 5ith this kno5le1/e an1 un1erstan1in/$
they can take an in2orme1 1ecision a0out the port2olio elective courses in 5hich they
5ant to specialiIe.
Prof! ,! Unni8ri(hnan Nair (a'(&
#he stu1ent shoul1 not ri/i1ly con2ine himsel2 to the narro5 0oun1aries o2 the pro3ect
5hich he is currently un1ertakin/. e shoul1 also o0serve the processes$ interactions an1
the human relations in the or/aniIation. Just o0servin/ people at their 5ork coul1 0e a
tremen1ous learnin/ eFperience.
Durin/ his summer trainin/$ 5hich is 2or a perio1 o2 oneNt5o months$ the trainee /ets to
see the culture o2 the or/aniIation$ ho5 the or/aniIation copes 5ith crises an1 ho5 the
en/ineers han1le stress un1er varie1 situations. <hen he /oes 0ack to the institute$ he can
share his eFperiences 5ith his 2ello5 classmates an1 learn 2rom their &n1ivi1ual
eFperiences. #his 5ill help him in not only mentally preparin/ himsel2 a0out the li2estyle
an1 pressures o2 a en/ineer 0ut also evolvin/ a 1istinct 5ay o2 1ealin/ 5ith 1iverse
0usiness situations.
3ow will thi( eB*erien"e hel* me in the futureG
#he meanin/ o2 #rainin/ is to learn a skill. #rainin/ is the act o2 increasin/ the
kno5le1/e an1 skill o2 a person 2or 1oin/ a particular 3o0. #rainin/ ena0les to acLuire
latest skills$ thus increase versatility 2or Luali2ication 2or 0ustin/ carrier. &t provi1es 0etter
sa2ety$ remuneration an1 security. &t also ena0les to 1rive /reater satis2action an1 utiliIe
the 2ull skills an1 capacity. 7roper trainin/ teaches proper operation an1 chan/es the
5ron/ attitu1e an1 also tells the sa2e points.
=ou 3ust ima/ine stu1ent 5ho are in *n1 an1Nor Cr1 year o2 their 1e/ree course ri/ht no5
they 5ill spen1 a 2e5 years 2inishin/ colle/e an1 a 2e5 year 3ust learnin/ the ropes at
their 2irst 3o0. 'o it 5ill really 0e a0out B year 0e2ore their career really starts. <hat 5ill
the so2t5are technolo/y 5oul1 0e like at that stu1ent can 5ork on acLuirin/ ri/ht no5 to
ensure that they are 5ell positione1 to thrive.
'ummer trainin/ 2or en/ineerin/ stu1ents is important 0ecause it is the time to o0tain as
much kno5le1/e a0out their 2iel1. As an en/ineerin/ stu1ent$ trainin/ can help you to
implement the concepts you learne1 at your classes. A2ter learnin/ concepts 2rom
pro2essors$ lecturers an1 also 2rom 0ooks 5e 2eel like 5e no5 kno5 everythin/ an1 5e
can no5 1evelop any type o2 pro/ram 0ase1 on those concepts 0ut the 2act is that learnin/
a concept an1 implementin/ a concept 0oth are 1i22erent thin/s$ 0oth are ti/htly couple1
0ut still there are 1i22erences. &t is true that 5ithout learnin/ a concept you can>t
implement it$ 0ut 3ust learnin/ a concept 1oesn>t mean that you can correctly implement
it.
Actual challen/es appear 5hen 5e have to 1evelop realA5orl1 so2t5are. All the
so2t5areNpro/ram 0ase1 on the concepts you may ha1 alrea1y learne1 1urin/ your
en/ineerin/ course$ 0ut there are lot more thin/s involve1 in 1evelopin/ a live application
(that is to 0e use1 0y some 0usiness or/aniIation) an1 those thin/s can 0e learne1 only
2rom a /oo1 so2t5are companies pro1uctive environment an1 never tau/ht at classes.
#rainin/ helps you to learn those thin/s that are availa0le only at pro1uction environment
an1 0y 5orkin/ on a live pro3ect.
#rainin/ 1evelops con2i1ence in 5hatever 5e have learne1. A2ter completin/ trainin/
you 5ill 2eel much con2i1ent a0out your 2iel1. &2 your concepts not clear or you have
con2usions 5ith them$ then at the time o2 intervie5$ eFams or in pro2essional li2e you 2ace
many pro0lems. All eFperience1 people al5ays like to hear accurate to the point solution
to every pro0lem$ your carrier 1epen1s on your sharpness$ intelli/ence an1 o2Acourse your
con2i1ence. 'o as much as possi0le$ clear your con2usions an1 /et ne5 i1eas o2 your
2iel1s 5ith the help o2 summer trainin/$ pro3ect trainin/ an1 0ecome con2i1ent an1
sincere a0out your 2uture.
REFEREN+E
555.mahin1ra.com
555. 5ikipe1ia.com
555. so2tpe1ia.com