TATA MOTORS

PROJECT ON
REVALIDATION OF SIGNA LINE

UNDER THE SUPERVISION OF

Mrs Ushashi Chakraborty

()

SUBMITTED BY- SATISH MISHRA

SHRI RAMSWAROOP MEMORIAL COLLEGE OF ENGINEERING AND
MANAGEMENT, LUCKNOW

1
 DEPARTMENT OF MECHANICAL ENGINEERING, 3RD YEAR

CONTENTS

1. Acknowledgement
2. About Company
2.1 Company Profile
2.2 History
3. Work Measurement System
4. MOST
5. SIGNA Line
6. BIW SHOP
7. Layout of CAB Line
8. MOST Revalidation of Front Wall SIGNA Line
9. Conclusion

2
 ACKNOWLEDGEMENT

I Satish Mishra, student of Shri Ramswaroop Memorial College of Engg. and Management, Lucknow
pursuing B.E has made this report on In-plant training under gone at TATA Motors Ltd., Lucknow
during the period of 13th June – 11th July 2017.

First and foremost, I would like to thank my college for giving me this opportunity to undergo an
Inplant training during this period. Then I thank the management of TATA Motors, Lucknow for
allowing me to carry out me in-plant training in their esteemed concern. I would like to thank the HR
Mr. Prashant Pandey and my mentor during the training session, Mr. Ritesh Shrivastav and my guide,
Mrs Ushashi Chakraborty who guided me and helped me to complete my training with ease.

I would also like to thank various employees of the concern who spared their time answering my
questions in spite of their heavy workload and busy schedule. Last but not the least I thank the almighty
for keep using good health and for giving me this wonderful opportunity.

Yours Sincerely

Satish Mishra.

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 ABOUT COMPANY
COMPANY PROFILE

Tata Motors Limited (formerly TELCO, short for Tata Engineering and Locomotive Company)
is an Indian multinational automotive manufacturing company headquartered in Mumbai,
Maharashtra, India, and a subsidiary of the Tata Group. Its products include passenger cars, trucks,
vans, coaches, buses, construction equipment and military vehicles. It is the world's 17thlargest motor
vehicle manufacturing company, fourth-largest truck manufacturer, and second-largest bus
manufacturer by volume.

Tata Motors has auto manufacturing and assembly plants in Jamshedpur, Pantnagar, Lucknow,
Sanand, Dharwad, and Pune in India, as well as in Argentina, South Africa, Thailand, and the United
Kingdom. It has research and development centres in Pune,
Jamshedpur, Lucknow, and Dharwad, India and in South Korea, Spain, and the United Kingdom. Tata
Motors' principal subsidiaries purchased the British premium car maker Jaguar Land Rover (the maker
of Jaguar, Land Rover, and Range Rover cars) and the South Korean commercial vehicle manufacturer
Tata Daewoo. Tata Motors has a bus-manufacturing joint venture with Marcopolo S.A. (Tata
Marcopolo), a construction-equipment manufacturing joint venture with Hitachi (Tata Hitachi
Construction Machinery), and a joint venture with Fiat Chrysler which manufactures automotive
components and Fiat Chrysler and Tata branded vehicles.

Founded in 1945 as a manufacturer of locomotives, the company manufactured its first commercial
vehicle in 1954 in a collaboration with Daimler-Benz AG, which ended in 1969. Tata Motors entered
the passenger vehicle market in 1991 with the launch of the Tata Sierra, becoming the first Indian
manufacturer to achieve the capability of developing a competitive indigenous automobile. In 1998,
Tata launched the first fully indigenous Indian passenger car, the Indica, and in 2008 launched the Tata
Nano, the world's cheapest car. Tata Motors acquired the South Korean truck manufacturer Daewoo
Commercial Vehicles Companyin 2004 and purchased Jaguar Land Rover from Ford in 2008.

Tata Motors is listed on the (BSE) Bombay Stock Exchange, where it is a constituent of the BSE
SENSEX index, the National Stock Exchange of India, and the New York Stock Exchange. Tata Motors
is ranked 287th in the 2014 Fortune Global 500 ranking of the world's biggest corporations.

Tata Motors Limited is India’s largest automobile company, with consolidated revenues of INR
2,32,834 crores (USD 38.9 billion) in 2013-14. It is the leader in commercial vehicles in each
segment, and among the top in passenger vehicles with winning products in the compact, midsize car
and utility vehicle segments.

4
The Tata Motors Group’s over 60,000 employees are guided by the mission “to be passionate in
anticipating and providing the best vehicles and experiences that excite our customers globally.''

Established in 1945, Tata Motors’ presence cuts across the length and breadth of India.
Over 8 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The company’s
manufacturing base in India is spread across Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow
(Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and Dharwad (Karnataka). Following a
strategic alliance with Fiat in 2005, it has set up an industrial joint venture with Fiat Group
Automobiles at Ranjangaon (Maharashtra) to produce both Fiat and Tata cars and Fiat
powertrains. The company’s dealership, sales, services and spare parts network comprises over 6,600
touch points, across the world.

Tata Motors also introduced India’s first Sports Utility Vehicle in 1991 and In 1998, the Tata
Indica, India’s first fully indigenous passenger car.

In January 2008, Tata Motors unveiled its People’s Car, the Tata Nano. The Tata Nano has been
subsequently launched, as planned, in India in March 2009, and subsequently in 2011 in
Nepal and Sri Lanka. A development, which signifies a first for the global automobile
industry, the Nano brings the joy of a car within the reach of thousands of families.

Tata Motors is equally focused on environment-friendly technologies in emissions and alternative

fuels. It has developed electric and hybrid vehicles both for personal and public transportation. It has
also been implementing several environment-friendly technologies in manufacturing processes,
significantly enhancing resource conservation.

Type Public

Traded as
BSE: 500570 (BSE SENSEX Constituent)
NSE: TATAMOTORS
NYSE: TTM

Industry Automotive

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 Founded 1945

Founder(s) Jahangir Ratanji Dadabhoy Tata

Headquarters Mumbai, Maharashtra, India

Area served Worldwide

Through its subsidiaries, the company is engaged in engineering and automotive solutions,
automotive vehicle components manufacturing and supply chain activities, vehicle financing, and
machine tools and factory automation solutions

6
Key people
Ratan Tata (Chairman Emeritus)
Natarajan Chandrasekaran(Chairman)
Guenter Butschek(CEO & Managing
Director)

Products Automobiles
Commercial vehicles
Coaches
Buses
Construction equipment
Military vehicles
Automotive parts

Services
Automotive design, engineering and
outsourcing services
Vehicle leasing
Vehicle service

Revenue US$ 39 billion (FY 2012-13)

Operating income US$ 3.9 billion (2012)

Profit US$ 1.9 billion (2012)

Total assets US$ 35 billion (2012)

Total equity US$ 7.9 billion (2012)

Employees 90,485 (2015)

Parent Tata Group

7
Divisions Tata Motors Cars

Subsidiaries
Jaguar Land Rover
Tata Daewoo
Tata Hispano

Slogan More dreams per car inspired by people.

Website www.tatamotors.com

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 TATA GROUP IN SEVEN SECTORS: 44

Chemicals • Voltas, consumer electronics company

• Tata International Ltd.

• Tata Chemicals • Tanishq

Rallis India
• • Fastrack, Youth Fashion Brand
• Tata Pigments Limited • Titan Eye+, Optical Stores from Titan

• General Chemical Industrial Products Industries

• Brunner Mond • Tata Refractories

• Advinus Therapeutics • Westside

• Magadi Soda Company

Energy
Consumer products
• Tata Power is one of the largest private
• Tata Salt sector power companies.
• I-shakti • Tata Power Solar, started as a joint

9
• Casa Décor venture between Tata Power and BP
• Tata Swach Solar, now a wholly owned company.
• Tata Global Beverages, is the world's • Hooghly Met Coke and Power second
largest manufacturer of Company
packaged tea and tea products. • Jamshedpur Utilities and Services
• Tata Starbucks, is a 50:50 joint venture Company company, owned by Starbucks •
Tata Power Delhi Distribution Ltd
Corporation and Tata Global (Formerly Known as North Delhi
Beverages Power Ltd)
• Eight O'Clock Coffee • Power links Transmission
• Tetley • Tata Power Trading
• Tata Coffee • Tata Projects
• Himalayan, mineral water brand
• Lakme
• Tata Ceramics Engineering
• Infiniti Retail (Cromā)
• Tata Industries • TAL Manufacturing Solutions
• Titan Industries • Tata Auto Comp Systems Limited
(TACO)
• Trent (Westside)
• Landmark Bookstores • Hispano Carrocera
• Tata Sky

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• Tata Motors, manufacturer of
• Tata DoCoMo
commercial (largest in India)
and passenger cars • Tata Communications

• Jaguar Land Rover (Manager of Tata's • CMC Limited

British brands cars and Land Rover) • VSNL International Canada
• Tata Daewoo Commercial Vehicle • Tatanet, Managed connectivity and
VSAT service provider

• Tata Projects
Services
• Tata Technologies Limited
• Tata Marcopolo • Tata Sons
• Tata Consulting Engineers Limited • Taj Air
• Tata Cummins • Mjunction
• Telco Construction Equipment • Vistara
• TRF • Air Asia India joint venture with Air
• Voltas Global Engineering Centre Asia
• Tata Advanced Materials • The Indian Hotels Company
• Tata Advanced Systems • Taj Hotels
• Tata Motors European Technical Centre • Vivanta By Taj
• Tata Petro dyne • The Gateway Hotels & Resorts
• Tata Precision Industries • Ginger Hotels
• Telcon Construction Equipment • Roots Corporation
• Tata Housing Development Company
Ltd. (THDC)
Information systems and communications
• Tata Limited
• TATA AIG General Insurance
• Computational Research Laboratories
• TATA AIA Life Insurance
• INCAT
• e-NXT Financials ltd.
• Nelco
• TKM Global, Logistics and Supply
• Nelito Systems
Chain
• Tata Business Support Services
• Tata AG
• Tata Consultancy Services Ltd. (TCS) is
one of the world's largest IT Services • Tata Asset Management
companies. • Tata Financial Services
• Tata Elxsi • Tata Capital Financial Services Limited
• Neotel • Tata International AG
• Tata Interactive Systems • Tata Investment Corporation
• Tata Teleservices • Tata Advanced Systems Limited •
Drive India Enterprise Solutions

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• Tata Quality Management Services Steel
• Tata Realty and Infrastructure Limited
• Tata Steel
• Tata Interactive Systems
• Tata Steel Europe
• Tata Africa Holdings
• Tata Steel KZN
• Tata Auto Comp Systems
• Tata Steel Processing and Distribution
• Tata Industrial Services
• JAMIPOL
• Tata NYK
• NatSteel Holdings
• Tata Services
• Tata BlueScope Steel
• Tata Strategic Management Group
• Tata Metallic
• Tata Sponge Iron
• Tayo Rolls
Core sciences
• The Tinplate Company of India
• Tata Institute of Fundamental Research • Tata Bearings
• Tata Institute of Social Sciences • TM International Logistics

10
13
 TATA MOTORS, LUCKNOW PLANT

• Year of commencement: 1991

• Plant Area: 600 acres

• Number of employees: 4500

• Divisions: Manufacturing Training Assembly

Engineers (first phase) started which also included ITI's and Occupancy of administration office
of assembly shop in September 1992. First vehicle r olled out from Lucknow plant on 20th
October 1992 which was LP 1210 52. Construction of MRS finished on 6th January 1993. It took
approximately 9 years since the conception of the p lan and to rollout the first vehicle from this
latest manufacturing facility of TATA MOTORS. TATA Motors Lucknow is one of the
youngest production facilities among all the TATA M otors locations and was established in 1992
to meet the demand for Commercial Vehicles in the I ndian market. The state of art plant is
strongly backed by an Engineering Research Centre a nd Service set-up to support with latest
technology and cater to the complexities of automob ile manufacturing. Fully Built Vehicle
business, which is one of the fast growing areas of our business, is also established in Lucknow.
The plant rolls out commercial vehicles and is spec ialized in the designing and manufacturing of
a range of modern buses which includes Low-floor, U ltra Low-floor, CNG & RE Buses. The
Lucknow facility also specializes in manufacturing HCBS (High capacity Bus System) buses for
existing Infrastructure.
In light of Company’s aggressive growth plans, it is currently in expansion phase and production
at Lucknow would grow many-fold in near future. The expansion shall be in there as of painting,
welding, vehicle assembly & testing and utility services, driven by latest technology.

WESTERN & EASTERN BLOCK

TATA Motors Ltd. Lko, has total plant area of 600 acres of which 280 acres are covered in the
Western Part called the Western Block which has a present production capacity of 120 vehicles
per day and now they have planned to increase its daily production capacity to 520 vehicles by
extension which is already going in the form of eastern complex on the other side of „Dewa‟ road
covering the remaining 320 acres. The production capacity of this new assembly plant will
expected to be 320 vehicles per day. The eastern complex would have longest conveyor line of
India i.e. 375 meters. This eastern complex will have two conveyers formed by the combination
of single chain conveyor and double chain slat conveyor. These conveyors are named as „Line2‟
and „Line-3‟ (Line-1 is the name given to the conveyor at western complex). There is also a
provision of a future expansion in form of „Line-4‟ and „Line-5‟ and two more trim lines to cater
their cowl/cab needs. Line-2‟ and „Line-3‟will be composed of 30 stations of 12.5 meters each in
comparison to the 19 stations in the existing line. The complete assembling activity for the
vehicle chassis will be done in these 30 stations. The assembly of cowl/cab will be catered by the
two trim lines, which will be composed of 34 and 40 stations respectively. Apart from this, it
would also have the biggest paint shop, which will be dedicated for the painting of cowls and
cabs along with the BIW (Body in White) shop. Presently the cowls are being received from the
Jamshedpur which carries a lot of extra transportation charges will now be seized with the start of
Eastern Complex.

Moreover, in the Eastern Complex there are many other changes made for the efficient working
on the line. Firstly, the line will accommodate the assembling of chassis of various types of
MCV`s and HCV`s up to the upcoming model WORLD TRUCK of TATA. All the equipment’s
and tools etc. will l operate over-head so as to make the more floor surface available and reducing
hindrance on the shop floor. Platforms for accommodating different types of over-head
equipment’s and machines are hanged to the top with various beams and hangers. Also the
aggregates which are the heavy parts required during the chassis assembly (Engine, Axles, and
Cab etc.) will now be moved from storage to the fitment station through 33

15
EMS (Electric Monorail System) which will freeze the movement of fork-lifters on the shop
floor. Moreover, the docking stations are built aside the wall to dock the material from outside in
front of the station in which that part will go to the assembly line directly. Above all the main
thing is that the flow of work is made in efficient & systematic way to enhance the productivity
with the increased safety.

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 FACTORIES IN TATA MOTORS LUCKNOW

1. CV-CX (Commercial Vehicle) Factory -

1) WESTERN COMPLEX-

a) Frame-CX
b) Trim-CX-1
c) Chassis Assembly Line-1

2) EASTERN COMPLEX-

a) BIW
b) Trim-CX-2
c) Trim-CX-3
d) Chassis Assembly Line-2
e) Chassis Assembly Line-3

2. Transmission Factory –

a) CWP-CX (Crown Wheel Pinion)

b) HT-CX

3. TATA MARCOPOLO MOTORS Limited (TMML)

4. Integral Bus Factory (IBF)

5. RECON Factory

17
 WORK MEASUREMENT SYSTEM

Work Measurement is the application of techniques designed to establish the

time for an average worker to carry out a specified manufacturing task at a
defined level of performance. It is concerned with the length of time it takes to
complete a work task assigned to a specific job.

 TECHNIQUES USED IN WORK MEASUREMENT

 TIME STUDY
 MOTION STUDY
 PMTS (Predetermined Motion Time System)
 MTM I (Method Time Measurement)
 Work Factors
 MTM II
 MOST (Maynard Operation Sequence Technique)

TIME STUDY :-

Time study is a direct and continuous observation of a task, using a timekeeping

device (e.g., decimal minute stopwatch, computer-assisted electronic stopwatch, and
videotape camera) to record the time taken to accomplish a task. The use of time-
study methods in standard setting and the planning of work, was pioneered by
Frederick Winslow Taylor.

MOTION STUDY :-

The Gilbreths made use of scientific insights to develop a study method based upon
the analysis of work motions', consisting in part of filming the details of a worker’s
'activities and their body posture while recording the time.The films served two main
purposes. One was the visual record of how work had been done, emphasizing areas
for improvement. Secondly, the films also served the purpose of training workers
about the best way to perform their work.

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PREDETERMINED MOTION TIME SYSTEM

A predetermined motion time system (PMTS) is frequently used to set labor rates
in labour oriented industry by quantifying the amount of time required to perform
specific tasks. The first such system is known as Methods-time measurement, released
in 1948 and today existing in several variations

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MOST (MAYNARD OPERATION SEQUENCE TECHNIQUE)

Maynard Operation Sequence Technique (MOST)[1] is a predetermined motion time

system that is used primarily in industrial settings to set the standard time in which a
worker should perform a task. To calculate this, a task is broken down into individual
motion elements, and each is assigned a numerical time value in units known as time
measurement units, or TMUs.

MOST is divided into various systems on the basis of level of accuracy and they are
 Mini MOST (Used for repetitive operation)
 Maxi MOST (Used for non-repetitive operation)
 Basic MOST (Used for general operation)
 Clerical MOST (Used for clerical operation)

Basic MOST

In general, objects can be moved in only two ways, either they are picked and
moved freely through the space, or they are moved while maintaining contact with
another surface. For each type of move, a different sequence of event occurs,
therefore, a separate MOST activity model applies. The use of tools analysed
through a separate activity sequence model.

Consequently, only three basic MOST activity sequences are needed for
describing manual work.
 The General Move Sequence (for the movements of an objects free1y
through air)
 The controlled Move Sequence (for the movements of an objects when it
remain in contact with a surface or is attached to another object during the
movement)
 The Tool Use sequence (for the use of common hand tools).

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 GENERAL MOVE SEQUENCE MODEL:-
General Move is defined as moving objects manually from one location to
another freely through the air. To account for the various ways in which a
General Move can occur. The activity sequence is made up of four sub activities:

 A-Action distance (mainly horizontal)

 B-Body motions (mainly vertical)
 G-Gain control
 P-Placement
These sub activities are arranged in a sequence model , consisting of a series of
parameters organized in a logical sequence. The General model defines the
events or actions that always take place in a prescribed order when an object is
being moved from one location to another.

GET PUT RETURN

A B G A B P A

CONTROLLED MOVE SEQUENCE MODEL:-

This sequence is used to cover such activities as operating a lever of crank,
activating a button or switch, or simply sliding an object over a surface. In
addition to the A, B, and G parameters from the General Move Sequence, the
sequence model for a controlled move contains the following subactivities:
 M-Move controlled
 X-Process time
 I-Align
As many as one -third of the activities occurring in machine shop operations
may involve controlled moves. In assembly work, however, the fraction is
usually much smallest. A Typical activity covered by the controlled move
sequence is the engaging of the feed lever on the milling machine. The sequence
model for this activity might be indexed as follows:-
GET MOVE RETURN

21
A B G M X I A

TOOL USE SEQUENCE MODEL:-

This sequence model covers the use of hand tools for such activities as fastening
or loosening, cutting .cleaning. Gauging, and recording .Also, certain activities
requiring the use of the brain for mental processes can be classified as tool use.

GET PUT TOOL ACTION TOOL ASIDE RETURN

A B G A B P T A B P A

22
 SIGNA LINE
SIGNA range of commercial vehicle is engineered & built to offer Medium & Heavy
commercial vehicle buyers, a newly designed Cabin, with proven Tata Motors
aggregates. With its smartly designed cabin space, improved ergonomics and NVH
levels, the TATA SIGNA range of cabins are built to offer a superior in-cab
experience, enabling drivers to operate fatigue free over long hauls, which in turn
offers significant improvement in productivity. With an inbuilt telematics system, by
TATA FLEETMAN, the new TATA SIGNA empowers fleet operator with a more
connected experience, to better manage their transport business through optimum
driver, vehicle and fuel management.

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BIW (BODY IN WHIITE) SHOP

What is Body in White?

BIW refers to a stage in automotive design or automobile manufacturing in which a car
body’s sheet metal components have been welded together – but before moving parts
(doors, hoods, and deck lids as well as fenders) the motors, chassis sub-assemblies, or
trim have been added and before painting has been done.

24
 BIW Shop

COWL
CAB Line
Line

Sleeper Non- Without With

(R & C) Sleeper Face Face

As can be seen from the above flowchart, the BIW shop at tata motors, Luccknow is
composed of two main parts:

On one side of th shop is the CAB Line and on the other side is the COWL Line

CAB LINE

The closed pilot cabine are known as CABs. The CAB line is almost 40 years old. It
was first commissioned at Pune plant and was later transferred to Jamshedpur. After
being written off at Jamshedpur, it was finally transferred to lucknow in 2008. The
CAB comes in two models:

1. Sleeper: This CAB comes with a berth box in which the driver can sleep.
Generally customers who have to move large distances prefer the Sleeper
model.

25
 2. Non-Sleeper: This model comes without the berth box and is smaller as
compared to sleeper model.

Unlike Cowls, CABs remain the same irrespective of the model and make of the
overall truck or lorry i.e there is no difference between the CAB of one model and that
of another model

The following is a basic flow diagram for the production of a CAB:

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ASSY. FRONT WALL ASSY. ROOF

ASSY. REAR WALL ASSY. SUB-STRUCTURE

MAIN FRAMER

LAYOUT OF CAB LINE

27
 (For Both Sleeper and Non-Sleeper Models)

ROOF ASSEMBLY FRONT WALL ASSY.

 Assy. Roof & Panel
 Seam Welding
 Brazing
 Top Rail Sub-assy.
 Reinforcement Assy.
 Roof Final Dropping
REAR WALL ASSY.
 Rear Wall Assy.
 Face panel sub-assy.
 Assy. Wind shield
panel
 Assy. Door post
 Assy. Frame Front
 Assy. Toe Panel
 Assy. Bonnet centre
 Assy. Dashboard SUB-STRUCTURE ASSY.
 Assy. Foot-step  Assy. Floor Panel
 Partition Wall Assy.  Floor Panel Respot
 Wind Shield Inner  Assy. Mud-Guard
Top
 Sub –structure Full
 Wind Shield Spot Welding
Welding

MAIN FRAMER
Assy. Of Sub-structure, Roof, Front
Wall and Rear Wall

FINISHING LINE
 Wheel Are Respot
 CAB Respot
 Full Welding 1,2,3
 Loose Fitment
 Corner Panel
 Gas Welding
 Grinding
 Door Fitment
 Dusting Cleaning And Buffing
 Buy Off Gate

28
 COWL LINE
The Open Pilot Cabins are known as Cowls. The Cowl Line is almost 30 year old. It
was first commissioned at the Pune plant and then it was transferred to Lucknow in
2009.
A total 27 models of cowl are manufactured in the BIW Shop. However, the difference
between the various models are minor. The major classification of Cowls is as follows:

1. Face Cowls: These are the more prominent type of Cowls produced in the BIW
Shop. Face Cowl differ depending on the make and model of the lorry or truck
even though the differences are only minor.
2. Faceless Cowls: Faceless Cowls have no Front wall as the name very well
suggests.

29
MOST REVALIDATION OF FRONT WALL SIGNA LINE

STATION 1: FACE PANEL SUB ASSEMBLY

30
31
32
STATION 2: ASSEMBLY WIND SHEILD PANEL

33
34
STATION 3: ASSEMBLY FRAME FRONT

35
STATION 4: ASSEMBLY TOE PANEL

PLACING TOE PANEL

36
STATION 5: ASSEMBLY BONNET CENTRE

SPOT WELDING OF BONNET CENTRE

37
STATION 6: ASSEMBLY DASHBOARD

MIG WELDING OF DASHBOARD

38
 CONCLUSION
During the training at WABCO India Ltd. Lucknow Plant I got to know and learn
about the various parts used in the braking systems. I gained knowledge about the
various parts, function of the braking systems, and the working atmosphere at the
industry. It was overall a very nice experience and also got to see the real time
functioning of braking system. I also understood the assembling of various parts used
in the braking system. Finally I would like to thank my college and the HR at WABCO
for giving me this wonderful opportunity to undergo this In Plant Training.

39