tvs report

Gaurav Batra -- UE99018 UIET, PU

1

“Improve Process Capability”

A PROJECT REPORT

(One Month Training)

CARRIED OUT AT

NALAGARH (H.P.)

SUBMITTED IN PARTIAL FULLFILLMENT OF THE REQUIREMENT FOR

THE AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY

(MECHANICAL ENGINEERING)

SUBMITTED BY

GAURAV BATRA

ROLL. NO. UE99018

UNIVERSITY INSTITUTE OF ENGINEERING AND TECHNOLOGY

PANJAB UNIVERSITY

(CHANDIGARH)

http://uiet.puchd.ac.in/images/emblem.jpg

http://uiet.puchd.ac.in/images/emblem.jpg


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TVS PLANT IN H.P.

“A PICTURE IS WORTH A THOUSAND WORDS”

This Chinese proverb clearly states the importance experience over theoretical

knowledge. It is the practical field where a person actually applies, what he has

learnt in theory. The in plant training gives a chance to the student to understand the

practical organizational culture.


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DECLARATION

I hereby declare that the project work entitled “Improve process capability of Cup

top and bottom diameter of frame component (Star/Sport)” is an authentic

record of my own work carried out at TVS MOTOR COMPANY LTD.

NALAGARH, HIMACHAL PRADESH as requirement of One month industrial

training for the award of Degree of Mechanical Engineering from UNIVERSITY

INSTITUTE OF ENGINEERING AND TECHNOLOGY, PANJAB

UNIVERSITY under the guidance of Mr. Virender Chadha.

GAURAV BATRA

Roll No. - UE99018

I certify that the above statement made by the student is correct and true to the best

of my knowledge and belief.

Mr. T K J SRIDHARAN

(Manager ENGG. & SQA DEPT.)


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ACKNOWLEDGEMENT

The concept of industrial training, being a part of the engineering curriculum

is of great use to the students. They get an opportunity to work in a company or an

organization and gain much needed practical experience and exposure while

working with the experts in their fields of specialization.

I consider myself extremely fortunate that I got the opportunity to gain this

valuable practical knowledge during the course of my industrial training at TVS

Motor Company, Nalagarh.

I express my sincere gratitude to Mr. P. N. KANNA, Mr. T K J

SRIDHARAN and Mr. Virender Chadha for guiding me through the training and

making my industrial training a meaningful experience.

I give my heartiest thanks to Mr. SUSHIL DWIVEDI and Mr. ASHISH

JINDAL who provided me valuable information regarding my project.

I also thanks for all those persons in other departments too who provided me

valuable information that I required in my project work.


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PREFACE

Project report on “Improve Process Capability” creates a sense of

Critical analysis of a real technical situation to which a project trainee is

going to exposed.

This gives an opportunity to me apply their conceptual, theoretical

and imaginative skills to real life situation and to evaluate the results

thereof. This project report is written on account of what I learnt and got

experience during my studies while accomplishing B.TECH. This helped

me in boosting up my confidence and determination, which helped me to

face any type of situation in years to come.

I wish those who going through it, will not only find it reliable but

also will find useful and accurate information.


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INTRODUCTION TO COMPANY

INTRODUCTION

TVS Motor is the third largest two-wheeler manufacturer in India and ranks among

the top ten globally. It is the first company in the world to be honoured with The

Deming Prize for Total Quality Management. The company was the first in India to

launch 2-seater 50cc moped and 100cc Indo-Japanese motorcycles. At present TVS

Apache, TVS Flame, TVS Scooty, TVS Star City and TVS Sport are the popular

bikes in Indian market.

TV Sundaram Iyengar and Sons Limited (TVSs) is the holding company for the

TVS Group of companies engaged in the manufacturing of various automotive

components, two wheelers and a few other industrial products. They are also into the

financial services sector. TVS was founded by T. V. Sundaram Iyengar in 1911. It is

the only automotive manufacturer in India to get the prestigious Deming Prize. One

of its subsidiaries Sundaram Clayton was the first company in India to receive the

Deming followed by Sundaram Brake Linings also getting the Deming Prize. This

prize is "given to organizations or divisions of organizations that have achieved

distinctive performance improvement through the application of TQM in a

designated year. Sundaram Clayton went on to be awarded the Japan Quality Medal.

http://en.wikipedia.org/wiki/T._V._Sundaram_Iyengar

http://en.wikipedia.org/wiki/Deming

http://en.wikipedia.org/w/index.php?title=Japan_Quality_Medal&action=edit&redlink=1


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COMPANY PROFILLE

TVS GROUP

TVS group started its journey in 1911 by Sri Trichur Venkgaruswami Sundaram

Iyengar. TVS group marked its beginning as a transport company and now has

grown to its diversification and expansion programs to a giant business family

comprising of 35 companies and employing 40000 people worldwide. It has been

one of India’s largest industrial entities.

TVS MOTOR COMPANY

In 1979, Sundaram Clayton Limited (SCL) started a moped division at Hosur to

manufacture TVS-50 mopeds indigenously designed and developed, marking the

start of automobile giant TVS Motors Pvt. Ltd. TVS motors is the 3rd

largest 2-

wheeler manufacturer in India with a market share of 18% and one of the top 10 in

the whole world with an annual turnover of over USD 650 millions. TVS motor

company has manufacturing units at Hosur, Mysore, Indonesia and Nalagarh. TVS

has launched 36 models starting from mopeds XL in 1979 to Flame-125 in 2008.

The first 18 models were launched in the first 18 years and next set of 18 has been

launched in next 8 years. Out of our total product range 22% are mopeds, 60% are

motorcycles and 18% of scooters.


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Sundaram-Clayton Moped Division Suzuki Motor Corporation

Sundaram-Clayton Group of Companies

1979

1982

2001 Parted Suzuki Motor Corporation

TTVVSS MMOOTTOORR CCOOMMPPAANNYY LLTTDD..

TVS-SUZUKI LIMITED

THE TVS GROUP


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MEANING OF TVS

TVS stands for

T – TRUST

V – VALUE

S – SERVICE

MISSION STATEMENT:

“We are committed to being a highly profitable and socially responsible, leading

manufacturer of high value for money, environmentally friendly, lifetime personal

transportation products under TVS brand for customers predominantly in Asian

markets and to provide fulfillment and prosperity for employees, dealers and

suppliers.”

Shri Venu Srinivasan

Managing Director


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VISION STATEMENT:

TVS Company will be:

Driven by customer

TVS Motor will be responsive to customer requirements consonant with its core

competence and profitability. TVS Motor will provide total customer satisfaction by

giving the customer the right product, at the right price, at the right time.

Industry leader

TVS Motor will be one among the top two two-wheeler manufacturers in India and

one among the top five two-wheeler manufacturers in Asia.

Global overview

TVS Motor will have profitable operations overseas especially in Asian markets,

capitalizing on the expertise developed in the areas of manufacturing, technology and

marketing. The thrust will be to achieve a significant share for international business in

the total turnover.

At the cutting edge of Modern technology

TVS Motor will hone and sustain its cutting edge of technology by constant

benchmarking against international leaders.


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Committed to total quality

TVS Motor is committed to achieving a self-reviewing organization in perpetuity

by adopting TQM as a way of life. TVS Motor believes in the importance of the process.

People and projects will be evaluated both by their end results and the process adopted.

Employee dependent

TVS Motor believes that people make an organization and that its well-being is

dependent on the commitment and growth of its people. There will be a sustained effort

through systematic training and planning career growth to develop employees’ talents and

enhance job satisfaction. TVS Motor will create an enabling ambience where the

maximum self-actualization of every employee is achieved. TVS Motor will support and

encourage the process of self-renewal in all its employees and nurture their sense of self

worth.

KEY MILESTONES FOR TVS MOTORS:-

1980 - Started Manufacturing India’s first 2- SEATER MOPEDS.

1982 - Joint Venture with SUZUKI MOTOR Corporation (SMC), Japan.

1984 - Became First Company to introduce 100cc Motorcycle in India.

1994 - Launched India’s First Sub-100 cc indigenous scooter – TVS SCOTTY.

1996 – Introduced India’s first catalytic converter enabled motorcycle,

the 100cc SHOGUN.


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1998 - Established 2nd

Manufacturing Plant in MYSORE.

2000 – Launched TVS FIERO, India’s first 150cc 4-stroke motorcycle.

2001 - Became independent Company – TVS Motor Company after exit of SMC from

joint venture.

2001 - Launched India’s First indigenously designed 4-Stroke Motorcycle.

2002 - Won Deming Award for Best Quality.

2004 – Launched TVS CENTRA with revolutionary VY-I engines for best in

class mileage.

2004 – Won TPM excellence award.

2005 - INDONESIAN Subsidiary formed.

2005 – Launched TVS APACHE in November.

2006 - Established 3rd

Manufacturing plant in NALAGARH, Himachal Pradesh

2008 - Launched 125 cc 3 valves CC-Vti Engine Motorcycle ‘TVS FLAME’

2009 – Launched TVS JIVE, TVS WEGO in November, the first Bike

without Clutch.

LOCATION OF TVS MANUFACTURING PLANTS

TVS Motor Company has 9 manufacturing plants all over the world, which are as follows:

Plant 1 – Moped Division, Hosur started in 1979

Plant 2 – Motorcycle Division, Hosur started in 1984

Plant 3 – Engine Component Division, Hosur started in 1988

Plant 4 – Scooter & Motorcycle Division, Mysore started in 1998


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Plant 5 – Spares Warehouse Division, Hosur started in 1988

Plant 6 – Engine Component Division, Mysore started in 2003

Plant 7 – Motorcycle Division, Nalagarh started in 2007

Plant 8 – Bebeks Motorcycle Division, Jakarta Indonesian started in 2007

Plant 9 – Auto Manufacturing Division, Hosur started in 2007

NALAGARH PLANT This is the latest manufacturing plant, started its operations last year. Nalagarh plant is situated at

village Bhatian, 4 Kms away from Nalagarh city on Bharatgarh Road in Himachal Pradesh. First

vehicle rolled out at this plant on 29th

April 2007, which marked the beginning of new chapter in

TVS motors.

CLIMATIC CONDITIONS

Temperature - 45C

Minimum Temperature - 3C

Humidity – 60 Maximum %(min) to 90 %(max)

PRODUCTS

TVS Star City 110

TVS Sport

Star Basic

Moped


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DEPARTMENT IN H.P. PLANT

MPG (MATERIAL PROCUREMENT GROUP):

There are four deptt. Under MPG

1. Stores.

2. Vendor development.

3. Material procurement.

4. Production planning & control.

DM STORES:

All the materials, which are directly assembled on line, are known as Direct Material. The

DM stores are the department, which takes care of the stock of the direct materials.

IDM STORES:

Indirect material e.g. stationary, free cloth, gloves.

QAD Himachal: - (Quality Assurance Department):

This department at Himachal is looking after the day-to-day quality issues in the plant. The

materials handled by this department are the incoming and outgoing materials. It keeps a check on

the material if it is within the specified norms and if not it rejects the material and notifies its

supplier.


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ISD: - (Information System Department):

Manages the information system and technology of the plant.

Paint shop-ACED:

The ACED paint shop paints the finished metal components (only primer coating) and then

passes them on to the Lacquering line where the components are then painted with a Topcoat

color, which the customer wants.

Paint shop-Metal:

At this stage the metal components are painted with a topcoat of the wanted color and then

Lacquering is done on them.

Paint shop-Plastic:

In this paint shop all the plastic parts of the vehicle are painted and then supplied to the

customer, Vehicle assembly.

PMD: - (Plant Maintenance Department):

PMD looks after the supply of Water, Electricity and Air to each and every spot in the

plant. It also has to look after the maintenance of the same.

Fabrication:

This Department maintains the stock of fuel tanks wanted by its customers and has to

check the quality of the same before supplying it to them.

Vehicle Assembly:

All the departments that manufacture different products stages of the plant have vehicle

assembly as their final customer. Here the whole assembly of vehicle is done.


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PRODUCTS & SPECIFICATIONS

MOTOR CYCLES:

ENTRY LEVEL: 1) BRAND: TVS STAR CITY

LAUNCHED: 2004

2) BRAND: TVS STAR SPORT

LAUNCHED: 2009


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3) BRAND: TVS JIVE

LAUNCHED: 2009

EXECUTIVE LEVEL: 1) BRAND: TVS FLAME

LAUNCHED: 2008


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PREMIMUM LEVEL:

1) BRAND: TVS APACHE RTR 160

LAUNCHED: 2005

2) BRAND: TVS APACHE RTR 180

LAUNCHED: 2009


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3) BRAND: TVS APACHE RTR 180 with ABS

LAUNCHED: 2011

SCOOTERS:

1) BRAND: TVS SCOOTY PEP+

LAUNCHED: 2005


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2) BRAND: TVS WEGO

LAUNCHED: 2009

MOPEDS: 1) BRAND: TVS XL SUPER, XL HD

LAUNCHED: 1979


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3 WHEELER: 1) BRAND: TVS KING

LAUNCHED: 2009


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VENDOR FACTORY

BRANCH DEALER CUSTOMER

SSKKFF BBeeaarriinngg

TTVVSS MMoottoorr

CCoommppaannyy

Parts

Vehicle

TVS Motors

Co.

FLOW CHART OF A TWO-WHEELER FROM VENDOR TO CUSTOMER


23

PLANT LAYOUT


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INTRODUCTION TO PROJECT

QAD (Quality Assurance Department) is the department,

where the production quality will be controlled. In this

department skilled person, who knows about all instruments

and gauges, takes inspection. When the inward material is

unloading, then skip and non-skip will be decided by

inspection. Quality department takes all of the inspection.


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PROJECT

Improve Process Capability

Parameters: Cup top diameter and cup bottom diameter of head

pipe.

I have been allotted SUPPLIER QUALITY department for my project

training.

I have been given the project to improve the process capability. The

whole department inspects the quality of all the incoming supplier parts.

The inspection process of each part is carried out in accordance with the

TSES (TVS System of Engineering Standards).

Checking the quality of the material etc.

Physical verification of material.

Quality inspection is done of the material.

Material sends to the assembly line after inspection.


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IMPORTANCE OF PROBLEM

This problem is aimed to achieve zero quality defects in the supplier parts.

If the problem is not solved it will lead to:

Increase in rework,

Increase in rectification hours,

Increase in vehicle loss,

Customer dissatisfaction,

Late delivery of vehicle,

Extra time taken in segregation of parts.

PROCESS VARIATION

0

10

20

30

40

50

60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

SAMPLE

VA

LU

E

USL

50.031

LSL

49.969


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BACKGROUND OF PROBLEM:

This problem arises because in Supplier Quality Assurance Department inspection

facility for some parts is available and for others it is not.

So the parts which are inspected without proper facility leads to:

More time consumption,

More unnecessary movement of worker,

Un-checked internal defects.

THEME AND TARGET

THEME:

Improve process capability by the detail knowledge of the process and

their ability, with never ending improvement cycle.

TARGET:

To made the process more capable.

CONTINUOUS PROCESS

0

10

20

30

40

50

60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

SAMPLE

VA

LU

E

Series1

USL LSL


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OBSERVATION

Before observing all the data about project firstly I understand the

problem and what is the background of that problem. After that all

observation are done for completing the project. All the observations were

done in the JBM group of company “Thai Summit Neel Auto Pvt. Ltd.,

Nalagarh”.

OBSERVATION:

Less skill labor is employed

Lot of time wastage because of improper placement of material

Process is very slow due to unskilled labor.

Setting of the tool bit is not done properly.

Not proper division of work among the worker.

More time consumed in transporting of material.

More unnecessary movement of worker.

Storage area is less.

These problems arise because no proper setting is done on the machine.

The operator has more workload on the machine. He picked the material

himself and after boring he checked the diameter of the hole and then

placed the material on the other place himself.


29


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ANALYSIS AND INTERPRETATION

ANALYSIS:

After observing all the facts related to project, analysis on these facts is

done. Analysis is done by considering 4M i.e. men, machine, material and

method. Then I collected new data to validate the main causes.

All material should be placed in store properly.

There should be proper supply of material from store to line.

All material should be placed systematically.

There are need of the one more helper on the boring machine

The parts should be inspected as per the standard set of instructions.

All the parts should be inspected systematically.

The testing facility should be in accordance with the TSES.

Best utilization of 4M.


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CAUSE AND EFFECT DIAGRAM LEVEL 1

` Poor maintenance of machine

Machine tool bit not changed

Unskilled operator

Defective material supplied

Improper distribution of work

Improper placement

of material

Less space for storage

Process capability

MEN MACHINE

MATERIAL METHOD


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CAUSE AND EFFECT DIAGRAM LEVEL II:

Improper work distribution

No placement of material

MEN MACHINE

MATERIAL

Boring process

METHOD

Unskilled labor Machine tool bit

change not done


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CAUSE AND VERIFICATION:

STRONG RELATIONSHIP MEDIUM RELATIONSHIP

WEEK/NO RELATIONSHIP

SR.NO CAUSE SPEC/STD INVESTIGATION ANALY

SIS

1.

2.

3.

4.

Ok and not ok

frames are

placed

together

Machine tool

bit not change

Working place

are not

suitable

No proper

distribution of

the work.

Should be placed in

separate trolleys.

Tool bit change

Less movement of

worker

Work should be

properly distributed

Both frames are

placed together.

Tool bit not changed

There is more

movement of worker.

Work not properly

distributed.


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INTERPRETATION:

It is analyzed that after implementing this project working efficiency

increased by 50% to 60%. Also total time consumed is less than the

previous time. There is best utilization of manpower. Both workers do the

equal amount of work i.e. proper division of work among the worker.

Increase in working efficiency.

Proper division of work

Proper utilization of manpower

Saving in time.

Reduce the operator workload.


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ACTION

After analyzing I have to take suitable action to eliminate the causes of

problem. Different proposals are made for eliminating the root causes. All

the advantages and disadvantages are examined of the proposals and best

proposal is selected. It is examined that action does not produce other

problems by doing time study. Different actions taken are:

Material placed near the operator systematically

One more helper is placed with the operator.

The carbide tool bit is changed after the 150 pieces.


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STANDARDIZATION

Before


37

AFTER

(O.K. and not O.K. frames are

separated O.K. frames are

placed in the trolley)


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Before After

No. of pieces which were produced

before the replacement of the

carbide tool bit were 200. After the

production of 160 pieces it was

seen that the pieces produced were

under size.

Now when I took the action the

carbide tool bit is replaced after

the production of 150 pieces.

Due to this action the no. of

defects were reduced, and the

standard size of the frame was

maintained.

49.988

49.99

49.992

49.994

49.996

49.998

50

SAMPLE

VALUE

49.98

49.99

50

50.01

50.02

50.03

SAMPLE

3-D Column 2

VALUE


39

Before

After

The operator has the more work

load to complete the process.

There will be the more

movement of the operator to

complete the process. Operator

pick the material from the other

place and after the boring he put

the material other place. Due to

this more time is consumed.

Due to this reason the

production was less.

Now when I took the action

the material is placed near

the operator to reduce his

movement.

And the helper is placed

with the operator who after

the production put the

material other place.

49.988

49.99

49.992

49.994

49.996

49.998

50

SAMPLE

VALUE

49.98

49.99

50

50.01

50.02

50.03

SAMPLE

3-D Column 2

VALUE


40


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CONCLUSION

This solution is best in my views because, using this process capability. This

project is aimed at best utilization of manpower and error reduction. This

project helps in maintaining proper workflow, orderliness and cleanliness in

store.

So this project is helpful in:

Error reduction in parts.

Proper workflow.

Improvement in working efficiency.

Proper utilization of manpower.

Maintaining 4M system in store.

Coordination of different depts. in Company.


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FUTURE SCOPE OF PROJECT

Nothing in this world is constant as change is rule of the world. Change is

good only if it will yield good improvements that are desirable. This

project is based upon the best and proper utilization of 4M i.e. man,

machine, materials, and method. Also this project is based upon the time

study so very helpful in increasing working efficiency. This project also

helps in maintaining high production rate. This project also helps in

maintaining System in future. The concept applied will help in designing

other inspection facilities for the supplier parts.

tvs report

Documents

carbide tool bit

suzuki motor corporation

tvs star city

quality assurance department

gaurav batra roll

machine tool bit

tvs motor company

tool bit