MEDICAPS INSTITUTE OF SCIENCE &

TECHNOLOGY
INDUSTRIAL TRAINING REPORT

Pithampur Industrial Area, District Dhār, Pithampur, Madhya

Pradesh, Pin code-454775
Training duration -30 Days (5th June 2018 to 4th July
2018)
Project topic
To eliminate the problem come into the a.c. ventilation
(nozzle) or the r.p.m. meter polling in Trax vehicle.

Submitted by- Submitted to Guide-

Sandeep raghuvanshi Mr.B.Naikwadi

B.E.(Automobile engineering)
Medicaps ,
Indore (M.P.)
 CONTENTS
S.NO TOPIC PAGE
NO.
1. Declaration 1

2. Acknowledgement 2

3. Certificate 3

4. Company profile 4

5. History and 5
heritage
6. Overseas presence 6

7. Vehicles 7-8

8. Pithampur plant 9

9. Vehicle assembly 10-14

10. Project description 15-27

11. Conclusion 28
 DECLARATION

I hereby declare that this Project on “To eliminate the problem come
into the a.c. ventilation (nozzle) or the r.p.m. meter polling in Trax
vehicle’’ has been prepared by me, under the guidance & supervision of
Mr.PANKAJ BAIRAGI, FORCE MOTORS LIMITED. As a part of my
course B.E and all the work submitted by me is my original work.

It was great experiences working in esteem organization of FORCE

MOTORS Ltd. I learnt a lot and consider lucky to get an opportunity
and look forward to such an opportunity again.

Through the suggestion our mind creation there was a lot of sources that
helped me in understanding the working system and theoretical aspects
of the industry.

SANDEEP RAGHUVANSHI
B.E (Automobile Engineering)
Medicaps, Indore (M.P)
 ACKNOWLEDGEMENT

I would like to thank the organization and respected Dr. Abhay

Firodia (Chairman), Mr. Prasan A. Firodia (Managing Director),Mr.
Sudhir Mehta (Director),Mr.Abhay Patil (Senior General Manager) for
providing us with the opportunity of training at Force Motors Limited .

We would like to extend my thanks and regards to Mr. Pankaj

Bairagi,Mr. O.P Gorkhe for assigning us with valuable projects that
helped to gain a lot during my training and for being such an
inspirational guide.

Our sincere thanks to Mr. Sinhakar for guiding us throughout the project
and being a supportive mentor.

I would also like to thank all the acquaintances of Force Motors Limited
who supported us directly or indirectly and solved queries and made us
stay pleasant.

We perceive this opportunity as a big milestone in our career

development. We will strive to use gained skills and knowledge in the
best possible way, and will continue to work on their improvement, in
order to attain desired career objectives. Hope to continue cooperation
with you all in the future.

Sincerely,
SANDEEP RAGHUVANSHI
 CERTIFICATE

This is to certify that SANDEEP RAGHUVANSHI of Medicaps,

Indore has prepared her report on the Project entitled “To eliminate the
problem come into the a.c. ventilation (nozzle) or the r.p.m. meter
polling in Trax vehicle.” and is submitted to the R & D department of
Force Motors Limited . To the best of my knowledge the work has not
been submitted to any other department. This work is an authentic work
carried out by him under my supervision and guidance.

Guide: Mr. Pankaj Bairagi

FORCE MOTORS LIMITED

 Company profile

Force Motors was established in 1958 by Shri. N. K. Firodia, with the

vision to provide affordable commercial transport for the masses by
harnessing the best available technology and offering economical,
reliable and efficient products.
Today, its range includes Small Commercial Vehicles (SCV), Multi-
Utility Vehicles (MUV), Light Commercial Vehicles (LCV), Special
Utility Vehicles (SUV) and Agricultural Tractors. So no matter what the
need be, Force has a solution to offer.
FULLY VERTICALLY
INTEGRATED

Force Motors is fully vertically integrated, making its own engines,

chassis, gear boxes, axles, bodies etc. for the entire product range.
Force provides appropriate solutions for transport –both goods, as well
as passenger - rugged, reliable and efficient transport solutions for every
need - rural or urban, long distance or local, over good roads or bad
tracks.

The company continues in the founder's vision of providing efficient,

utilitarian vehicles that empower the individual entrepreneur to meet his
and the country's ever changing needs.
 HISTORY

The foundation of the Group was laid by Late Shri. N. K. Firodia

freedom fighter and pioneering industrialist.
He gave India two paradigms - the concept of 'low cost public transport'
- the Autorikshaw (a word he coined that now finds a place in the
Oxford Dictionary).The Tempo Matador was the first diesel light
commercial vehicle in India. The word Tempo (a registered trade mark
of Daimler) is now generic for any small goods carrier in India
Over the last five decades it has partnered with leading global
automotive names like Daimler, ZF, Ricardo, Bosch and MAN etc.
Through these associations it has developed necessary expertise in-
house to harness the latest advances in technology and developing
relevant mobility solutions.
 OVERSEAS PRESENCE

Force Motors is a highly flexible automotive company that has the

capability to cater to different types of markets, by providing customized
'country specific' solutions.

Force Motors has a formidable product range in all segments, be it small

commercial vehicles, light commercial vehicles, multi utility vehicles
and agricultural tractors. The company exports its range of world class
products to various countries in Middle East, Asia, Latin America and
Africa.

Over the last five decades it has partnered with leading global
automotive names like Daimler, ZF, Ricardo, Bosch and MAN etc.
Through these associations it has developed necessary expertise in-
house to harness the latest advances in technology and developing
relevant mobility solutions.

The company exports its complete range of world class products to

various countries Middle east , Asia, Latin America,and Africa.
 BRANDS

TRAVELLER(LIGHT COMMERCIAL VEHICLES

PASSENGER CARRIER)

TRAX(MULTI UTILITY VEHICLES

PASSENGER CARRIER)
 GURKHA (OFF-ROADER)

BALWAN(AGRICULTURAL VEHICLE)

KARGO KING (MUV GOODS CARRIER)

PITHAMPUR PLANT
Pithampur plant is having 5 shops:

PRODUCTION FLOW
VEHICLE
ASSEMBLY SHOP
ASSEMBLY SHOP LAYOUT
FORCE-1 SHOP LAYOUT (GURKHA)
OPERATION WISE LINE STRATIFICATION
GURKHA MODEL DESCRIPTION:

GURKHA XPLORER
Wheel Base (mm) 2400 2750
Drive 4x4 4x4
Body Type HT/ST 3 Door HT 5 Door
Engine FM 2.6 CR, BS-IV
Power (hp) / Torque (Nm @ 85 HP / 230 Nm @ 1400 ~ 2400
rpm) rpm
Gear box G 28/5-Overdrive, Cable Shift
Axle Front Live Independent
Rear Live Rigid

GURKHA XPEDITION
Wheel Base (mm) 2750
Drive 4x2
Body Type HT 5 Door
Engine FM 2.6 CR, BS-IV
Power (hp) / Torque (Nm @ 85 HP / 230 Nm @ 1400 ~ 2400
rpm) rpm
Gear box G 28/5-Overdrive, Cable Shift
Axle Front Live Independent
Rear Live Rigid

PROJECT TOPIC-
To eliminate the defect of uneven gap between 3rd stop
light mounting holder and body in Gurkha vehicle.

 Project Theme: To eliminate the defect of uneven gap

between the 3rd mounting bracket(spoiler light) and body.
  Justification:
 PARETO CHART:

 DESCRIPTION OF PROBLEM
4W1H

To reduce the uneven gap between high mount stop lamp.

A.What is problem

It is an existing problem.
B.When it is started

C.Where is the At gurkha trim line.

problem

D.
Internal costumer.
Who is complaining

E.How much 80% of the vehicle

  GEMBA OBSERVATION
 SOP is available.
 Operator is following SOP.
 Operator is trained.
 Tapping is done on the welded nut of the body bracket.
 Grinding of the end profile of the holder is done by the operator.
 After fitment of spoiler light on the body of Gurkha vehicle there is
uneven gap observed between body and the bracket.

 4-M ANALYSIS
  CAUSE VALIDATION

CAUSE
S.NO PROBABLE CAUSES STATUS
VERIFICATION
It is not a
1 OPERATOR IS TRAINED OK
cause.
 It is not a
2 OPERATOR FOLLOWS SOP OK
cause.
TAPPING TOOL IS IN GOOD It is not a
3 OK
CONDITION cause.
PNEUMATIC GRINDER IS It is not a
4 OK
IN GOOD CONDITION cause.
It is not a
5 SOP IS AVAILBLE OK
cause.
END PROFILE OF THE
It is a
6 MOUNTING HOLDER NOT OK
cause.
FOUND UNEVEN

 WHY-WHY ANALYSIS

ANALYSIS
S.NO CAUSE
END PROFILE OF THE MOUNTING HOLDER FOUND UNEVEN

1.
WHY
2.
WHY
3.
WHY

 ACTION PLAN
Sr. No. Major causes identified Action Plan

 BENEFITS

 STANDARDISATION

LEARNINGS

1. Poka Yoke –
Poka-yoke is a Japanese term that means "mistake-proofing" or "inadvertent error
prevention".
 2. Kaizen -
Kaizen, also known as continuous improvement, is a long-term approach to work that
systematically seeks to achieve small, incremental changes in processes in order to
improve efficiency and quality.

3. Cycle time –
Cycle time is the total time from the beginning to the end of your process, as defined by
you and your customer.Cycle time includes process time, during which a unit is
acted upon to bring it closer to an output, and delaytime, during which a unit of
work is spent waiting to take the next action.

4. Take time –
Takt time may be thought of as a measurable “beat time,” “rate time” or “heartbeat.”
In Lean, takt time is the rate at which a finished product needs to be completed in
order to meet customer demand.
5. Lead time –
the time between the initiation and completion of a production process.
6. Throughput time –
throughput time is the amount of time required for a product to pass through a
manufacturing process, thereby being converted from raw materials into finished
goods. The concept also applies to the processing of raw materials into a
component or sub-assembly.
7. 5S
Removing all unnecessary items from the
Sort (Seiri)
workplace
Set In
(Seiton) Creating a specific location for everything
Order
Shine (Seiso) Clean the work area
Standardise the best practice within the
Standardise (Seiketsu)
workplace
Sustain (Shitsuke) Never slip back into the old ways

8. 4M
Man
 a. Skill
b. Technology
c. Organization
d. Resources
e. Communications
Machine
f. Design
g. Installation
h. Supplier
Methods
i. Schedule
j. Procedure
Material
k. Design
l. Quality

9. 3M
Muda (waste), Muri(overburden) and Mura(unevenness)

10. PDCA
The plan–do–check–act cycle (Figure 1) is a four–step model for carrying out change.
Just as a circle has no end, the PDCA cycle should be repeated again and again for
continuous improvement.

11. 7 QC Tools
Histograms
Cause and Effect Diagram
Check Sheets
Pareto Diagrams
Graphs
Control Charts
Scatter Diagrams
12. QC STORY (QUALITY CONTROL )
QC story is a systematic methodology commonly used in practical procedures and
practical methods of problem solving in team.
The Quality Control Story (QC Story) method represents, for the automotive industry
companies, a problem-solving method based on considering the facts and data,
 without speculation, for a problem caused by several factors. QC Story method is
applicable not only to quality problems, but also to problems of productivity, costs,
logistics, and energy. This paper presents the improvement in the customer
complaints process achieved by an effective use of the QC Story methodology. It is
presented the QC Story methodology and its performance in influencing the
customer complaints management process throughout a case study in the
automotive industry

CONCLUSION

The whole experience of working in this environment of Force Motors was great
.The organization has good culture , best minds of industry , cutting edge
technology and high quality of work which has yielded great results .
 Throughout my internship I could learn more about the definition of
mechanical engineer and prepare myself to more responsible and innovative
engineer in future .

Throughout my project I got deep knowledge of working with Vehicle Assembly

department.

The work I accomplished is satisfactory and I tried my best to grasp as much as I

can learn various aspect of how Vehicle assembly department works and
how defect analysis is done.

It is really great learning experience at Force Motors Ltd.

Thank you all for your support and guidance .