“ImproveProcess 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) Gaurav Batra -- UE99018 UIET, PU 1 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. Gaurav Batra -- UE99018 UIET, PU 2 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.) Gaurav Batra -- UE99018 UIET, PU 3 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. Gaurav Batra -- UE99018 UIET, PU 4 which helped me to face any type of situation in years to come. PU 5 . Gaurav Batra -. This project report is written on account of what I learnt and got experience during my studies while accomplishing B.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. I wish those who going through it.TECH. theoretical and imaginative skills to real life situation and to evaluate the results thereof. will not only find it reliable but also will find useful and accurate information. This gives an opportunity to me apply their conceptual. This helped me in boosting up my confidence and determination.UE99018 UIET. V. Sundaram Iyengar in 1911. Sundaram Clayton went on to be awarded the Japan Quality Medal. 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. At present TVS Apache.INTRODUCTION TO COMPANY INTRODUCTION TVS Motor is the third largest two-wheeler manufacturer in India and ranks among the top ten globally. 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. TVS Scooty. two wheelers and a few other industrial products. Gaurav Batra -. 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. It is the first company in the world to be honoured with The Deming Prize for Total Quality Management.UE99018 UIET. The company was the first in India to launch 2-seater 50cc moped and 100cc Indo-Japanese motorcycles. It is the only automotive manufacturer in India to get the prestigious Deming Prize. PU 6 . They are also into the financial services sector. TVS Flame. TVS Star City and TVS Sport are the popular bikes in Indian market. TVS was founded by T. 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. The first 18 models were launched in the first 18 years and next set of 18 has been launched in next 8 years. Mysore. Sundaram Clayton Limited (SCL) started a moped division at Hosur to manufacture TVS-50 mopeds indigenously designed and developed.COMPANY PROFILLE TVS GROUP TVS group started its journey in 1911 by Sri Trichur Venkgaruswami Sundaram Iyengar. Gaurav Batra -. marking the start of automobile giant TVS Motors Pvt. TVS has launched 36 models starting from mopeds XL in 1979 to Flame-125 in 2008. Out of our total product range 22% are mopeds. Indonesia and Nalagarh. Ltd. TVS motor company has manufacturing units at Hosur. PU 7 . TVS MOTOR COMPANY In 1979. 60% are motorcycles and 18% of scooters. It has been one of India’s largest industrial entities. TVS motors is the 3 rd largest 2wheeler 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.UE99018 UIET. PU 8 .UE99018 UIET. Gaurav Batra -.THE TVS GROUP Sundaram-Clayton Group of Companies 1979 Sundaram-Clayton Moped Division 1982 Suzuki Motor Corporation TVS-SUZUKI LIMITED 2001 Parted Suzuki Motor Corporation TVS MOTOR COMPANY LTD. UE99018 UIET. leading manufacturer of high value for money. lifetime personal transportation products under TVS brand for customers predominantly in Asian markets and to provide fulfillment and prosperity for employees. PU 9 . environmentally friendly.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. dealers and suppliers.” Shri Venu Srinivasan Managing Director Gaurav Batra -. TVS Motor will provide total customer satisfaction by giving the customer the right product. capitalizing on the expertise developed in the areas of manufacturing.UE99018 UIET. at the right time. Gaurav Batra -. Global overview TVS Motor will have profitable operations overseas especially in Asian markets. technology and marketing. at the right price. PU 10 . The thrust will be to achieve a significant share for international business in the total turnover.VISION STATEMENT: TVS Company will be: Driven by customer TVS Motor will be responsive to customer requirements consonant with its core competence and profitability. 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. At the cutting edge of Modern technology TVS Motor will hone and sustain its cutting edge of technology by constant benchmarking against international leaders. 1984 . People and projects will be evaluated both by their end results and the process adopted. Gaurav Batra -. 1996 – Introduced India’s first catalytic converter enabled motorcycle. KEY MILESTONES FOR TVS MOTORS:1980 . Committed to total quality TVS Motor is committed to achieving a self-reviewing organization in perpetuity by adopting TQM as a way of life.Joint Venture with SUZUKI MOTOR Corporation (SMC).Became First Company to introduce 100cc Motorcycle in India. There will be a sustained effort through systematic training and planning career growth to develop employees’ talents and enhance job satisfaction. the 100cc SHOGUN. 1994 . Japan. TVS Motor will support and encourage the process of self-renewal in all its employees and nurture their sense of self worth. 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. TVS Motor will create an enabling ambience where the maximum self-actualization of every employee is achieved.UE99018 UIET.Started Manufacturing India’s first 2.Launched India’s First Sub-100 cc indigenous scooter – TVS SCOTTY.SEATER MOPEDS. TVS Motor believes in the importance of the process. 1982 . PU 11 . 2004 – Won TPM excellence award. 2001 .UE99018 UIET. 2005 – Launched TVS APACHE in November. LOCATION OF TVS MANUFACTURING PLANTS TVS Motor Company has 9 manufacturing plants all over the world.INDONESIAN Subsidiary formed. 2000 – Launched TVS FIERO.Established 3rd Manufacturing plant in NALAGARH. the first Bike without Clutch.Established 2nd Manufacturing Plant in MYSORE. 2001 .Launched 125 cc 3 valves CC-Vti Engine Motorcycle ‘TVS FLAME’ 2009 – Launched TVS JIVE. Mysore started in 1998 Gaurav Batra -. Hosur started in 1984 Plant 3 – Engine Component Division.Launched India’s First indigenously designed 4-Stroke Motorcycle. TVS WEGO in November. India’s first 150cc 4-stroke motorcycle. 2005 . Himachal Pradesh 2008 . 2004 – Launched TVS CENTRA with revolutionary VY-I engines for best in class mileage. Hosur started in 1988 Plant 4 – Scooter & Motorcycle Division. 2006 . 2002 . Hosur started in 1979 Plant 2 – Motorcycle Division.Won Deming Award for Best Quality.1998 . which are as follows: Plant 1 – Moped Division.Became independent Company – TVS Motor Company after exit of SMC from joint venture. PU 12 . started its operations last year. Hosur started in 1988 Plant 6 – Engine Component Division. First vehicle rolled out at this plant on 29th April 2007. Mysore started in 2003 Plant 7 – Motorcycle Division.45C Minimum Temperature . Hosur started in 2007 NALAGARH PLANT This is the latest manufacturing plant. Nalagarh started in 2007 Plant 8 – Bebeks Motorcycle Division. Nalagarh plant is situated at village Bhatian. Jakarta Indonesian started in 2007 Plant 9 – Auto Manufacturing Division.3C Humidity – 60 Maximum %(min) to 90 %(max) PRODUCTS TVS Star City 110 TVS Sport Star Basic Moped Gaurav Batra -. 4 Kms away from Nalagarh city on Bharatgarh Road in Himachal Pradesh. CLIMATIC CONDITIONS Temperature . which marked the beginning of new chapter in TVS motors.UE99018 UIET.Plant 5 – Spares Warehouse Division. PU 13 . 3. are known as Direct Material. 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. The materials handled by this department are the incoming and outgoing materials.UE99018 UIET. The DM stores are the department.DEPARTMENT IN H. 2.g. Stores. Vendor development. PU 14 . which takes care of the stock of the direct materials. Under MPG 1. QAD Himachal: .P.(Quality Assurance Department): This department at Himachal is looking after the day-to-day quality issues in the plant. 4. stationary. Material procurement. free cloth. gloves. DM STORES: All the materials. which are directly assembled on line. IDM STORES: Indirect material e. Production planning & control. PLANT MPG (MATERIAL PROCUREMENT GROUP): There are four deptt. Gaurav Batra -. Gaurav Batra -. Vehicle assembly.(Information System Department): Manages the information system and technology of the plant. PMD: . 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. Vehicle Assembly: All the departments that manufacture different products stages of the plant have vehicle assembly as their final customer.ISD: .UE99018 UIET.(Plant Maintenance Department): PMD looks after the supply of Water. It also has to look after the maintenance of the same. Paint shop-Plastic: In this paint shop all the plastic parts of the vehicle are painted and then supplied to the customer. which the customer wants. PU 15 . Electricity and Air to each and every spot in the plant. 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. Here the whole assembly of vehicle is done. 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. UE99018 UIET. PU 16 .PRODUCTS & SPECIFICATIONS MOTOR CYCLES: ENTRY LEVEL: 1) BRAND: TVS STAR CITY LAUNCHED: 2004 2) BRAND: TVS STAR SPORT LAUNCHED: 2009 Gaurav Batra -. PU 17 .3) BRAND: TVS JIVE LAUNCHED: 2009 EXECUTIVE LEVEL: 1) BRAND: TVS FLAME LAUNCHED: 2008 Gaurav Batra -.UE99018 UIET. UE99018 UIET. PU 18 . PREMIMUM LEVEL: 1) BRAND: TVS APACHE RTR 160 LAUNCHED: 2005 2) BRAND: TVS APACHE RTR 180 LAUNCHED: 2009 Gaurav Batra -. 3) BRAND: TVS APACHE RTR 180 with ABS LAUNCHED: 2011 SCOOTERS: 1) BRAND: TVS SCOOTY PEP+ LAUNCHED: 2005 Gaurav Batra -. PU 19 .UE99018 UIET. XL HD LAUNCHED: 1979 Gaurav Batra -.UE99018 UIET.2) BRAND: TVS WEGO LAUNCHED: 2009 MOPEDS: 1) BRAND: TVS XL SUPER. PU 20 . UE99018 UIET. 3 WHEELER: 1) BRAND: TVS KING LAUNCHED: 2009 Gaurav Batra -. PU 21 . FLOW CHART OF A TWO-WHEELER FROM VENDOR TO CUSTOMER VENDOR SKF Bearing FACTORY TVS Motors Co.UE99018 UIET. Parts Vehicle TVS Motor Company CUSTOMER DEALER BRANCH Gaurav Batra -. PU 22 . PU 23 .UE99018 UIET.PLANT LAYOUT Gaurav Batra -. In this department skilled person. PU 24 . Gaurav Batra -. who knows about all instruments and gauges. takes inspection. Quality department takes all of the inspection. where the production quality will be controlled.INTRODUCTION TO PROJECT QAD (Quality Assurance Department) is the department. then skip and non-skip will be decided by inspection. When the inward material is unloading.UE99018 UIET. UE99018 UIET. I have been given the project to improve the process capability. Checking the quality of the material etc. Gaurav Batra -.PROJECT Improve Process Capability Parameters: Cup top diameter and cup bottom diameter of head pipe. The inspection process of each part is carried out in accordance with the TSES (TVS System of Engineering Standards). PU 25 . Quality inspection is done of the material. The whole department inspects the quality of all the incoming supplier parts. Material sends to the assembly line after inspection. I have been allotted SUPPLIER QUALITY department for my project training. Physical verification of material. Increase in vehicle loss. Increase in rectification hours. Extra time taken in segregation of parts.IMPORTANCE OF PROBLEM This problem is aimed to achieve zero quality defects in the supplier parts.969 Gaurav Batra -. Customer dissatisfaction.UE99018 UIET. PU 26 . USL 50. If the problem is not solved it will lead to: Increase in rework. Late delivery of vehicle.031 PROCESS VARIATION 60 50 VALUE 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 SAMPLE LSL 49. USL 60 50 CONTINUOUS PROCESS LSL VALUE 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 SAMPLE Series1 Gaurav Batra -. TARGET: To made the process more capable. with never ending improvement cycle.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. More unnecessary movement of worker. THEME AND TARGET THEME: Improve process capability by the detail knowledge of the process and their ability. So the parts which are inspected without proper facility leads to: More time consumption. PU 27 . Un-checked internal defects.UE99018 UIET. Setting of the tool bit is not done properly. 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. These problems arise because no proper setting is done on the machine. All the observations were done in the JBM group of company “Thai Summit Neel Auto Pvt. PU 28 . More unnecessary movement of worker. Not proper division of work among the worker.UE99018 UIET. Storage area is less. Gaurav Batra -. Ltd. More time consumed in transporting of material.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. The operator has more workload on the machine.. OBSERVATION: Less skill labor is employed Lot of time wastage because of improper placement of material Process is very slow due to unskilled labor. Nalagarh”. UE99018 UIET.Gaurav Batra -. PU 29 . Analysis is done by considering 4M i. Gaurav Batra -. men. Then I collected new data to validate the main causes. All material should be placed systematically. PU 30 . There are need of the one more helper on the boring machine The parts should be inspected as per the standard set of instructions.UE99018 UIET.e. All material should be placed in store properly. Best utilization of 4M. material and method. There should be proper supply of material from store to line. machine. All the parts should be inspected systematically. analysis on these facts is done. The testing facility should be in accordance with the TSES.ANALYSIS AND INTERPRETATION ANALYSIS: After observing all the facts related to project. UE99018 UIET. PU 31 .CAUSE AND EFFECT DIAGRAM LEVEL 1 MEN ` MACHINE Poor maintenance of machine Machine tool bit not changed Unskilled operator Process capability Defective material supplied Improper distribution of work Improper placement of material Less space for storage MATERIAL METHOD Gaurav Batra -. UE99018 UIET. PU 32 .CAUSE AND EFFECT DIAGRAM LEVEL II: MEN MACHINE Unskilled labor Machine tool bit change not done Boring process Improper work distribution No placement of material MATERIAL METHOD Gaurav Batra -. Work not properly distributed.UE99018 UIET. Machine tool bit not change Tool bit change Tool bit not changed 3. PU 33 . STRONG RELATIONSHIP MEDIUM RELATIONSHIP WEEK/NO RELATIONSHIP Gaurav Batra -.CAUSE AND VERIFICATION: SR. No proper Work should be distribution of properly distributed the work. Both frames are placed together.NO CAUSE SPEC/STD INVESTIGATION ANALY SIS 1. Working place Less movement of worker are not suitable There is more movement of worker. 2. 4. Ok and not ok frames are placed together Should be placed in separate trolleys. e. PU 34 .UE99018 UIET. Gaurav Batra -. Increase in working efficiency. Reduce the operator workload. There is best utilization of manpower.INTERPRETATION: It is analyzed that after implementing this project working efficiency increased by 50% to 60%. Both workers do the equal amount of work i. Proper division of work Proper utilization of manpower Saving in time. Also total time consumed is less than the previous time. proper division of work among the worker. All the advantages and disadvantages are examined of the proposals and best proposal is selected. Different proposals are made for eliminating the root causes.ACTION After analyzing I have to take suitable action to eliminate the causes of problem. Gaurav Batra -. PU 35 . It is examined that action does not produce other problems by doing time study. The carbide tool bit is changed after the 150 pieces. Different actions taken are: Material placed near the operator systematically One more helper is placed with the operator.UE99018 UIET. STANDARDIZATION Before Gaurav Batra -.UE99018 UIET. PU 36 . PU 37 . and not O.UE99018 UIET.AFTER (O.K.K. frames are separated O.K. frames are placed in the trolley) Gaurav Batra -. Due to this action the no. 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. of defects were reduced.03 50.01 50 49.998 49.99 49.UE99018 UIET.98 SAMPLE 3-D Column 2 VALUE Gaurav Batra -.988 SAMPLE VALUE 50. and the standard size of the frame was maintained.992 49. PU 38 .02 50.994 49. 50 49.996 49. of pieces which were produced before the replacement of the carbide tool bit were 200.Before After No.99 49. UE99018 UIET.99 49. And the helper is placed with the operator who after the production put the material other place. Now After when I took the action the material is placed near the operator to reduce his movement.998 49.988 SAMPLE VALUE 50. There will be the more movement of the operator to complete the process.01 50 49. Due to this reason the production was less. 50 49.994 49.02 50.992 49.996 49.Before The operator has the more work load to complete the process. PU 39 .03 50.98 SAMPLE 3-D Column 2 VALUE Gaurav Batra -.99 49. 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. Gaurav Batra -.UE99018 UIET. PU 40 . CONCLUSION This solution is best in my views because. This project helps in maintaining proper workflow. Maintaining 4M system in store.UE99018 UIET. using this process capability. Gaurav Batra -. This project is aimed at best utilization of manpower and error reduction. orderliness and cleanliness in store. So this project is helpful in: Error reduction in parts. Coordination of different depts. Proper utilization of manpower. Improvement in working efficiency. Proper workflow. in Company. PU 41 . This project is based upon the best and proper utilization of 4M i. man. machine. Change is good only if it will yield good improvements that are desirable.UE99018 UIET. This project also helps in maintaining System in future.FUTURE SCOPE OF PROJECT Nothing in this world is constant as change is rule of the world. This project also helps in maintaining high production rate. The concept applied will help in designing other inspection facilities for the supplier parts. PU 42 . materials. Gaurav Batra -. and method.e. Also this project is based upon the time study so very helpful in increasing working efficiency.