Project Report at TATA MOTORS, Pantnagar

ENGINE MOUNT NOISE 2012

INTRODUCTION

“A promise is promise and I kept my promise”- this is the historical statement which Mr. RATAN TATA said when he launched his ambitious TATA NANO; the people’s car in India on 23 rd march 2009. Tata has always given value products in the Indian Car Market whether it is path breaking recently launched TATA NANO or TATA INDICA (which created great brand into the car industry in the diesel segment).

TATA GROUP OF COMPANIESThe Tata group comprises over 100 operating companies in seven business

sectors: communications and information technology, engineering, materials, services, energy, consumer products and chemicals. The group has operations in more than 80 countries across six continents, and its companies export products and services to 85 countries.

Every Tata company or enterprise operates independently. Each of these companies has its own board of directors and shareholders, to whom it is answerable. There are 31 publicly listed Tata enterprises and they have a combined market capitalization of about $80.61 billion (as on July 12, 2012), and a shareholder base of 3.6 million. The major Tata companies are Tata Steel, Tata Motors, Tata Consultancy Services (TCS), Tata Power, Tata Chemicals, Tata Global Beverages, Tata Teleservices, Titan, Tata Communications and Indian Hotels.

Founded by Jamsetji Tata in 1868, Tata’s early years were inspired by the spirit of nationalism. Tata Industries was set up by Tata Sons in 1945 as a managing agency for the businesses it promoted. Following the abolition of the managing agency system, Tata Industries'

GLOBAL INSTITUTE OF TECHNOLOGY

http://en.wikipedia.org/wiki/File:Tata_Motors_Logo.svg


mandate was recast, in the early 1980s, to promote Tata's entry into new and high-tech businesses.

Tata Industries has initiated and promoted Tata ventures in several sectors, including control systems, information technology, financial services, auto components, advanced materials, telecom hardware, airlines and telecommunication services. In more recent times, its pioneering spirit has been showcased by companies such as TCS, India’s first software company, and Tata Motors, which made India’s first indigenously developed car, the Indica, in 1998 and recently unveiled the world’s lowest-cost car, the Tata Nano.

Areas of businessTata Industries has two operating divisions which function as independent profit centers:

Tata Strategic Management Group: An independent management consulting division that assists Tata as well as non-Tata companies in enhancing their competitive edge.

Tata Interactive Systems: Among the world's leading e-learning organizations, it offers services such as project management, instructional design and graphics, and technical know-how.

Tata Motors makes passenger cars, multi-utility vehicles and light, medium and heavy commercial vehicles.

Passenger cars: compact Tata Indica in 1998, the sedan Indigo in 2002 and the station wagon Indigo Marina in 2004. Tata Motors also distributes Fiat’s cars in India.

Utility vehicles: The Tata Sumo was launched in 1994 and the Tata Safari in 1998.

Commercial vehicles: The commercial vehicle range extends from the light two-tonne truck to heavy dumpers and multi-axled vehicles in the above 40-tonne segment.




Passenger buses: The Company also manufactures and sells passenger buses, 12-seaters to 60-seaters, in the light, medium and heavy segments.

Tata Industries' main activities are:

To promote Tata’s entry into new businesses To maintain shareholding in promoted companies To invest in operating companies to facilitate growth

Board of directors Ratan N Tata, Chairman Farrokh K Kavarana RK Krishna Kumar Ishaat Hussain S Ramadorai B Muthuraman Prasad R Menon

Ravi Kant Cyrus P Mistry Kishor A Chaukar, managing

director KRS Jamwal, executive director RR Bhinge, executive director

Tata Group of Companies

Chemicals

Tata Chemicals Rallis India Tata Pigments Limited General Chemical Industrial

Products Brunner Mond Advinus Therapeutics Magadi Soda Company

Consumer Products

Tata Salt

I-shakti Casa Décor Tata Swach Tata Global Beverages Eight O’clock Coffee Tata Ceramics Infiniti Retail Tata Tea Limited is the world's

second largest manufacturer of packaged tea and tea products.

Tetley


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

http://en.wikipedia.org/wiki/Eight_O'Clock_Coffee

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

http://en.wikipedia.org/wiki/I-shakti

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

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



Tata Coffee Tata Industries Titan Industries Trent (Westside) Cromā Tata Sky TajAir Tata International Ltd. Tanishq Tata Refractories Westland

Energy

Tata Power is one of the largest private sector power companies.

Tata BP Solar , a joint venture between Tata Power and BP Solar

Hooghly Met Coke and Power Company

Jamshedpur Utilities and Services Company

North Delhi Power Powerlinks Transmission Tata Power Trading Tata Auto

Comp Systems Limited Tata Projects

Engineering

TAL Manufacturing Solutions

Tata Auto Comp Systems Limited (TACO)

Hispano Carrocera Tata Auto Comp Systems Limited

Tata Motors , manufacturer of commercial vehicles (largest in India) and passenger cars

Jaguar and Land Rover Tata Daewoo Commercial

Vehicle Tata Projects Tata Consulting Engineers

Limited Tata Cummins Telco Construction Equipment TRF Voltas , consumer electronics

company Voltas Global Engineering

Centre Tata Advanced Materials Tata Advanced Systems Tata Motors European Technical

Centre Tata Petrodyne Tata Precision Industries

Information systems and Communications

Computational Research Laboratories


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

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

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

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

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

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

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

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

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

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

http://www.tacogroup.com/




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

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

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

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

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

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

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

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

http://en.wikipedia.org/wiki/Crom%C4%81

http://en.wikipedia.org/wiki/Trent_(Westside)

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

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



INCAT Nelco Nelito Systems Tata Business Support Services Tata Consultancy Services Ltd.

(TCS) is Asia's largest software company.

Tata Elxsi Tata Interactive Systems Tata Technologies Limited Tata Teleservices Virgin Mobile India Tata Communications CMC Limited VSNL International Canada Tatanet , Managed connectivity

and VSAT service provider Tata Teleservices Tata Teleservices (Maharashtra) Tatanet

Services

Tata Sons The Indian Hotels Company Ginger Hotels Roots Corporation Landmark Tata Housing Development

Company Ltd. (THDC) Tata Limited TATA AIG General Insurance

TATA AIG Life Insurance Tata AG Tata Asset Management Tata Financial Services Tata Capital Tata International AG Tata Investment Corporation Tata Advanced Systems Limited Drive India Enterprise Solutions Mjunction services Tata Quality Management

Services Tata Realty and Infrastructure

Limited Tata Interactive Systems Tata Africa Holdings Tata Auto Comp Systems Tata Industrial Services Tata NYK Tata Services Tata Strategic Management

Group Telco Construction Equipment

Steel

Tata Steel Tata Steel Europe Tata Steel KZN Tata Steel Processing and

Distribution JAMIPOL


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

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

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

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

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

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

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

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

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

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

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

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

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

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



NatSteel Holdings Tata BlueScope Steel Tata Metaliks Tata Sponge Iron

Tayo Rolls The Tinplate Company of India TM International Logistics

TATA MOTORS

Tata Motors Limited is India's largest automobile company, with consolidated revenues of INR 1, 65,654 crores (USD 32.5 billion) in 2011-12. It is the leader in commercial vehicles in each segment, and among the top three in passenger vehicles with winning products in the compact, midsize car and utility vehicle segments. It is the world's fourth largest truck and bus manufacturer.

The Tata Motors Group’s over 55,000 employees are guided by the vision to be ''best in the manner in which we operate, best in the products we deliver, and best in our value system and ethics.''

Established in 1945, Tata Motors' presence indeed cuts across the length and breadth of India. Over 6.5 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 3,500 touch points.

Tata Motors, the first company from India's engineering sector to be listed in the New York Stock Exchange (September 2004), has also emerged as an international automobile company. Through subsidiaries and associate companies, Tata Motors has operations in the UK, South Korea, Thailand, Spain and South Africa. Among them is Jaguar Land Rover, a business comprising the two iconic British brands that was acquired in 2008. JLR supports two state of the art engineering and design facilities and three manufacturing plants (Solihull, Castle Bromwich & Halewood) in the UK.

Tata Motors is also expanding its international footprint, established through exports since 1961. The company's commercial and passenger vehicles are already being marketed in several countries in Europe, Africa, the Middle East, South East Asia, South Asia, CIS, Russia and South America. It has franchisee/joint venture assembly operations in Bangladesh, Ukraine, and Senegal.

The foundation of the company's growth over the last 66 years is a deep understanding of economic stimuli and customer needs, and the ability to translate them into customer-desired offerings through leading edge R&D. With over 4,500 engineers and scientists, the company's Engineering Research Centre, established in 1966, has enabled pioneering technologies and products. The company today has R&D centers in Pune, Jamshedpur, Lucknow, Dharwad in India, and in South Korea, Spain, and the UK. It was Tata Motors, which developed the first indigenously developed Light Commercial Vehicle, India's first Sports Utility Vehicle and, in 1998, the Tata Indica, India's first fully indigenous passenger car. Within two years of launch, Tata Indica became India's largest selling car in its segment. In 2005, Tata




Motors created a new segment by launching the Tata Ace, India's first indigenously developed mini-truck.

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.

With the foundation of its rich heritage, Tata Motors today is etching a refulgent future.

PLANT LAYOUT



BODY IN WHITE (Welding) 1A,1B,1C & 1D

Overhead conveyerPAINT-SHOP

ENGINE & GEAR-BOX ASSEMBLY

Overhead conveyer

TRIM CHASIS FITMENT (ASSEMBLY)1A, 1B, 1C & 1D

DISPATCH YARD


Location

Tata Motors' plants are located at Jamshedpur (eastern India), Pune and Sanand (western India), Lucknow and Pantnagar (northern India). Tata Motors and Fiat have a common manufacturing facility at Ranjangaon,

near Pune.

TATA MOTORS (Small Car Division) Pantnagar

The Company has set up a plant for its mini-truck Ace and the passenger carrier Magic (based on the Ace platform) & Venture at Pantnagar in Uttarakhand. The plant began commercial production in August 2007. This is the company's fourth plant, after Jamshedpur (commercial vehicles), Pune (commercial vehicles and passenger vehicles) and Lucknow (commercial vehicles). The plant is spread over 953 acres, of which 337 acres is occupied by the vendor park.

State-of-the-art facilities include weld shops, paint shops, engine and gear box shops and assembly lines. The Company has invested over Rs.1000 crores in the



MANUFACTURING

PRODUCTION SYSTEM

BIW(Body in white)PAINTTCF(Trim chassis fitment)PDI (Pre-Delivery Inspection)POWERTRAINMATERIAL SUPPLY (JIT,KAIZEN,JIS)QUALITY MANAGEMENT

MES(Manufacturing execution system)SAP

PRODUCTION PLANNING


plant. Vendors for the vehicle have made additional investments to set up their plants in the vendor park adjoining the plant. The operation has generated about 7500 direct and indirect jobs in the plant, among vendors and service providers in the area.

DESCRIPTION OF SHOPS

ASSEMBLY SHOP –

o Also known as TCF Shop (TRIM CHASSIS FITTING). In this shop all the assembly works like Engine,

o Suspension, Tyres, Lights, Dashboard etc. fitment is carried out.

WELD SHOP –

o Also known as BIW Shop (BODY IN WHITE).



UNDER BODY LINE

SUB ASSEMBLIES

MAIN FRAME

LINE

SUB ASSEMBLIES

METAL FINISH LINE PAINT SHOP


o Here the different parts are welded together and the whole structure of the car is built.

o This shop plays very important role in framing the body shell. The press panels are transported from Bhuj and Pune plant.

o It has three main assemblies, which includes-UB(under body), ML(Main line or main frame) and MF(metal finish) where different welding processes of Projection welding Stud welding Spot welding

CO2 welding MIG welding

Are done and after that the parts are attached to the main assemblies.

POWER TRAIN SHOP –

o This shop is divided into Power Train and Engine shop. Here various operations related to Engine, Gear Trains etc. are performed.

o It consists of Engine Assembly Shop Transaxle Assembly Shop Engine Dressing Line

In Engine assembly the various components of the Engine are assembled into a single unit and sent for the various tests.



ED OVEN

SOL SEALING (UB) SEALANT

WELD BODY ELECTRODEPOSITIONPRETREATMENT

INTERMEDIATE COAT (I/C)

TOUCH UP AND INSPECTION

UNDERCOAT OVEN

DRY SANDINGI/C OVEN COOLING

DRY SANDINGTOP COAT (T/C)T/C OVENTCF

COOLING UNDER COAT


PAINT SHOP –

o The TAIKISHA paint shop is the beauty parlors of the car plant. This shop paints the car in various shades. It takes 18 steps spread over less than 10 hours to accomplish the task.

o Here in Paint shop: Colour and appearance Covering of gaps between the weld joints Corrosion resistance Smothering of sharp corners

Shop layout




TCF SHOP

Here the painted chassis delivered from the Paint shop is accessorized from scratch to a finish car ready for dispatch and also tested.

The car delivered by the TCF shop is completely checked with reference to product’s utility quality and manufacturing quality. After several inspections made by line operators for operational conformance and ethical looks the Car is permitted to be dispatch from TCF shop by the assurance of Line supervisors and operators.

The cart dispatched from the TCF shop is delivered, through drive test to the PDI (Pre-Delivery Inspection) shop where final touching to looks is given and the conformance of working of all the accessories is done.

SHOP LAYOUT



NOK

ROLL AND BRAKE TESTCANOPY TEST

REWORK PRE DISPATCH INSPECTION (PDI)

OK

PADTo

costumer

TRIM LINE(TR1, TR2)

UNDER BODY LINE(UB1, UB2, UB3, UB4)

MECHANICAL LINE

WHEEL ALIGNMENT


PDI SHOP –

o PDI is the final quality check, in this the overall checking of the vehicle takes place, in this the fitment is not done, only the outward checking is completed. The final QA OK of the vehicle is done here and after this the vehicle is sent for dispatch.

o Parts which are checked are mentioned below:





1. Brake, Brake oil. 21. Inner handle.2. Carpet fitment. 22. Instrument cluster.3. Central lock 23. Keys.4. Coolant filling 24. RH front door.5. Dents 25. Roof lamp.6. Door pad 26. Roof lining.7. Drive shaft 27. Rear bumper.8. Engine oil. 28. Rear door LH, RH.9. Engine wiring harness. 29. Rear door lock LH10. Front bumper. 30. Rear door lock RH.11. Front door LH 31. Rear seat12. Front door lock LH 32. Seat. Belt13. Front door lock RH 33. Spare wheels14. Front seat 34. Scratches on whole body15. Fuel. 35. Steering wheels.16. Gear shifter. 36. Tail lamp.17. Head lamp. 37. Washer jet.18. Hood LH. 38. Window glass.19. Hood RH 39. Wind shield washer.20. Horn 40. Wiper.



TATA MOTORS SUMMER INTERNSHIP PROJECT

ELIMINATION OF ENGINE MOUNT NOISE IN ACE ZIP & MAGIC IRIS

What is Engine Mount?

Engine mounts hold a vehicles engine in place on the frame. An engine mount is just that it mounts the engine to a vehicle. It keeps the engine from moving or shifting out of place while the vehicle is operating. If a mount becomes worn out or broken it can allow the engine to move excessively providing a rougher ride. If allowed to persist extra strain will be put on the other mounts increasing their chance of failure, allowing the engine to come free in the vehicle causing very costly repairs.

Structure

An engine mount consists of two attached metal parts with rubber in between. One side of the mount is bolted to the engine while the other




is attached to the frame. The rubber in the center absorbs vibrations while allowing a small amount of movement.

Function

The engine mount keeps the engine secured, prevents it from vibrating excessively and ensures that it stays properly connected. It also keeps vibrations from traveling through the frame and other parts of the vehicle.

Malfunction

Engine mounts may malfunction due to the bolts or rubber on the mount being cracked and worn. The symptoms of a faulty mount include excessive shaking or vibration from the engine and thumping noises from under the hood. If symptoms indicate the engine mount is not secure, it should be replaced right away to avoid damage to the engine.

The Engine Mount acts as a transition between the motor and the surrounding components, and allows installers to secure the motor within the device. The right motor mount can extend the life of the device while the wrong mount may result in excess vibration and a shortened lifespan for the engine. When choosing motor mounts, take the time to match the type of mount with the application in order to maximize its performance.

Types of Engine Mounts:-

Rigid Mounts

In a rigid mount, the motor mount is attached to the frame of the device with fasteners or bolts. Some rigid mounts may even be built into the vehicle or equipment or permanently welded in place. According to "Electrical Construction and Maintenance" magazine, rigid




mounts are most often used with small motors rather than large ones. Rigid mounts provide the most accurate alignment between the motor and the surrounding mechanisms, but may be damaged by vibration under heavy-duty operation.

Resilient Mounts

Resilient motor mounts feature a layer of rubber or insulation between the mount and the motor. This material helps to reduce noise and vibration, which may extend the life of the motor and related parts. Resilient motor mounts also allow for some flexibility and movement without compromising the performance of the motor. According to "Electrical Construction and Maintenance" magazine, these mounts are often found in larger motors or in applications where excess noise or vibration could be problematic. These mounts also help to reduce the impact as the motor starts and stops, which minimize shock to the surrounding system.

Hydraulic Mounts

Hydraulic, or hydro motor, mounts contain some form of gel or liquid to help absorb impact and vibration during operation. This may include glycol or hydraulic fluid, or any other types of fluid substance. This type of mount is often used in four-cylinder motors, which produce large amounts of vibration or noise. They may also be used with other types of motors when noise levels must be kept to a minimum.

Face Mounts

In a motor designed for face mounting, or NEMA "C" mounting, the motor attaches directly to the surrounding components without the use of a standard mount. Often, installers will use a NEMA "C" face mount adapter in order to adapt a face-mounted motor to a vehicle designed for another type of motor mount. In this type of mount, the




bolts on the motor pass right through pre-drilled holes in the motor casing and into the surrounding components or devices.

Mechanical problems caused by bad Engine Mount:

Excessive Engine Vibration

Motor mounts help to keep a vehicle's engine anchored securely inside the engine compartment. Bad motor mounts, especially broken motor mounts, frequently allow a vehicle's engine to move or shake excessively; causing excessive engine vibration, which often gets transmitted into the passenger compartment of the vehicle.

Abnormal Engine Position

An engine that appears lopsided or out of alignment relative to its normal position is normally an engine, with broken or severely damaged motor mounts. In addition to securing an engine within the vehicle hood compartment and stabilizing its movements, motor mounts serve to keep an engine aligned and positioned properly to allow for adequate engine operation, and adequate operation of all of the supporting mechanical devices underneath a car's hood. Bad motor mounts can allow an engine to sag or tilt, a situation that is easily spotted by a diligent individual.

Engine Damage

In extreme cases, bad motor mounts can totally lose their structural integrity and allow a vehicle's engine to shift excessively to one side, especially during rapid engine acceleration or at high rates of speed, which can allow various mechanical engine parts, including pumps, pulleys, and diaphragms to contact the vehicle frame and break.




Broken Belts/Hoses

In addition to broken engine parts, bad motor mounts can cause damage to an engine's belts and hoses. If bad motor mounts allow excessive engine movement or tilting, various engine fan belts and/or radiator hoses can be damaged or broken, especially under heavy engine acceleration when engine movement is most pronounced.

So, what is Engine Mount Noise?

Many times bad or broken engine motor mounts will cause loud or excessive engine noise, usually knocking or clanking types of noises. These types of engine noises are usually the result of the engine block pounding or bumping against the broken or damaged motor mounts that have lost their snug fit against the engine.

The engine of Magic Iris and Ace Zip is rear drive type. The engine is mounted/ supported on four mounts, namely – A, B, C and D.

Fig: A mount Fig: B mount




Fig: C mount Fig: D mountWhen the engine is started, it produces torque. Due to the torque produced

by the engine, it vibrates. If the mounts on which the engine is mounted are loose, broken or not fixed in correct position, it produces unwanted noise. This outcome comes in the form of metal-metal clanking noise. Usually, this mount noise are found and solved in the UNDER PIT section of the TCF shop. Then the vehicle goes for road test. After road test, any further mount noise which was not found in the U/P section is found and repaired.

Specification of mounts

A mount B mount C mount D mount

Bracket bolt

Centre bolt

Bracket bolt

Centre bolt

Bracket bolt

Centre bolt

Bracket bolt

Centre bolt

No. of bolts

2 1 4 1 3 1 4 1

Torque used (KgM)

4.5 8 2.3 7.7 2.3 4.5 2.3 4.5




Potential causes at each mount which leads to mount noise are as follows:1) A mount

a) Gap between engine mount and engine bracket is less.

b) Bracket bolt is loose or free.c) Centre bolt is loose or broken.d) A-mount arm bolt is free or loose. (will cause mount noise if 2 or more bolts

are loose).

2) B mount a) Centre bolt loose or free.b) Bracket of B-mount bend due to over-tightening.c) Bracket bolt missing or free.

3) C mount a) Bracket bolt loose or free.b) Bracket of C-mount bend due to over-tightening.c) Centre bolt loose or free.

4) D mount a) Bracket bolt loose or free.b) Bracket of D-mount bend due to over-tightening.c) Gap between engine bracket and engine mount more than required limit.


Due to over tightening the B mount and engine bracket clash with each other



Engine Mount Noise Monitoring SheetUnder Pit Section

SL. No.

Fouling Location

`No. of Vehicles Cause

5th July 6th July 7th July 9th July

1. A- mount ||||

= 4

|||| |

=6

|||| |||

=8

|||| ||||

=9

Bracket bolt is loose Amount arm bolt is free Arm bracket is not proper

2. B- mount |

=1

||||

=5

||

=2

|

=1

Bracket bolt loose or free Centre bolt is loose Bracket bend


Due to loose fitment of bracket bolt of C mount the engine bracket and BIW part clash with each other.



3. C- mount |

=1

|||

=3

|||

=3

||

=2

Bracket bolt is loose Centre bolt loose or free

4. D- mount |

=1

|

=1

NIL

|

=1

Bracket bolt is loose or free Centre bolt is loose or free

Engine Mount Noise Monitoring SheetRoad Test Section

SL. No.

Fouling Location

`No. of Vehicles Cause

5th July 6th July 7th July 9th July

1. A- mount NIL NIL NIL NIL NIL

2. B- mount |

=1

||||

=5

|||| ||

=7

|||| ||

=7

B MOUNT over-tight or loose




3. C- mount |

=1

|||

=3

||||

=5

||||

=5

Bracket bolt is loose Centre bolt loose or free

4. D- mount NIL NIL NIL |||

=3

Bracket bolt is loose or free Centre bolt is loose or free

B mount C mount D mount A mount0

5

10

15

20

25

0

20

40

60

80

100

120

VolumeCum.

Figure: Pareto Chart for Mount Noise Monitored

Analysis:


80-20 point

No.

of V

ehic

les w

ith m

ount

noi

se



Potential Mount Noise Area

A mountB mountC mountD mount

After taking readings from the monitoring sheet, it is found that maximum mount noise is coming from B and C mount.

Proposed Solution:

Here at TCF-1D, I was trained by the Line-supervisor to identify the root cause of mount which can be reduced by proper functioning during fitment process.

During fitment due to human error or by some other way in Under Body section, mount noise can occur. So proper care need to be to eliminate it.

For resolving the problem mentioned above a standard procedure is followed during the fitment of mount at trim line.

The procedure is in the form of Work Sheet. It is as follows:

WORK SHEET

Subject: Fitment of B-mountModel: All ACE ZIP & MAGIC IRIS




Sl. No. OPERATION SEQUENCE

Step1. Pick B mount and hand tighten it in the BIW (Body in White) with 4 Nos. of MBX22 Hex. Flange screws.

Step2. Tack these bolts and torque tighten these bolts with torque ranch at 2.3 KgM.

Step3. Pick up the central bolt and fit it into the hole of B mount and engine bracket and hand tighten it.

Step4. At the quality gate check whether the screws are there & are tight or not.

Step5. Torque tighten the central bolt of B mount with torque ranch at 7.7 KgM. Avoid over tightening or applying torque more than required.

WORK SHEET

Subject: Fitment of C-mountModel: All ACE ZIP & MAGIC IRIS

Sl. No. OPERATION SEQUENCE

Step1. Pick C mount and hand tighten it in the BIW (Body in White) with 3 Nos. of MBX22 Hex. Flange screws.

Step2. Tack these bolts and torque tighten these bolts with torque ranch at 2.3 KgM.

Step3. Pick up the central bolt and fit it into the hole of B mount and engine bracket and hand tighten it.

Step4. At the quality gate check whether the screws are there & are tight or not.




Step5. Torque tighten the central bolt of B mount with torque ranch at 4.5 KgM. Avoid over tightening or applying torque more than required.

After following the above mentioned procedure 20 vehicles were monitored, which are as follows:

We see that after following the procedure, the no. of vehicles with mount noise has reduced.


SL. No.

Vehicle No.U/P(Under

Pit)R/T(Road Test)

1) MAT491005CJG26351 2) MAT491005CJG26352 3) MAT491005CJG26353 4) MAT491005CJG26354 5) MAT491005CJG26355

6) MAT491005CJG26356 7) MAT491005CJG26357 8) MAT491005CJG26358 9) MAT491005CJG26359 10) MAT491005CJG26360 11) MAT491005CJG26361 12) MAT491005CJG26362 13) MAT491005CJG26363 14) MAT491005CJG26364 15) MAT491005CJG26365 16) MAT491005CJG26366 17) MAT491005CJG26367 18) MAT491005CJG26368 19) MAT491005CJG26369 20) MAT491005CJG26370



Major reasons which caused are:

The body parts which are sent from BIW are not properly fabricated. The line man of TCF-1D are not using proper means like torque wrench for

the fitment of Under Body. So, over tightening case become prominent.

Hence I observed that:

Testing and inspection should be carried out at every quality gate.

Tightening of nut and bolt should be proper.

By using automation and precise machinery.

The assembly parts should be manufactured by advanced manufacturing processes in Vendor Company.

The training and motivating policy should be applied to workers.




Kaizen should be applied.

Job rotation policy should be applied.

Possible further aspects in the project:

“WHAT CAN GO WRONG ANALYSIS”: By doing this one can also find the root cause of the untraceable line problems and take suitable steps towards its elimination and thus TML TCF-1D shop can assure nearly perfect fitment for the car .

CONCLUSIONS

After analyzing the problem, in the Under Body section (Magic iris and Ace Zip) the

mount noise was eliminated with positive results.



Project Report at TATA MOTORS, Pantnagar

Career

Transcript of Project Report at TATA MOTORS, Pantnagar