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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)
Gaurav Batra -- UE99018 UIET, PU
2
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
3
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
4
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
5
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.
Gaurav Batra -- UE99018 UIET, PU
6
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.
Gaurav Batra -- UE99018 UIET, PU
7
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.
Gaurav Batra -- UE99018 UIET, PU
8
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
Gaurav Batra -- UE99018 UIET, PU
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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
Gaurav Batra -- UE99018 UIET, PU
10
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.
Gaurav Batra -- UE99018 UIET, PU
11
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.
Gaurav Batra -- UE99018 UIET, PU
12
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
Gaurav Batra -- UE99018 UIET, PU
13
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
Gaurav Batra -- UE99018 UIET, PU
14
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.
Gaurav Batra -- UE99018 UIET, PU
15
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.
Gaurav Batra -- 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 -- UE99018 UIET, PU
17
3) BRAND: TVS JIVE
LAUNCHED: 2009
EXECUTIVE LEVEL: 1) BRAND: TVS FLAME
LAUNCHED: 2008
Gaurav Batra -- UE99018 UIET, PU
18
PREMIMUM LEVEL:
1) BRAND: TVS APACHE RTR 160
LAUNCHED: 2005
2) BRAND: TVS APACHE RTR 180
LAUNCHED: 2009
Gaurav Batra -- UE99018 UIET, PU
19
3) BRAND: TVS APACHE RTR 180 with ABS
LAUNCHED: 2011
SCOOTERS:
1) BRAND: TVS SCOOTY PEP+
LAUNCHED: 2005
Gaurav Batra -- UE99018 UIET, PU
20
2) BRAND: TVS WEGO
LAUNCHED: 2009
MOPEDS: 1) BRAND: TVS XL SUPER, XL HD
LAUNCHED: 1979
Gaurav Batra -- UE99018 UIET, PU
21
3 WHEELER: 1) BRAND: TVS KING
LAUNCHED: 2009
Gaurav Batra -- UE99018 UIET, PU
22
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
Gaurav Batra -- UE99018 UIET, PU
23
PLANT LAYOUT
Gaurav Batra -- UE99018 UIET, PU
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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.
Gaurav Batra -- UE99018 UIET, PU
25
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.
Gaurav Batra -- UE99018 UIET, PU
26
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
Gaurav Batra -- UE99018 UIET, PU
27
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
Gaurav Batra -- UE99018 UIET, PU
28
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.
Gaurav Batra -- UE99018 UIET, PU
29
Gaurav Batra -- UE99018 UIET, PU
30
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.
Gaurav Batra -- UE99018 UIET, PU
31
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
Gaurav Batra -- UE99018 UIET, PU
32
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
Gaurav Batra -- UE99018 UIET, PU
33
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.
Gaurav Batra -- UE99018 UIET, PU
34
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.
Gaurav Batra -- UE99018 UIET, PU
35
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.
Gaurav Batra -- UE99018 UIET, PU
36
STANDARDIZATION
Before
Gaurav Batra -- UE99018 UIET, PU
37
AFTER
(O.K. and not O.K. frames are
separated O.K. frames are
placed in the trolley)
Gaurav Batra -- UE99018 UIET, PU
38
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
Gaurav Batra -- UE99018 UIET, PU
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
Gaurav Batra -- UE99018 UIET, PU
40
Gaurav Batra -- UE99018 UIET, PU
41
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.
Gaurav Batra -- UE99018 UIET, PU
42
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.