Internship Report for completion of two

months Internship at TATA Motors

AN INTERNSHIP REPORT SUBMITTED IN PARTIAL FULFILLMENT OF
T.E. Mechanical Engineering

Submitted By
TANVI JUNGHARE T190311011

Under the Guidance of

Prof. Jagannath Gawande

Department of Mechanical Engineering,

PES’s Modern College of Engineering
Pune – 411 005
[2021-22]
 Progressive Education Society’s
Modern College of Engineering, Pune

CERTIFICATE
This is to certify that the Mini-Project/Internship report entitled “Internship Report
for completion of two months Internship at TATA Motors” is successfully
completed by-

TANVI JUNGHARE T190311011

In the partial fulfilment of

T.E. MECHANICAL ENGINEERING
In
SAVITRIBAI PHULE PUNE UNIVERSITY
Under the guidance of
PROF. Jagannath Gawande
During the Academic Year 2021-22

Prof. Jagannath Prof. Dr. S. Y. Bhosale Prof. Dr. Mrs. K. R. Joshi

Gawande Associate Professor & Head of Principal,
Asst. Professor Mechanical Engineering PES’s MCOE, Pune
Department

Seal

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

1
PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]
2
 Progressive Education Society’s
Modern College of Engineering, Pune

CERTIFICATE
This is to certify that the Mini-Project/Internship report entitled “Internship
Report for completion of two months Internship at TATA Motors”
has successfully completed by

TANVI JUNGHARE T190311011

In the partial fulfilment of

T. E. MECHANICAL ENGINEERING

In
SAVITRIBAI PHULE PUNE UNIVERSITY
Under the guidance of
PROF. Jagannath Gawande
During the Academic Year 2021-22

Internal Examiner External Examiner

Seal

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

3
 INTERNSHIP COMPLETITION CERTFICATE

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

4
 ACKNOWLEDGEMENT

I take this opportunity to thank all those who have contributed in successful
completion of T.E Mini-Project/Internship work. I would like to express my sincere
thank you to my guide Prof. Jagannath Gawande who has encouraged me to work
on this topic and valuable guidance wherever required. I also extend my gratitude to
Prof.Dr.S.Y.Bhosale (HOD of Mechanical) who has provided to explore the subject
with more enthusiasm.

I am extremely indebted to TATA GROUP for giving me the opportunity to

undertake my summer training at their prestigious TATA MOTORS LIMITED. It was
an incredibly good learning experience for me to have worked at this site. I would like
to convey my heartiest thanks to Mr. Nitin Kalamkar, General Manager, I would also
like to give my heart-felt thanks to Mrs. Archana Satav, HR Manager, who heartily
welcomed me for the internship, Mr. Vijay Peshkar who guided and encouraged me
all through the summer training and imparted in-depth knowledge of the programme.
Also, I would like to thank Mr. Bhushan Shinde, who assisted and guided me
whenever I needed. I would like to thank all the department heads of TATA
MOTORS LIMITED, for giving their precious time and valuable guidance during my
internship programme.

I express my immense pleasure and thankfulness to all the teachers and staff of the
Department of Mechanical Engineering, PES’s Modern College of Engineering, Pune
for their co-operation and support.

TANVI JUNGHARE

T190311011

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

5
PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]
6
 ABSTRACT

Internships are educational and career development opportunities, providing practical

experience in a field or discipline. Internships are far more important as the employers
are looking for employees who are properly skilled and having awareness about
industry environment, practices, and culture. Internship is structured, short-term,
supervised training often focused on tasks or projects with defined time scales. Core
objective is to expose technical students to the industrial environment, which cannot
be simulated/experienced in the classroom and hence creating competent
professionals in the industry and to understand the social, economic and
administrative considerations that influence the working environment of industrial
organizations. Engineering internships are intended to provide students with an
opportunity to apply conceptual knowledge from academics to the realities of the field
work/training.

OBJECTIVES:

Internship provides an excellent opportunity to learner to see understand the

conceptual aspects learned in classes and deployed into the practical world.
Industry/on project experience provides much more professional experience as value
addition to classroom teaching.

1. To encourage and provide opportunities for students to get professional/personal

experience through internships.

2. To learn and understand real life/industrial situations.

3. To get familiar with various tools and technologies used in industries and their
applications.

4. To nurture professional and societal ethics.

5. To create awareness of social, economic, and administrative considerations in the

working environment of industry organizations

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

7
PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]
8
 INDEX

Sr. TITLE PAGE

No. NO.
1 Introduction 7

2 Literature review - About Tata Motors 9

3 Tata Motors Operations 12

4 Tata Motors Vision, Mission, Culture Credo 13

5 Types and Models Produced 14

6 Vehicle Aggregates 15

7 Basic Steps involved in Automobile Production 21

8 Body in White(BIW) Line 23

9 Body in White(BIW) Main Framing Line 24

10 Body in White(BIW) Finishing Line 25

11 Trim line 26

12 LCV Chassis Line 28

13 MHCV Chassis line 30

14 Safety Precautions 32

15 Information Fitment Drawing (IFD) 33

16 Vehicle Layout (VLO) 34

17 Basic Steps involved in IFD/VLO 35

18 Activities Involved in Vehicle Production 36

19 Launch Management 37

20 Conclusion 38

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

9
 1. INTRODUCTION
Internship program has become the bridge for those who want to enter to industry
level from the college life, through internship I got to know the real working
environment that was very much different from my course study. As part of
Engineering Curriculum under Savitribai Phule Pune University, students of Third
year, currently in Semester 6 were required to complete an internship and training
program of 4-6 weeks.

In the period of 8 weeks, I had the opportunity to learn and experience many things. I
was able to develop in depth understanding of not only technical but also non-
technical aspects involved in production and manufacturing. I was able to experience
the dynamics of working of different departments in the company and the way they
co- ordinate to increase their efficiency and get better results. I was able to grasp the
nitty gritties of the complete process from acquiring raw material to the development
and dispatch of the final product.

Within the first few weeks of my internship, I was able to identify the different
departments working together towards a common goal. During this time, I was given
the opportunity to observe and understand the workshop floor. While doing so, I was
able to identify, understand and learn the varied small and big processes which lead to
the manufacturing of the final product. I was able to observe –
1. BIW main framing line
2. BIW finishing line
3. Trim line
4. Chassis line

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

10
I was able to observe the processing on workshop floor for LCV (light commercial
vehicle) as well as MHCV (Medium and Heavy Commercial Vehicle). This helped
me develop better insights about the working on the shopfloor.

In the following weeks, my Project Guide briefed me about my Project. I was

acquainted with the different models of trucks produced according to various
customer needs. Further, I was introduced to IFD, DMU and VLO sheets. My role as
an intern was to study, understand the IFD/DMU sheets, and comply it with the
developing product which is to be launched. Later, the vehicle is checked and
quantified with the help of VLO sheets to find any discrepancies.

My experience as an intern was deeply knowledgeable at TATA Motors Limited. In a

short span of two months, I was able to develop basic understanding of automobiles,
their manufacturing process, production planning, vehicle aggregates, Quality
inspections, line quality, launch management, etc along with this I was also able to
develop qualities like humility, integrity, empathy, collaboration, accountability, etc.

OBJECTIVE’s OF INTERNSHIP

 To acquire exposure in the working environment of Light Commercial

Vehicles and understand working of different assembly lines.
 To better understand the corporate world and the interconnectivity of different
departments within an organisation
 To understand and apply IFD, DMU and VLO sheets practically in the
workplace before launching.
 To develop interpersonal, managerial and communication skills.

DETAILS OF INTERNSHIP

Organization: TATA MOTORS LIMITED

Address: PIMPRI, PUNE - 411018
The Title of Project: “IFD/VLO OF NEW MODEL/VEHICLE COMBINATION”
Department: LAUNCH MANAGEMENT
Name of Project Guide: Mr. Vijay Peshkar
Duration of Internship: 01/03/2022 to 30/04/2022

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

11
 2. LITERATURE REVIEW – ABOUT TATA MOTORS

Part of the USD110 billion Tata group founded by Jamshedji Tata in 1868, Tata
Motors is among the world’s leading manufacturers of automobiles. They believe in
‘Connecting aspirations’, by offering innovative mobility solutions that are in line
with customers' aspirations. TATA Motors is India's largest automobile manufacturer
and continue to take the lead in shaping the Indian commercial vehicle landscape,
with the introduction of leading-edge powertrains and electric solutions packaged for
power performances and user comfort at the lowest life-cycle costs. Their passenger
cars and utility vehicles are based on Impact Design and offer a superior blend of
performance, driveability, and connectivity.

Tata Motors Group (Tata Motors) is a $34 billion

organisation. It is a leading global automobile
manufacturing company. Its diverse portfolio includes an
extensive range of cars, sports utility vehicles, trucks,
buses and defence vehicles. Tata Motors is one of India's
largest OEMs offering an extensive range of integrated,
smart and e-mobility solutions.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

12
Their tech-enabled products keep them at the forefront of the market. Their key focus
areas are-
-modular architecture,
-complexity reduction in manufacturing,
-connected & autonomous vehicles,
-clean drivelines, shared mobility, and
-low total cost of ownership.
Their mission - across globally dispersed organisation – is to be passionate in
anticipating and providing the best vehicles and experiences that excite our global
customers.

FACILITIES
Tata Motors strongly focuses on manufacturing excellence and ensures that their
facilities carry out every step in the manufacturing process backed by leading-edge
R&D and meeting the highest standards of quality.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

13
PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]
14
 3. TATA MOTORS OPERATIONS
The company is headquartered in Mumbai. Tata Motors has vehicle assembly operations in
India, the United Kingdom, South Korea, Thailand, Spain, and South Africa. It plans to
establish plants in Turkey, Indonesia, and Eastern Europe. In India, Tata Motors operates
manufacturing and assembly plants at Jamshedpur, Ranjangaon, Pune, Lucknow, Sanand,
Pantnagar and Goa. The manufacturing plants at Jamshedpur and Pune are among the oldest
and largest of Tata Motors, while Lucknow facility was setup in 1992 and Sanand, Pantnagar,
Goa and Dharwad facilities are among the newest.

Tata Motors has more than 250 dealerships in more than 195 cities across 27 states and four
Union Territories of India. Tata's dealership, sales, service, and spare parts network comprises
over 3,500 touch points. Tata also has franchisee/joint venture assembly operations in Kenya,
Bangladesh, Ukraine, Russia, and Senegal. Tata has dealerships in 26 countries across 4
continents. Tata is present in many countries, it has managed to create a large consumer base
in the Indian subcontinent, namely India, Bangladesh, Bhutan, Sri Lanka and Nepal. Tata is
also present in Italy, Spain, Poland, Romania, Turkey, Chile, South Africa, Oman, Kuwait,
Qatar, Saudi Arabia, United Arab Emirates, Bahrain, Iraq, Syria and Australia.

Jaguar Land Rover, a subsidiary of the company is headquartered in Whitley, Coventry,

United Kingdom. This company have its manufacturing plants in Gaydon, Whitley
(Coventry), Liverpool, Solihull, Changshu, Itatiaia, Nitra and Pune. The Tata Motors
European Technical Centre (TMETC) is an automotive design, engineering, and research
company based at Warwick Manufacturing Group (WMG) on the campus of the University of
Warwick in England. It was established in 2005 and is an owned subsidiary of Tata Motors. It
was the joint developer of the World Truck. In September 2013, it was announced that a new
National Automotive Innovation Campus would be built at WMG at Warwick's main campus
at a cost of £100 million. The initiative will be a partnership between Tata Motors, the
university, and Jaguar Land Rover, with £30 million in funding coming from Tata Motors.

Tata Daewoo operates a manufacturing plant in Gunsan, South Korea. In a joint venture with
Afzal Motors, Tata Daewoo have a manufacturing plant in Karachi, Pakistan. It also operates
a manufacturing plant in Jamshedpur, India manufacturing Tata Novus HCV.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

15
4. TATA MOTORS MISSION, VISION AND CULTURAL CREDO

MISSION

CULTURE CREDO

VISION
PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]
16
 5. TYPES AND MODELS PRODUCED
Various load transport solutions provided by Tata Motors are-

LCV TRUCKS ICV TRUCKS

Trucks carrying a maximum gross vehicle Intermediate commercial vehicle with GVW of
weight of 3.5 metric tons and above until 8 to 10 ton. Intermediate Commercial Vehicles
15 metric Ton can be categorized as light come between the light commercial vehicles
commercial vehicles (LCVs). and M&HCV.

ULTRA LCV ULTRA MHCV

Tata Mators has launched the advanced Light Tata Mators has launched the Ultra series for
Commercial Vehicle (LCV) Ultra MHCV range too.

ILCV TIPPERS
MHCV CONSTRUCK
intermediate and light commercial
vehicle (ILCV) segment under the Ultra brand. Tata Construck offers a wide range of powerful
& fuel efficient Tippers for Construction and
Mining Applications. The vehicles range from
Tippers, Tip Trailers, Transit Mixers, Truck
mounted Cranes & Concrete Boom Pumps.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

17
 6. VEHICLE AGGREGATES
Major parts of a vehicle are known as Aggregates. These Aggregates are common to all
different Vehicles ranging from a bicycle to a truck.

1) LADDER FRAME CHASSIS

 Named for its resemblance to a ladder, the ladder frame is one of the oldest, simplest
and most frequently used under-body, separate chassis/frame designs. It consists of
two symmetrical beams, rails, or channels, running the length of the vehicle,
connected by several transverse cross-members.
 Originally seen on almost all vehicles, the ladder frame was gradually phased out on
cars in favour of perimeter frames and unitized body construction. It is now seen
mainly on large trucks.
 This design offers good beam resistance because of its continuous rails from front to
rear, but poor resistance to torsion or warping if simple, perpendicular cross-members
are used. The vehicle's overall height will be greater due to the floor pan sitting above
the frame instead of inside it.
 Ladder chassis is known as body-on-frame chassis. It is used as support for
automobiles. It is in the shape of the ladder as its name suggests. The ladder chassis
frame consists of two longitudinal members called as longitudinal rails. These
longitudinal rails are laterally connected by a series of shorter members called as
cross- members.
 The cross-members are attached to these longitudinal rails to provide strength and
prevent twisting of the frame. This has a straightforward design and can be used for
multiple applications with slight modifications.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

18
2) ENGINE

An engine or motor is a designed to convert one or more forms of energy into mechanical
energy. Mechanical heat engines convert heat into work via various thermodynamic
processes. The internal combustion engine is perhaps the most common example of a
chemical heat engine, in which heat from the combustion of a fuel causes rapid
pressurisation of the gaseous combustion products in the combustion chamber, causing
them to expand and drive a piston, which turns a crankshaft.

 An internal combustion engine (ICE or IC engine) is a heat engine in which

the combustion of a fuel occurs with an oxidizer (usually air) in a combustion
chamber that is an integral part of the working fluid flow circuit.
 In an internal combustion engine, the expansion of the high-temperature and
high- pressure gases produced by combustion applies direct force to some
component of the engine. The force is applied typically to pistons (piston
engine), turbine blades (gas turbine), a rotor (Wankel engine), or a nozzle (jet
engine).
 This force moves the component over a distance, transforming chemical
energy into useful kinetic energy and is used to propel, move or power whatever
the engine is attached to. This replaced the external combustion engine for
applications where weight or size of the engine is important.
Diesel Engine

The diesel engine gains its energy by burning fuel injected or sprayed into the
compressed, warm air charge within the cylinder. The air must be heated to a temperature
greater than the temperature at which the injected fuel can ignite. Fuel sprayed into air
that has a temperature higher than the “auto-ignition” temperature of the fuel
spontaneously reacts with the oxygen in the air and burns. Air temperatures are typically
in excess of 526 °C (979 °F); however, at engine start-up, supplemental heating of the
cylinders is sometimes employed, since the temperature of the air within the cylinders is
determined by both the engine’s compression ratio and its current operating temperature.
Diesel engines are sometimes called compression-ignition engines because initiation of
combustion relies on air heated by compression rather than on an electric spark.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

19
 3) GEAR BOX

 A Gear Box is often called a transmission. Gear boxes simply refer to a set of
gears and their casing, most found in automobiles. Since most motor vehicle
engines have high operating and idling speeds, transmissions allow the
machinery to operate efficiently and even aid in slowing and shutting down
machinery.
 Propulsion transmission is the mode of transmitting and controlling propulsion power
of a machine. The term transmission properly refers to the whole drivetrain, including
clutch, gearbox, prop shaft, differential, and final drive shafts.
Non-Synchromesh Truck Gearbox
The non-synchromesh gearbox is not that difficult to operate. To change gears, the engine
revs need to match the road speed for the gear change to happen successfully. This process is
called doubling the clutch or double clutching. On the simplest level, the steps are as follows:
 Depress the clutch and disengage the current gear
 Let out the clutch to re-engage the neutral gear and then match the revs to the gear
that you want to engage
 Depress the clutch and engage the next gear

Synchromesh Truck Gearbox

A synchromesh gearbox does not require the driver to double clutch as the truck gearbox has
synchro rings which match the road speed and the engine revs which allows the gear to be
selected. Many trucks doing local deliveries tend to use this type of gearbox as it is easier for
the driver to operate and allows companies more choice when selecting drivers.

Automatic Truck Gearbox

More trucks are being manufactured and purchased with automatic gearbox due technological
improvements over the last decade. The automatic truck gearbox is slightly different to car
automatic gearbox in that they are an automated manual transmission. This means that there
is an automated shifter changing gears for the driver in the manual gearbox.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

20
4) CABIN

 The "cab" is an enclosed space where the driver is seated.

 A "sleeper" is a compartment attached to or integral with the cab where the driver can
rest while not driving, sometimes seen in semi-trailer trucks.
 Modern long-haul (long distance) trucks cabs usually feature air conditioning, a good
sound system, and ergonomic seats (often air-suspended). Pickup truck cabs have
options that can make them as comfortable to drive as a car.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

21
5) FRONT AXLE
 The front axle is used to carry the weight of the front part of the vehicle as well
as to facilitate steering and absorb shocks due to road surface variations.
 It must be right and robust in construction. The front axle is usually a steel drop
forging having 0.4% carbon steel or 1-3% nickel steel.
 It is made of I-section in the centre portion, while the ends are made either
circular or elliptical. With this construction, it takes bending loads due to the load
of the vehicle.
 Also, the torque centre portion is given a downward sweep. The different
components of the front axle are the beam, stub axle, swivel pin and track rod.
Usually, there are two main types of the front axle:

1. Live front axle.

2. Dead front axle.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

22
6) REAR AXLE

 In between the differential and the driving wheels is the rear axle to transmit
power from the differential to the driving wheels.
 It is clear from the construction of the differential, that the rear axle is not a single
piece, but it is in two halves connected by the differential, one part is known as
the half shaft.
 The inner end of the half shaft is connected to the sun gear of the differential. and
the outer end of the driving wheel. In rear-wheel-drive vehicles, the rear wheels
are the driving wheels.
 Whereas, in front-wheel drive vehicles, the front wheels are the driving wheels.
Almost all rear axles on modern passenger cars are live axles, that is, they
revolve with the wheels.
 Dead axles simply remain stationary, do not move with the wheels. A housing
completely encloses the rear axles and the differential, protecting them from
water, dust and injury, in addition to mounting their inner bearings and providing
a container of the lubricant.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

23
 7. BASIC STEPS INVOLVED IN AUTOMOBILE PRODUCTION
Automobile manufacturing process is one of the most interesting and technologically
advanced process. Probably one of the most advanced in terms of the use of technology as
well as execution of complex logic. To appreciate the Manufacturing process, one needs to
know that an automobile comes together with 3000 - 4000 parts and a typical manufacturer
churns out anywhere between 700 - 2000 vehicles per day.

Chassis Assembly

1. PRESS SHOP

This is where the production process starts, with most of the Metal parts getting pressed out
of Steel Sheets. The door panels, Roof, Bonnet, etc are typically pressed in to form the basic
structure of the automobile. The pressing process is a multi-step process where the sheets are
pressed into shape in stages.

2. WELD SHOP

The Weld shop is typically the place where the automobile is born. The point of birth for most
monoque design cars are where the Underbody takes shape from the Pressed parts. It can be
the marriage of the Underbody front & rear or in some cases the entire underbody can be a
single pressed unit. In stages, the Side panels, the roof are then welded to the underbody and
the automobile begins to take its shape. The welding process is typically Tungsten Inert Gas
(TIG) welding, mostly done by Robots.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

24
3. PAINT SHOP

The output of the Weld Shop is called as a BIW or a Body in White. These are the cabs that
enter the Paint Shop. The painting process is one of the most complex and cleanest of process.
The Paint booths for example must be completely dust free.

4. ENGINE SHOP AND TRANSAXLE:

The birth or identity of an engine is given when the Engine Block gets machined, and the EIN
(Engine Identification Number) is punched into the Engine Block. The assembly process of
the Engine is again precision controlled with various stages of machining the Pistons, fitment
of the Piston rings and then lowering the assembly into the Engine Block. Finally, the Engine
Head comes and then the engine undergoes a series of tests. The Transaxle, consisting of the
Gear Box assembly is typically made ready and made available at the marriage point.

5. TRIM/FINAL FITMENT

This part of the production process is where most of the fitment is done by human hands. The
complicity lies in making the right parts available in the right sequence of production at the
fitment area. (Right Place, Right Time, and Right Sequence is the key to it all). Most of the
components of the car like the windshields, trims, Steering Column, electronics, and the
engine
- vehicle marriage happens here. Before getting dispatched out of production, the Vehicle
undergoes stringent quality tests as well as the various vital component information of the
vehicle is captured and stored into the production databases. Following the drive test, the
vehicle reaches the yard from where they are dispatched to the dealership and finally to
customers

6. CHASSIS LINE-

The assembly process itself has a quite uniform pattern throughout the world. As a rule, there
are two main assembly lines, body, and chassis. On the first the body panels are welded
together, the doors and windows are installed, and the body is painted and trimmed (with
upholstery, interior hardware, and wiring). On the second line the frame has the springs,
wheels, steering gear, and power train (engine, transmission, drive shaft, and differential)
installed, plus the brakes and exhaust system. The two lines merge at the point at which the
car is finished except for minor items and necessary testing and inspection.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

25
 8. BODY IN WHITE (BIW) LINE
 Body-in-white (BIW) is the name given to a car body’s sheet when all its components
—barring moving parts (e.g., hoods, fenders, etc.), trims (e.g., glass, seats, etc.), or
chassis subassemblies—have been welded together. Usually, BIW constitutes about
27% of a car’s curb weight, and remains the key determinant of how the car will
perform.
 BIW can be made into two structures: the more common monocoque structure where
all body members are carrying load with chassis in-built with BIW and are integrated
with each other, and the body-on-frame structure where the frame is the main load-
carrying member.
 BIW is expected to possess several significant properties. It must have high tensile
strength as well as high stiffness—bending, torsional, static, and dynamic. It must
also provide superior quality safety both to the car body and to its occupants against
crashes of all kinds—front, rear, side, or even rollover. It should also be able to
protect occupants from noise, vibration, and/or harshness (NVH) by absorbing or
reducing these conditions.
 Also, it should be easy to weld and form, as well as be highly paintable and easy to
design. It should provide a good surface finish that is smooth and should also be
corrosion resistant. Improvement of fuel economy also necessitates the use of
lightweight materials in BIW, as it constitutes a significant share of car’s weight; in
addition, given environmental concerns in recent times, it is expected to be
recyclable.
 The BIW line in Tata Motors is divided into two lines i.e., BIW main framing line
and BIW finishing line.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

26
 9. BODY IN WHITE (BIW) MAIN FRAMING LINE
The BIW main Framing line receives input from Press shop and gives its output to BIW
finishing line. This is divided into various stations. Different processes and operations take
place at each Station. The whole line is Operated by a Supervisor who must achieve daily,
weekly, and monthly goals.

Processed and cut

metal sheets are Sealant is applied
brought on trolley's using robotic
from press shop and arms
unloaded at Station

Studs are welded on Robotic geospot

the sheet metal using welding of Assembly
robots for efficient and Firewall and rear wall
precise welding outer panel.

Robotic geospot Robotic geospot

welding of Assembly BSI welding of assembly
and assembly roof body shell with BSI and
structure body side outer panels

Robotic Sealant
Application and robotic Unloading of BIW and
geospot welding of carrying it to the BIW
body shell with finishing line
assembly roof
completed
PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]
27
PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]
28
 10. BODY IN WHITE (BIW) FINISHING LINE
The BIW Finishing line receives input from BIW Main Framing line and gives its output to
Paint shop. This line is also divided into various stations. Different processes and operations
like testing, drilling, cleaning, quality inspection, finishing, etc; take place at each Station.
The whole line is Operated by a Supervisor who must achieve daily, weekly, and monthly
goals.

Cuttting unwanted
Cab loading on Slat flanges, Smoothening
Conveyor rough edges using
sanding process

Number plate Drilling

Fittment of Glass run
and fittment.
Channel on both left
Assembly of door
and right side
fittment

Quality gate- the cab

Removal of extra
is throughly examined
sealent and manual
at this gate for any
cab cleaning
irregularities or dents

Unloading of the cab

from the Slat
Conveyor

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

29
 11. TRIM LINE
This part of the production process is where most fitment is done by human hands. The
complicity lies in making the right parts available in the right sequence of production at the
fitment area. (Right Place, Right Time, and Right Sequence is the key to it all). Most of the
components of the car like the windshields, trims, Steering Column, electronics, etc are fitted
in this line. Before getting dispatched out of production, the Vehicle undergoes stringent
quality tests as well as the various vital component information of the vehicle is captured and
stored into the production databases.

The input for this line comes from the Paint Shop and the output of this line is used as input
for the Chassis line. The trim line is divided into various Stations, the painted cabin is loaded
at the first Station on the conveyor belt. Various fitment occurs at different Stations hence,
making the right parts available in the right sequence of production at the fitment area is very
crucial. Each station has a ladder which specifies the Action Plan, Process Sheet, Necessary
Precautions and Quality Judgement if required. The Ladder also consists of Feedback form
from Customer, One point lesson, Supervisor sheet. The ladder also provides information
regarding probable fault areas and ways in which it can be prevented.

Each station is provided with trolleys which consist of the required fitments and fixtures
needed at that station. Some systems need to be picked and placed using cranes, these are also
controlled by the workers on the line. Sometimes these systems need to be prepared before
installation. For example, the clutch pedal or the accelerator pedal needs to be calibrated
before installing in the vehicle. Hence, these systems are prepared at another station close to
the line and then carried to the station where it is installed in the cabin.

The most crucial ideology followed by the workers and the supervisor on the line is that of –
“NOT ACCEPTING, BUILDING AND SHIPPING DEFECTS.” The primary goal is to
deliver 100% defect free product in the first shot itself.

The output of this line is a Cabin which is further transported to the Chassis line where it is
installed on the ladder frame and the vehicle is completed and dispatched for sales after
testing and quality inspections.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

30
1. Fitment of cab tilt 3. Fitment of air extractor,
2. Fitment of protective
cylinder, grommets, antenna, cable connection,
covers, mascot, dash
plugs,engine insulation, floor mounting plates,
insulation, flooor and door
reflective tapes. Removal of steering bellow, Accelerator
wiring harness. fitment of roof
Narrow front panel, plate,top marker lamp and
and fire wall wiring harness.
printing of bar code. top deflector.

4. Fitment of clutch
control assembly, clutch pipe 5. Fitment of rear wall trim, 6. Application of glass gluing
and brake sysytem. checking head/side wall lining, grab operations, glass primer. side
and setting of clutch pedal handles on roof, floor glass preparation and fitment.
and switch. Fitment and carpetseat belt kit,berth fitment of windshield glass ,
clamping of nylon pipe. panel, toggle clamps. tension belt and rear window.

7. Fitment of head box 8. Fitment of plugs, proxy

assembly, sun visor, roof mirror holes, front 9. Fitment of window winding
lamp fitment, blower unit, mirror,door check assembly, door glass, door
HVAC liquid pipesdrain pipe strap,outer/ inner handle secondary seal,door speaker
for HVAC/AC cab. assembly,latches and door and grommets.
cables

10. Fitment of pedal 11. Fitment of Cluster, music

lamp,door trim, door glass 12. unloading and insulation
system, cables, air pressure
lifter handleand spacer. of cockpit.Connect alll sockets
transducer and carpet front,
fitment of Auto drain scufff plate, duct foam, twitter of brake, clutch, door and
unit,ECU and blower.
cover, power socket.
connections.

14. Fitment of wiper motor

13. Fitment of parking brake harness mounting brackets, 15. Fitment of side repeater
lever, cable holding bracket, wiper system lamp, head lamp, dummy
nylon pipe, cable fitment mechanism,wiper arm and panel assembly. Re- fitment of
blade, washer bottlepipe line narrow front panel.
and wiper motor cover.

16. Fitment of cab 17. Fitment of Jack mounting 18. Fitment of Sleeper berth
lock bracket, cab bracket with foam, hydraulic seat/storage box, driver and
locking jack and jack rod, fire co-driver seat, seat bottom
kit,linkages, cab lock handle extinguisher and its bracket covers, steering wheel and
bracket, , snorkel,rear and door primary seal horn pad.
enginne cover.

19. Sticking of neceesary removing

stickers, i.e., speed limit, tyre instruction,cab tilting 20. Electrical testing- the cabin is tested
pressure, head lamp instructions, etc.
PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]
31
and checked if all its electronic 21. Inspecti
features are operationg on- last
correctly or not. step is to
inspect the
whole
cabin for
any errors/
irregularitie
s/ dents
/scratches.
Proper
placement
of stickers
and
Mascots is
also
ensured.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

32
 12. LCV CHASSIS LINE
 Chassis line or chassis assembly line gives output as vehicle and uses aggregates as
inputs. This line is also known as Assembly line. An LCV is defined in the Motor
Vehicles Act as a vehicle with GVW of 3.5 metric tons and above until 15 metric
Ton. LCVs are preferred for high volume low bulk cargo such as consumer goods,
textiles, for short distance haulage.
 The assembly process itself has a quite uniform pattern throughout the world. As a
rule, there are two main assembly lines, body and chassis. On the first the body
panels are welded together, the doors and windows are installed, and the body is
painted and trimmed (with upholstery, interior hardware, and wiring). On the second
line the frame has the springs, wheels, steering gear, and power train (engine,
transmission, drive shaft, and differential) installed, plus the brakes and exhaust
system. The two lines merge at the point at which the car is finished except for minor
items and necessary testing and inspection.
 Assembly lines have been elaborately refined by automatic control systems, transfer
machines, computer-guided welding robots, and other automated equipment, which
have replaced many manual operations when volume is high.
 A universal form of automatic control has used computers to schedule assembly
operations so that a variety of styles can be programmed along the same assembly
line. Customers can be offered wide choices in body styles, wheel patterns, and
colour combinations.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

33
 Station 1 - FRAME Station 2 - FRAME Station 3 - STEERING
LOADING PREPARATION GEARBOX FITMENT

Station 4 - FRONT Station 5 - REAR AXLE

Station 6 - FRONT
AND REAR AND PROPELLOR
SUSPENSION SYSTEM SHAFT FITMENT AXLE FITMENT

Station 7 - U- BOLT
Station 8 -FRAME Station 9 - DDU AND
TIGHTENING AND
GREASING INVERSION AIR TANK FITMENT

Station 10 - FUEL
Station 12 - ENGINE
TANK, AIR TANK, Station 11 - CHASSIS
AND GEARBOX
PURGE TANK AND AIR NUMBER PUNCHING ASSEMBLY FITMENT
TANK FITMENT

Station 14 - CHASSIS
Station 13 - REAR
LIFTING AND MOVING Station 15 - CHASSIS
TYRE AND RADIATOR
TO ANOTHER DROPPING
FITMENT
CONVEYOR

Station 18 -
Station 16 - EXHAUST Station 17 - BATTERY
FUELFILLING AND
FITMENT FITMENT COOLANT FILLING

Station 21 - FRONT
Station 19 -QUALITY Station 20 - CABIN TYRE FITMENT.
TEST GATE DROP CLUTCH AND BRAKE
BLEEDING

Station 23 - POWER
Station 22 - WHEEL Station 24 - ECU
STEERING, CLUTCH
TIGHTENING USING FLASHING AND
AND BRAKE OIL
TORQUE CRANKING
FILLING

Station 25 - FRONT Station 26 - TESTING Station 27 - BUY OFF

BUMPER FITMENT AND INSPECTION GATE

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

34
 13. MHCV CHASSIS LINE
 An assembly line is a production process that breaks the manufacture of a good into
steps that are completed in a pre-defined sequence. Assembly lines are the most used
method in the mass production of products. They reduce labour costs because
unskilled workers are trained to perform specific tasks.
 An assembly line is where semi-finished products move from workstation to
workstation. Parts are added in sequence until the final assembly is produced. Today,
automated assembly lines are operated by machines with minimal human
supervision. This increases efficiency by maximizing the amount of work a worker
could produce relative to the cost of labour.
 Companies use a design for assembly (DFA) approach to analyse a product and its
design in order to determine assembly order and identify issues that can affect each
task. Each task is then categorized as either manual, robotic, or automatic, and is then
assigned to individual stations along the manufacturing plant floor.
 The medium and heavy commercial vehicle segment of the truck market in India is
the most significant in terms of value. The segment comprises trucks starting from
19T to all the way 55T GVW.M&HCVs are used for transport of heavy commodities
such as steel cement, fertilizers etc. At TATA Motors, vehicles above 1212 are
produced in MHCV chassis line.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

35
 Station 2 - NYLON
Station 1 - FRAME PIPE, DDU, Station 3 - AIR
LOADING MUDGUARD TANK ASSEMBLY
FITMENT

Station 5 - REAR
Station 4 - Station 6 - FRONT
AND FRONT
PROPELLOR SHAFT AND REAR AXLE
SUSPENSION
FITMENT FITMENT
FITMENT

Station 7 - TAIL Station 8 - AXLE U- Station 9 -

LIGHT AND RUPD BOLT STEERING GEAR
BRACKET FITMENT TIGHTENINING BOX FITMENT

Station 10 - Station 12 - FUEL

Station 11 -
EXHAUST VALVE LINE AND AIR
CHASSIS INVERSION
FITMENT FILTER FITMENT

Station 15 -
Station 13 -ENGINE Station 14 -AIR
SILENCER AND
AND GEARBOX INTAKE PIPE
RADIATOR
FITMENT FITMENT
FITMENT

Station 18 -FUEL
Station 16 - Station 17 -
TANK AND UREA
EXHAUST FITMENT BATTERY FITMENT
TANK FITMENT

Station 21 -
Station 19 -SPARE Station 20 - CABIN ELECTRICAL
WHEEL FITMENT DROP CONNECTIONS ARE
COMPLETED

Station 23 - POWER
Station 22 - WHEEL Station 24 - ECU
STEERING, CLUTCH
TIGHTENING USING FLASHING AND
AND BRAKE OIL
TORQUE CRANKING
FILLING

Station 25 -
Station 26- BUY
TESTING AND
OFF GATE
INSPECTION

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

36
 14. SAFETY PRECAUTIONS
Various hazards are encountered at different Stations in various lines. A few of these hazards
are listed below and ways in which it can be avoided are also mentioned.

[A] HAZARDS IN BODY IN WHITE LINE

1. Wear PPE kit always.

2. Do not touch the sealant or the metal body.
3. Do not touch the BIW with bare hands as it has very sharp edges.
4. Maintain safe distance from the line (welding takes place on the line, hence it
is important to maintain to stay away from the line).
5. Walk in Gangways only.
[B] HAZARDS IN TRIM LINE

1. Stay away from the Conveyor belt as it is constantly moving.

2. Be cautious of moving cranes.
3. Since the conveyor belt is constantly moving, the pace of work is high on the
line. Thus, it is important to lookout for moving parts and machinery.
4. Be cautious of high-pressure air tubes.
[C] HAZARDS IN CHASSIS LINE

1. Chassis line employs heavy machinery and the work done is very fast paced, hence
it is important to be attentive and lookout for any potential hazards.
2. It is necessary to lookout for movement of cranes, trollies, forklift, tractors,
vehicles, palettes, frame trolley, etc

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

37
 15. INFORMATION FITMENT DRAWING (IFD)

 Information Fitment Drawing is a presentation of a structure or a product with its

components connected, in their relative working positions while in use. These
components are fabricated separately and are assembled or installed together at
their utility sites such that each part fits and matches with the others.

 Information fitment drawings are produced to communicate how the various parts
of a product or assembly fit together in their working condition and paint its
completed overall shape and dimensions.

 Information fitment drawings illustrate how to manufacture a product,

providing information about dimensions, materials, finishes, tools required,
methods of assembly and so on.

 The information fitment drawings describe the manufacturing processes that will be
followed to meet those requirements. They sometimes also specify instructions for to
be followed while fitment and provide a list of preventive steps to eliminate/ educe
error. They are used as instructional reference documents by workers and their
supervisors on the shop floor or production line to manufacture the products
required.

 It is also provided with exploded views to convey correct order of assembly and
pictorial directions for accurate alignment of components. Parts lists are generated
to provide a complete list of all parts needed to complete the project. Item numbers
matching the parts list are described in a tabular form.

 IFD may include instructions, lists of the component parts, reference

numbers, references to detail drawings or shop drawings, and specification
information.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

38
PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]
39
 16. VEHICLE LAYOUT (VLO)
VLO (Vehicle Layout) / W&T (Wire & Tube) To identify and evaluate any defect for wrong
routings, leakages, dangerous proximity and interferences caused by components, pipes,
cables of the various car systems, (feeding, lubrication, cooling, brakes, exhaust, electrical
equipment and subsidiary systems) in order to guarantee safety and reliability

Demerit score is awarded as per following criteria:

100 Demerit - serious / safety issues / can cause stoppage of vehicle

40 Demerit - incorrect functioning of the vehicle devices / potential technical stoppage

10 Demerit - do not affect the correct vehicle functioning

Following are the contents of the typical VLO sheets-

1. POINT - Provides a 1–2-line description of the error encountered and its

location along with potential risk that can be caused due to this error or fouling.

2. AGGREGATE – Name of the aggregate where the issue is encountered or the

component where the issue has raised.

3. DEMERIT SCORE – is measured numerically, its value ranges from 1 to

100, where,

SR. DEMERIT SCORE DESCRIPTION RISK

NO.
1. 100 DEMERIT SERIOUS / SAFETY ISSUES / CAN HIGH RISK
SCORE CAUSE STOPPAGE OF VEHICLE
2. 40 DEMERIT INCORRECT FUNCTIONING OF THE MEDIUM RISK
SCORE VEHICLE DEVICES / POTENTIAL
TECHNICAL STOPPAGE
3. 10 DEMERIT DOES NOT AFFECT THE CORRECT LOW RISK
SCORE VEHICLE FUNCTIONING

4. IMAGE – Actual Photo of the error is attached along with marking or

indication of the error in the image. This helps in easy identification and location of
the error/ fouling.

5. AGENCY – Mentions the Agency/ department responsible for rectifying the

error and executing further steps.

6. ROOT CAUSE - The Root cause for the error is also identified and mentioned
in VLO sheets.

7. ICA/ PCA – ICA (Intermediate corrective action) and PCA (Permanent

corrective action) refers to the level/status of the corrective action executed.

8. TARGET DATE - Estimated date by which the error or fouling will be

resolved, and the demerit score will be 100.

9. STATUS - The status of resolving the error/fouling is also mentioned in the

VLO sheets. This helps to communicate the action plan with different departments.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

40
 17. BASIC STEPS INVOLVED IN IFD/VLO ANALYSIS
After the vehicle is build, IFD/VLO/W&T analysis is performed on the vehicle to identify
errors and fouling at different locations. After locating the potential hazards, they are noted
down in the form of a checklist. Further, these risks are assessed and rectified. The status of
rectification is depicted by the R/Y/G colours. Further, these errors are rechecked and
evaluated before dispatching.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

41
 18. ACTIVITIES INVOLVED IN VEHICLE PRODUCTION
The basic steps involved int the production of vehicle are briefly stated below. The process
starts with idea conceptualization and ends with the dispatch of the Vehicle. The steps stated
in the flowchart are the Major steps involved in the process, however, many major as well as
minor steps take place in the background while these steps are being executed. Vehicle
production is a very complex yet dynamic process which involves active participation of
various departments, their contribution and co- ordination to execute the whole Production
plan successfully.

Market study and

Customer review

Customer review
is stored in Input to ERC for
databse and used concept
as input for development
future designs

Vehicle is
lauched in the CAD/CAM
market by the department
Sales and works on design
Marketing development
department

Vehicle is
Then, the Vehicle developed and
is mass constructed by
produced on the the Launch
Production line Managemnent
department

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

42
 19. LAUNCH MANAGEMENT
Launch Management is one of the many departments in Tata Motors Ltd. Working towards
Rolling out of new Vehicles/ Vehicle Combinations.

A product launch refers to a business’s planned and coordinated effort to debut a new product
to the market and make that product generally available for purchase. A product launch serves
many purposes for an organization— giving customers the chance to buy the new product is
only one of them. It also helps an organization build anticipation for the product, gather
valuable feedback from early users, and create momentum and industry recognition for the
company.

This department is concerned with building new vehicles, which are further inspected and
tested. After these new vehicles have passed all the tests, they are produced in huge numbers
and dispatched to the markets.

Sometimes, a specific vehicle is required by a customer overseas. These vehicles are also
built by this department and then shipped to the customer. Example- LHD truck, BS4/BS3
vehicles, etc.

CPA
Vehicle build OK Tagging Customer Product
Audit

Dispatched to
IFD/VLO/W&T DRR-4
Customers

Rework/Rectification
DRR-3
Status is depicted by
(Load Body testing)
R/Y/G colours.

DRR 1
DRR- 2
(Line Quality)

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

43
 20. CONCLUSION
The internship at TATA Motors Ltd. which lasted a duration of 2 months ranging from 1 st
March 2022 to 30th April 2022 was a really engaging and informative part of the academic
curriculum at SPPU. The internship familiarized me with the concepts of project
management, analysis of product lifecycles, working of an automotive manufacturing unit,
and many more aspects. The exposure granted to was extremely insightful as it is something
I wish to pursue in the future. Further, the ability to work and assist several projects was truly
useful in boosting my skillset. The skills attributed to this particular internship can be
summarized as follows -

• Practical understanding of the working of assembly lines, shop floors, and chassis lines.

• Product development process and how to manage all the requirement of parts as well as
the revisions.

• Part analysis with emphasis on modifications, revisions, and quality status.

• Satiating the requirement of parts for upcoming projects through portals and
understanding of the development process.

• Ensuring the availability of parts before and during the rollout of a particular vehicle.

• Study of IFD/VLO reports to analyse and devise the UPL of a vehicle/project.

• Coordinating with several departments for the rollout of a vehicle. Post rollout, working in
tandem with Launch Quality department to further the progress of the rolled-out vehicle
and get it ready for sale to the customers.

• Understanding part lifecycles and the requirement of revising certain parts based on
the technical feasibility as well as efficacy of overall vehicle assembly.

• Professional etiquettes and protocols to be followed and obeyed as the student venture
into the professional world.

• Understood the dynamics and the inter dependability of various departments in rolling out a
single vehicle.

• Understood the importance as well as the complexity behind the process planning
and management.

PES’s MODERN COLLEGE OF ENGINEERING, PUNE-05. [T. E. MECHANICAL]

44