TATA MOTORS, JAMSHEDPUR.

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NAME - SAURAV KUMAR
ROLL NO - 170497
BRANCH - ELECTRONICS
SESSION - 2017-2020
DAYALBAGH EDUCATIONAL INSITUITE
AGRA

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TATA MOTORS LTD., JAMSHEDPUR
Summer Training at
FRAME FACTORY
(A TATA ENTERPRISE)
A
PROJECT REPORT
ON
Flowchart of Servo EMC Heft Fixture professional
Submitted to
Mr. Ramesh Pandey
Frame Factory
Submitted By
SAURAV KUMAR
Diploma 3rd Year
Electronics Engineering
Roll No.:1704967
Dayalbagh Educational Institute, Agra

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TATA MOTORS LTD., JAMSHEDPUR
BONAFIDE CERTIFICATE
This is to certify that SAURAV KUMAR a 3rd
year student of Department of
Electronics Engineering from Dayalbagh Educational Institute has successfully
completed his project on Flowchart of Servo EMC Heft Fixture professional
during the period of 10th
June, 2019 to 12th
August, 2019 in partial fulfillment of the
requirement for the award of the degree of Diploma in Electronics Engineering,
under my supervision and guidance at FRAME FACTORY, TATA MOTORS,
JAMSHEDPUR.
Mr. Ramesh Pandey
Frame Factory Electronics
Tata Motors Ltd. Jamshedpur

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ACKNOWLEDGMENT
Industrial training is a crucial period in engineering curriculum since it exposes a
student to the real world which he or she is going to enter after the completion of the
graduation. This is the period during which an engineer actually becomes an
engineer by gaining the Industrial experience. I am very thankful to God who has
given me the opportunity to get training in TATA MOTORS, JAMSHEDPUR one
of the most renowned organization of India. I take this opportunity to express a deep
sense of gratitude to Mr. Ramesh Pandey Vehicle Factory Electronics, Tata Motors
Ltd., Jamshedpur for the facilities provided by him during the preparation of this
report. I am also thankful to my project supervisor, Mr. Subrata Samantha, for
sharing his valuable information and guidance, which helped me in completing this
task through various stages. I express my sincere thanks to staff members of the
Electronics and Communication Department of Frame Factory for giving me
innovative suggestions, timely advice, and suggestion during this endeavor.
I am also thankful to the shop floor employee for their guidance and valuable
support. I also express my thanks to the staff of MTC, who made sure that our
experience at the company was smooth.
SAURAV KUMAR
Dayalbabgh Educational Institute
DATE: 12TH
AUGUST 2019

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CONTENTS
SL. NO. TITLE PAGE NO.
1. About the company: Tata Motors Ltd. 6-12
2. Founder 13
3. Plant location 14-17
4. Company Background 18
5. Business overview 19-32
6. Organization structure 33
7. Department/Function 34-49
8. Product 50-53
9. Competitor 54
10. Machine details 55-62
11. My work as a trainee 63-65
12. Internship Certificate 66
12. Literature review 67
13. PLC 68-78
14. HMI 79-86
15. Servo drive 87-88

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16. Servo motor 89-90
17. TIA 91-92
18. Process 93-94
19. Project 95-100
20. My Internship experience 101-105
21. Improvement 106
22 Learning 107-109
23. Limitation 109
24. Abbreviation 110
25. Reference 111
26. Conclusion 112

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ABOUT THE COMPANY: TATA MOTORS LTD.
Tata Motors Limited (formerly TELCO, Tata Engineering, and Locomotive
Company) is an Indian multinational automotive manufacturing company
headquartered in Mumbai, Maharashtra, India and a subsidiary of the Tata Group.
Its products include passenger cars, trucks, vans, coaches, buses, construction
equipment, and military vehicles. It is the world's 17th-largest motor vehicle
manufacturing company, fourth-largest truck manufacturer, and second-largest bus
manufacturer by volume. Tata Motors has auto manufacturing and assembly plants
in Jamshedpur, Pantnagar, Lucknow, Sanand, Dharwad, and Pune in India, as well
as in Argentina, South Africa, Thailand, and the United Kingdom. It has research
and development center in Pune, Jamshedpur, Lucknow, and Dharwad, India,
Chintalapudi and in South Korea, Spain, and the United Kingdom. Tata Motors'
principal subsidiaries include the British premium car maker Jaguar Land Rover (the
maker of Jaguar, Land Rover, and Range Rover cars) and the South Korean
commercial vehicle manufacturer Tata Daewoo. Tata Motors has a bus-
manufacturing joint venture with Marco polo S.A. (Tata Marco polo), a
construction-equipment manufacturing joint venture with Hitachi (Tata Hitachi
Construction Machinery), and a joint venture with Fiat which manufactures
automotive components and Fiat and Tata branded vehicles.

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OVERVIEW OF JAMSHEDPUR TATA MOTORS PLANT
The plants of TATA Motors Ltd. are instrumental in giving shape to the goals of the
Company. They operate on the simple formula that well-managed processes ensure
quality products, which in turn ensure happy and loyal customers. Every stage of
product evolution- design and development, manufacturing, assembly, and quality
control is carried out meticulously.
Jamshedpur plant is one of the oldest plants of TATA Motors and comes under the
company's CVBU (Commercial Vehicle Business Unit) segment. Regarded as the
most strategic plant, it is responsible for manufacturing and assembly of most of
the heavy commercial vehicles produced by the company including military trucks
and the newly launched Prima series.
The Jamshedpur facility, Tata Motors' first, was established in 1945 to
manufacture steam locomotives. It led the company's foray into commercial
vehicles in 1954. It has been modernized through the decades, with a particularly

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intense scale in the last 10 years and has led the company's evolution into a
manufacturer of global repute.
state-of-the-art equipment and assembly lines to produce a truck every 5 minutes
Over 200 models, ranging from multi-axle trucks, tractor-trailers, tippers, mixers
and special application vehicles, catering to civilian and defense requirements 3D
visualization of new models Engine assembly shop, capable of supplying up to 200
engines per day Modern testing facilities.
Fig.: Jamshedpur Plant Tree

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The plant manufactures Tata Motors' entire range of medium and heavy
commercial vehicles, including the Tata Prima, both for civilian and defense
applications - over 200 truck variants, ranging from multi-axle trucks, tractor
trailers, tippers, mixers and special application vehicles. Besides India, these
vehicles are sold in South Africa, Russia, Myanmar, the SAARC region and the
Middle East. On February 19, 2013, Jamshedpur Plant rolled out its two millionth
truck.
The state-of-the-art Engine Factory manufactures the Tata 697/497 naturally
aspirated and turbo charged engines, with a capacity of supplying up to 200 engines
per day. The Vehicle Factory's main assembly line rolls out one truck every 5
minutes. Two other lines are dedicated to the Prima range, Multi-axle, special
purpose vehicles and for meeting the requirements of the defense sector. The chassis
frames are supplied by the frame factory which is equipped with a 5000 ton press
to manufacture frames up to 6.2.

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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, and Spain. Among them is Jaguar
Land Rover, a business comprising the two iconic British brands that were acquired
in 2008. In 2004, it acquired the Daewoo Commercial Vehicles Company, South
Korea's second largest truck maker. The rechristened Tata Daewoo Commercial
Vehicles Company has launched several new products in the Korean market, while
also exporting these products to several international markets. Today two-thirds of
heavy commercial vehicle exports out of South Korea are from Tata Daewoo. In
2005, Tata Motors acquired a 21% stake in Hispano Carrocera, a reputed Spanish
bus and coach manufacturer, and subsequently the remaining stake in 2009.
Hispano's presence is being expanded in other markets.

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ABOUT VEHICLE CLASSIFICATION
In the Commercial Vehicle Business Unit, the models are classified on the basis of
GVW as under:
HCV: Heavy Commercial Vehicles
MCV: Medium Commercia Vehicles
LCV: Light Commercial Vehicles.
The HCV segment can be further classified into three segments based on gross
vehicle weight as follows:
ICV: Intermediate Commercial Vehicle with GVW of 8 to 10 ton.
MCV: Medium Commercial Vehicle with GVW of 10 to 15 ton.
HCV: Heavy Commercial Vehicle with GVW of 16 ton and above.
MCV & HCVs can also be classified into two categories depending on their usage
as Trucks and Buses. Buses are passenger carriers. Trucks include goods carriers
along with specialized vehicles like dumpers, tractor-trailers etc. the ICVs fall in the
load category of 8 to 10-ton GVW and are often substituted for medium or heavy
commercial vehicles in trunk routes or cities. EICHER Motors and SWARAJ
MAZDA are two manufacturers operating in this segment.

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MILESTONES:
1945: Jamshedpur plant set up
1954: Truck manufacturing starts with Daimler Benz technology
1955: 2,000th vehicle rolls out
1965: 100,000th vehicle rolls out
5 June 1969: Produces first truck with the Tata ‘T’ logo
1990: One millionth vehicle produced
2013: Total production crosses 2 million vehicles
2014: Celebrates 60th year of automotive excellence
2015: 70 years of Tata Motors

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FOUNDER
Founded: 1945
Founder: JRD Tata
Key people: Ratan Tata, Ex-chairman; Cyrus P Mistry, Non-Executive Director &
Chairman
Parent: Tata Group

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PLANT LOCATIONS
Tata Motors’ presence cuts across the length and breadth of India. Over 4 million
Tata vehicles ply on Indian roads.

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The company has four major manufacturing bases in India: -
1.Jamshedpur (Jharkhand):
Established in1945, the Jamshedpur unit was the company's first unit and is spread
over an area of 822 acres. It consists of two major divisions - Truck Factory &
Engine Factory.
The Truck Division boasts of two assembly lines. The main assembly line,
measuring 180m in length has 20 work stations with a vehicle rolling out every 8
mins. The other line is dedicated to special purpose vehicles and for meeting the
requirements of the Indian Army.
2. Pune (Maharashtra):
It was established in 1966 and has a Production Engineering Division.
To cope with a diverse range of automobiles, four assembly lines have been
established, one each for MCVs and HCVs, LCVs, Utility vehicles and one for
Passenger Cars (Indica and Indigo).
3. Lucknow (Uttar Pradesh):
This plant was established in 1992 to meet the demand for Commercial Vehicles in
the Indian market. The state of art plant is strongly backed by an Engineering

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Research Centre and Service set-up to support with latest technology and cater to
the complexities of automobile manufacturing.
This plant is specialized in the designing and manufacturing of a range of modern
buses which includes Low-floor, Ultra Low-floor & CNG Buses.
4. Pantnagar (Uttarakhand):
The plant began commercial production in August 2007. The plant is spread over
953 acres, of which 337 acres is occupied by the vendor park.
Tata Motors plans to shift the entire production of its mini truck Ace and the
passenger carrier variant of the vehicle, Magic, to Uttarakhand.

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GLOBAL PRESENCE
Tata Motors owns Britain’s Jaguar Land Rover. Tata Motors is today present in
more than 170 countries around the globe. Today over 8.5 million vehicles of the
Tata Brand are plying in the world. Through exports, the company has been
expanding its international presence since 961. Today the company is well
positioned to satisfy the fast-changing automotive norms and customer
expectations.
BRANCHES:
• UK
• SOUTH KOREA
• RUSSIA
• EUROPE
• AFRICA
• THE MIDDLE EAST
• SOUTH EAST ASIA
• SOUTH ASIA
• SOUTH AMERICA

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COMPANY BACKGROUND
• Started in 1945 in Mumbai, India.
• Original production was on locomotives.
• 1954
• First car rolled off of the assembly line.
• Tatas are a family of Indian industrialists and
philanthropists.
• The family founded
• Ironworks
• Steelworks
• cotton mills
• hydroelectric-power plants
• Are of their endeavors have been proved to be
crucial to India's industrial development.
• Tata Motors is India’s owns the largest
independent company in India.
• Mercedes and Tata teamed up to create a truck
line.
• First major business deal with another firm.
• Together both companies started their commercial
vehicle operations in 1960.
• in 1986 the company created and sold the first
LCV
• LCV light commercial vehicle
• Was the Tata 407
• Tata Motors decided to pursue joint ventures.
• Cummins Engine Co., Inc., was the first company
to jointly venture with Tata in 1993.
• Manufactured a diesel engine that had high
horsepower and emitted less harmful chemicals.

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BUSINESS AREAS:
The activities of the enterprises promoted by the Tatas are classified in 11
sectors:
• Metals and associated Industries
• Automobiles
• Energy
• Engineering
• Chemicals and Pharmaceuticals
• Consumer Products
• Services
• Agro Industries
• Information Technology and Communication
• Exports and Overseas Operations
• Finance

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BUSINESS OVERVIEW
We primarily operate in the automotive segment. Our automotive segment includes
all activities relating to the development, design, manufacture, assembly and sale of
vehicles including financing thereof, as well as sale of related parts and accessories.
The acquisition of the Jaguar Land Rover business has enabled us to enter the
premium car market in developed markets such as the United Kingdom, the United
States and Europe as well as in emerging markets, including China, Russia and
Brazil. Going forward, we expect to focus on profitable growth opportunities in our
global automotive business, through new products and market expansion. Within
our automotive operations we continue to focus on integration and synergy through
sharing of resources, platforms, facilities for product development and
manufacturing, sourcing strategy and mutual sharing of best practices.
Our business segments are (i) automotive operations and (ii) all other operations.
Our automotive operations include all activities relating to development, design,
manufacture, assembly and sale of vehicles including financing thereof, as well as
sale of related parts and accessories. We provide financing for vehicles sold by
dealers in India. The vehicle financing is intended to encourage sales of vehicles by
providing financing to the dealers’ customers and as such is an integral part of our
automotive business. Our automotive operations segment is further divided into
Tata and other brand vehicles (including financing thereof) and Jaguar Land Rover.
We produce a wide range of automotive products, including: o Passenger Cars:
Our range of Tata brand passenger cars include the Nano, a micro, the Indica, the

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Vista, the Zest and the Bolt, which are compacts and the Indigo eCS and the
Manza, which are mid-sized, in the sedan category. We have expanded our
passenger car range with several variants and fuel options designed to suit various
customer preferences. Our Jaguar Land Rover brands have an established presence
in the premium passenger car category under the Jaguar brand name. There are
four car lines currently manufactured under the Jaguar brand name, including the
F-TYPE two-seater sports car coupe and convertible (including all-wheel drive
derivatives) the XF sedan (including the Sportbrake and all-wheel drive
derivatives), the XJ saloon, and the new XE sports saloon, which commenced sales
in May 2015.
Utility Vehicles: We manufacture a range of Tata brand utility vehicles, including
the Sumo and the Safari, which are SUVs, the Xenon XT, a lifestyle pickup, the
Tata Aria, a crossover, and the Venture, a multipurpose utility vehicle. We offer
two variants of the Safari: the Dicor and the Storme. We also offer a variant of the
Sumo, the Sumo Gold, and launched the new Movus in May 2014, which is an
entry level UV. There are six car lines under the brands of Range Rover and Land
Rover in the premium all-terrain vehicles categories: the Range Rover, Range
Rover Sport, including the Range Rover Sport SVR, the Range Rover Evoque
(available in 5-door and coupe versions), Land Rover Discovery, including the
Discovery 4 which features 7-seat capacity, the Discovery Sport and the Defender,
which will cease production in Fiscal 2016.

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Light Commercial Vehicles: We manufacture a variety of light commercial
vehicles, including pickup trucks and small commercial vehicles. This includes the
Tata Ace, India’s first indigenously developed mini-truck, with a 0.75 ton payload
with different fuel options, the Super Ace, with a 1-ton payload, the Ace Zip, with
a 0.6 ton payload, including a CNG variant launched in Fiscal 2015, the Magic and
the Magic Iris, including an electric variant, both of which are passenger variants
for commercial transportation developed on the Tata Ace platform, and the
Winger. In addition, we introduced a new generation of Ultra LCV trucks,
including the Ultra narrow cab, in Fiscal 2015. We also offer the City Ride and
Starbus ranges of buses.
Medium and Heavy Commercial Vehicles: We manufacture a variety of medium
and heavy commercial vehicles, which include trucks, tractors, buses, tippers, and
multi-axled vehicles, with GVWs (including payload) of between 8 tons and 49
tons. In addition, through Tata Daewoo Commercial Vehicles Co. Ltd., or TDCV,
we manufacture a wide array of trucks ranging from 215 horsepower to 560
horsepower, including dump trucks, tractor-trailers, mixers and cargo vehicles. Our
Prima line of trucks is aimed at its customers in India and South Korea, and we
have extended the Prima line by offering Prima LX and multi-axle truck variants.
We expect to gradually export our Prima products to other countries such as South
Africa, Russia, the other South Asian Association for Regional Cooperation
countries, the Middle East and various countries in Africa. We also offer a range of
buses, which includes the Divo Coach, the Semi Deluxe Starbus Ultra Contract
Bus and the new Starbus Ultra.

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Defence vehicles: Tata Group company whose relationship with India’s defence
and security forces is synonymous with that of the group is Tata Motors. India’s
largest automobile company (subsidiaries include Jaguar Land Rover), with
consolidated revenues of almost $35 billion in 2012-13, is strategically moving
from the logistics vehicle segment into the combat vehicle segment.
Tata Motors has been associated with country’s Defence forces since 1958. Over
100,000 vehicles have been supplied to Indian Military and Para-Military forces so
far. Tata Motors Defence Solutions cover the complete range of logistics and
tactical vehicles. Current range of products for Defence and security forces
includes Tata Armoured Safari, Tata Light Armoured Vehicle and Tata Light
Armoured Troop Carrier, Mine Protected vehicle and Light Armoured Multi Role
vehicle. High Mobility vehicle such as Tata 1623 (6x6), Tata 2038(6x6) and Tata
3138(8x8) are being well received by Defence. We also manufacture Shelters,
Containers on 4x4, 6x6 and 8x8 platforms for Missile, Rocket Launchers and
Command Post.
Tata Motors has now entered into tactical, combat support vehicles by introducing
Duty High Mobility All Wheel Drive Multi Axle Military Vehicles. Tata Motors
has supplied the multi-axle vehicle 8x8 to the Indian Air force and to LRDE Qty
06 Nos & 03 Nos respectively. The TATA 8x8 & 6x6 have also been also been

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supplied to RAFAEL, Israel for the SPYDER Missile System for the Indian Air
force. Tata Motors has also developed and trial evaluated the 8x8 prototype at
VRDE for the BrahMos programme. The acceptance trial was undertaken by the
trial team comprising reps from R & DE (E), VRDE, MAG 14 (rep of Army)
MSQAA, CQA & BrahMos. The schedule of trials was in conformance to the
GSQR and the Extended Acceptance Test was completed in five (05) phases. This
was carried out and was a success due to the active support received from
BrahMos.
CV Unit
Commercial Vehicle Business unit. The company has over 130 models of light,
medium and heavy commercial vehicles ranging from two tones to 40 tones, buses
ranging from 12-seaters to 60-seaters, tippers, special purpose vehicles, off-road
vehicles and defense vehicles.
Passenger Car Unit
The Company’s passenger car range comprises the hatchback Indica, the Indigo
sedan and the Marina, its station wagon variant, in petrol and diesel versions. The
Tata Sumo, its rural variant, the Spacio and the Tata Safari (the country's first sports
utility vehicle) are the company's multi-utility offerings. The Tata Indica, India's first
indigenously designed and manufactured car, was launched by Tata Motors in 1999
as part of its ongoing effort towards giving India transport solutions that were
designed for Indian conditions. Currently, the company's passenger cars and multi-
utility vehicles have a 16-per cent market share.

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In addition to the growth opportunities in the buoyant domestic market, the
company is pursuing growth through acquisitions (it acquired Daewoo Commercial
Vehicles, Korea, in 2004) and alliances (it has entered into a tie-up with MG Rover,
UK, to supply 1, 00,000 Indica’s to be budged as City Rover) in other geographies.
Research and Development
Tata Motors invests up to 1.3 per cent of its annual turnover on research and
development, with an emphasis on new product / aggregates development and
technology up gradation. Its Engineering Research Center in Pune employs over
900 scientists and engineers and has India's only certified crash-test facility and
hemi-anechoic chamber for testing of noise and vibration.
The company also draws on the resources of leading international design and
styling houses like the Institute of Development in Automotive Engineering, SPA,
Italy and Stile Bertoni, Italy. The company has also been implementing several
environmentally sensitive technologies in manufacturing processes and uses some
of the world's most advanced equipment for emission checking and control.

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Environmental Responsibility
Tata Motors has led the Indian automobile industry's anti-pollution efforts through
a series of initiatives in effluent and emission control. The company introduced
emission control engines in its vehicles in India before the norm was made statutory.
All its products meet required emission standards in the relevant geographies.
Modern effluent treatment facilities, soil and water conservation programs and tree
plantation drives on a large scale at its plant locations contribute to the protection of
the environment.
Exports
Tata Motors' vehicles are exported to over 70 countries in Europe, Africa, South
America, Middle East, Asia and Australia. The company also has assembly
operations in Malaysia, Bangladesh, Kenya, South Africa and Egypt.
Associates
With an aim to expand its business horizons, Tata Engineering has always sought
opportunities to form alliances with business leaders. In a world driven by
specialization, this policy adopted by Tata Engineering has ensured overall
business control and an edge over competition. The joint ventures that Tata
Engineering has formed over the years were guided by the contemporary
technologies of the partners.
Tata Engineering entered into a joint venture with Cummins Engine Company,
USA, in 1992 – long before emission control norms were prevalent in India.
Cummins was the leading name in manufacturing engines that used emission

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control technologies. This alliance was the result of Tata Engineering’s foresight
and concern for the environment.
It is a business practice at Tata Engineering to make strategic investments. These
investments provide technologies, markets and capabilities to strengthen the
company's existing businesses. Tata Engineering is India's largest exporter of
engineering goods.
Tata Engineering invests in opportunities that can enhance and reinforce its
presence in the corporate world. The Company has numerous subsidiary
companies, Foreign Collaborations, Technical Collaborations and Financial
Collaboration.
Tata Motors has made substantial investments in building associate and subsidiary
companies that complement and support its business activities. These include:
Tata Daewoo Commercial Vehicle Company manufactures heavy trucks ranging
from 15T GVW to 45T GVW. Tata Motors acquired this company in March, 2004
HV Transmissions, supplies gearboxes for the company's medium and heavy
commercial vehicles.
TAL Manufacturing Solutions manufactures painting systems, welding lines,
material handling systems and robotics. It also develops factory automation
solutions and provides consultancy services in the field of manufacturing processes
and factory layouts. Concorde Motors (India): Retails Tata Motors' range of
passenger vehicles.

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Tata Precision Industries, Singapore and Tata Engineering Services, Singapore, are
engaged in the manufacture of high precision tooling and spare parts, and
warehousing, respectively.
Nita Company, Bangladesh, is engaged in the assembly of Tata vehicles for
Bangladesh market.
JOINT VENTURES
Tata Cummins Limited (TCL)
During the year TCL supplied 6,207 engines to the Company. Turnover for the 18
month period ended March 31,1999 was Rs.288.47 crores.
The Company proposes to eventually switch over from its existing range
of engines for H/MCV s to those manufactured by TCL in collaboration with
Cummins Engine Co.
Tata Holset Limited (THL)
In the year 1998-99, THL produced 6,525 turbochargers and sold 6,888
turbochargers. Net sales turnover for the year was Rs.8.17 crores. (Previous year
Rs.4.13 crores). THL, which supplies the turbochargers to TCL for fitment on its

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engines, would also see a marked improvement in performance once the volumes
for TCL build up.
Joint Ventures Abroad
Tata Precision Industries
For the year ended December 31, 1998, Tata Precision Industries (TPI), Singapore,
achieved a turnover of Singapore $2.4 million (1997- Singapore $5.0 million). This
was mainly due to the fact that business in general was influenced by the economic
crisis that befell almost all countries in the ASEAN region. TPl's business was
particularly affected due to the drop-in consumer demand for electronic items. Due
to
the loss of Singapore $2.20 million (1997-loss of Singapore $0.35 million), no
dividend was paid for the year. With present indications of improved business,
including substantial orders from a new: customer, TPI expects to wipe out its losses
over the next two years.
Nita Company Limited
The Company's joint venture in Bangladesh which assembles TATA vehicles for the
Bangladesh market, sold 881 vehicles to yield a turnover of Tk 600.7 million
(approximately Rs.49.1 crores) for the year 1997-98 and declared a dividend @ 15%.
The dividend amount of $44,344 was paid to the Company in March 1999. Sales in

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1998-99 were lower at 580 nos. With the automobile market in Bangladesh showing
signs of recovery, the performance during the current year is expected to be better.

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KEY SUBSADRIES
1. Concorde Motors (India) Limited
Concorde Motors India Ltd. (CMIL) is a fully-owned subsidiary of Tata Motors. A
pioneer in professionalizing the automobile retail business in the country, CMIL is
a one-stop shop for the complete range of Tata Motors’ passenger vehicles, sales,
service and spare parts.
2. Jaguar Land Rover Automotive Plc
Jaguar Land Rover brings together two prestigious British car brands. Tata Motors
acquired the brands from Ford in 2008, merging them into a single company in
2013. One of the world’s leading premium car brands, Jaguar Land Rover presents
the future of sustainable mobility.
3.Tata Motors European Technical Centre PLC (TMETC)
Based in Coventry, UK, Tata Motors European Technical Centre PLC (TMETC) is
a wholly-owned subsidiary of Tata Motors. As a center of excellence for automotive
design and engineering, TMETC is an active partner in a number of collaborative
projects in low carbon technology, and electric and hybrid vehicle technology for
future passenger and light commercial vehicles.

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4.Tata Motors Insurance Broking and Advisory Services Limited (TMIBASL)
A wholly-owned subsidiary of Tata Motors, TMIBASL provides end-to-end
insurance solutions in the retail sector with a focus on the automobile sector.
TMIBASL offers services to various OEMs in the passenger vehicle, commercial
and construction equipment markets, including to us.
5.TMF Holdings Limited
TMF Holdings Limited (TMFHL) - a wholly owned subsidiary of the Company, is
the vehicle financing arm under the brand "TMF Holdings Limited".
TML Distribution Company Limited (TDCL)
TML Distribution Company Limited, or TDCL, our wholly-owned subsidiary, was
incorporated on March 28, 2008. TDCL provides distribution and logistics support
for distribution of our products throughout India.
6.Tata Technologies Limited
A global leader in engineering services outsourcing and product development IT
services to the global manufacturing industries, Tata Technologies is a company of
innovators, specialists in the design engineering space, who apply cutting-edge
technologies to provide competitive advantage to customers in the manufacturing
sector. The company is headquartered in Singapore.

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FUNCTION
The various functional groups operating in TATA Motors are:
1.HR:
Tata Motors has formalized selection, evaluation, and payroll processes. The HR
function of Tata Motors consists of tracking existing employee data which includes
personal histories, skills, capabilities, accomplishments and salary. The department
records basic selection, training and development, capabilities and skills
management, compensation planning records and other related activities.
2. Engineering & Research Centre (ERC):
. The Research Centre regularly upgrades components and aggregates.
The facilities in ERC includes:
• Facility for improving Engine Performance
• Reducing Emissions
• Test Tracks
• Safety
• Designing and Styling
3. Technical & Productivity Services (T & PS):
This group looks after the necessary technical assistance which is required for
carrying out smooth production in the plant. The functions of this group include
setting up new assembly lines, seeking prospects for modifications in the current

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assembly lines, preparing standard operating procedure (SOP) and preparing TS
16949 documents.
4. Production:
This group carries out production as per the production plan prepared by
production planning and control (PPC).
Passenger Cars produced in Pune plant includes India’s first indigenously built
Indian car ‘Indica’, Indigo, Indigo Marina. All the variants of these cars are
produced here. Production is also carried out for the brand-new model from Tata
Motors stable ‘Indica Vista’, which has been developed on a completely new
platform.
Maintenance group works in co-ordination with the production team. Scheduled
maintenance of the equipment’s is being done.
5. Vendor Development:
Manufacturing a car requires a large no. of small and large ancillaries which
cannot be produced inhouse due to various constraints. Hence some of these small
parts are outsourced to various vendors. The parts procured from these vendors
should be as per the quality standards maintained by Tata Motors. Vendor
development group identifies the appropriate vendor and ensures proper quality
standards.

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6. Maintenance
The maintenance department is responsible and accountable for maintenance. It is
responsible for the way equipment runs and looks and for the costs to achieve the
required level of performance. This is not to say that the operator has no
responsibility for the use of equipment when in his hands - he does. The point is
that responsibility and accountability must be assigned to a single function or
person whether it be a mechanic or operator. To split responsibility between
maintenance or any other department where overlapping responsibility occurs is to
establish an operation where no one is accountable. Alumax of SC considers this a
fundamental principle for effective operation of maintenance.
The maintenance function is responsible for the frequency and level of
maintenance. They are responsible for the costs to maintain, which requires
development of detailed budgets and control of costs to these budgets.
Just as the quality function in an organization should report to the top manager, so
does the maintenance function for the same obvious reasons. This allows
maintenance problems to be dealt with in the best interest of the plant or company
as a whole. Maintenance efforts and costs must not be manipulated as a means for
another department to achieve its desired costs results.
Where the maintenance department or group is held responsible and accountable
for maintenance, the relationship with other departments takes on new meaning.
The maintenance department can't afford to have adversary relationships with
others. They must have credibility and trust as the basis of interdepartmental
relationships. This is an essential element for the successful operation of a
maintenance management system.

37
These are the following: -
1.Technical Teams - Core Maintenance
These teams perform core maintenance for the plant. They are composed of qualified
electricians, mechanics, and technicians. The teams are assigned based on a
functional requirement plant wide or on the basis of a geographic area of
responsibility. The focus, direction of the team, and individual team member needs
are provided by an assigned member of the facilitator and directional control team.
2.Facilitator and Directional Control Team
Members of this team have been trained and qualified to provide team
organizational dynamics and traditional supervisory functions as required. With the
facilitator, the team must address work performance by categories, administrating,
training/safety/housekeeping, budgeting and cost control and information reporting
as well as the technical requirements of the team. These members perform the
necessary traditional supervisory functions, especially related to personnel
functions, for the technical teams.
3.Work Distribution and Project Coordination Team
This team works with the Facilitator, Planning and Engineering teams to staff
technical teams to meet work load requests, inventory requirements, contractor
support, and field superintendence of engineering projects.
4.Job Planning Team

38
This team works closely with the Technical teams and the Facilitator team to plan
and schedule maintenance, overhaul, and contractor work. Where operators are
doing maintenance functions, the same applies. In addition, information and reports
are prepared by this team for all other teams as required or requested. Quality control
of the data input is a responsibility of this team. Coordination of production
requirements must also be performed.
5.Technical Assistance Team –
This team is a resource to the Technical teams and Facilitator team for continuous
improvements, modifications, trouble shooting, and corrective action.
6.Materials Support Team
This team works with the Planning team, Facilitator team, and the Technical teams
to meet planned job requirements and emergency material requirements.
7.Maintenance Management Team
This team provides overall coordination of maintenance and material functions to
meet the plant capacity requirement. Overview of budget and cost control is also
provided.
8.User/Operator Maintenance Team
This is a team of designated operators who perform assigned and scheduled
maintenance work. They must be selected, trained and qualified prior to being
assigned to this team.
9.Plant Engineering Team

39
This team provides projected management for the Plant capital budget program.
They provide consulting and troubleshooting to the Technical Teams on an as
requested basis.
7.Quality
Quality Management (TQM) describes the culture, attitude, and organization of a
company striving to produce high quality products and services that meet or exceed
customer expectations. Originating in the 1950s, its popularity has increased since
the 1980s, and its quality management concepts have been implemented by
automotive companies such as Ford Motor Company, General Motors Company,
and Toyota Motor Company.
Customer Focus
This is the first and most important concept of the TQM Philosophy. Built upon the
understanding that quality value of a product is reduced if it does not meet the
customer’s needs, the customer focus concept states that the client’s wants and/or
needs must be met or exceeded. But first, a company must first determine what those
wants and needs are. To do this, they gather information through market studies,
research groups, and client meetings. Benefits of achieving this concept include:
• Increased revenue
• Increased effectiveness
• Improved customer loyalty
• Continuous Improvement

40
Taking into account that customer expectations are always changing (and typically
rising as quality management begins to provide results), the continuous
improvement concept stems from a belief that mistakes can be avoided and defects
can be prevented. It extends to all aspects of an organization, from the shop floor to
the marketing department to decision-making.
One common approach used to ensure continuous improvement remains a core
concept is the Plan-Do-Check-Act cycle. Its processes are as follows:
• Plan: evaluate the current processes and make plans to resolve the problems
found
• Do: implement the plan and collect data for evaluation
• Check: study data to determine if the plan is achieving the desired results
• Act: Communicate results and implement the new procedure if successful
It is important to remember that, because this approach is a cycle, the entire process
starts over once a new plan or procedure is implemented.
Employee Empowerment
In the TQM Philosophy, employees are considered a vital part of the quality
management process. They are empowered to make decisions, their contributions
are valued, and their suggestions are implemented. In order to ensure they are able
to make logical, valuable contributions, employees are given quality tools and
extensive training.

41
Use of Quality Tools
As already mentioned, quality tools are important for ensuring that employees are
able to make valuable and informed decisions and contributions. They must also
receive extensive training to help them understand access quality via quality control
and measurement tools. This gives employees the ability to accurately interpret their
findings and effectively correct problems.
Product Design
Providing a design that meets customer expectations is a critical element to building
a quality product. Unfortunately, this can be more difficult than it sounds because
most customers provide general descriptions, such as “safe,” “tough,” or “sleek.”
Automotive companies must translate these generalizations into specific technical
requirements.
One tool that helps them do this is known as QFD, or Quality Function Deployment.
This tool identifies the requirements of customers and then scores those
requirements numerically. The scores are then translated into specific product
requirements, such as side air bags for “safe”. This tool can also be useful for
enhancing communication between various company functions and departments.
Manage Supplier Quality
Most concepts of the TQM Philosophy apply only to the company itself, but the
supplier quality management concept extends to outside suppliers. It is built upon
philosophy that suppliers who strive to meet the company’s needs help the company
meet their customer’s needs. In many cases, as long as the supplier meets preset

42
quality standards, materials are accepted without inspection, which helps to speed
up the overall production process.
Quality control specialists most commonly work for manufacturing facilities,
although quality control specialists can be found in nearly every industry. Quality
control specialists ensure that the department or process they work with meets
minimum quality standards. Processes vary, depending on the specific process
involved. All quality control processes share some common functions.
Testing
The most basic function of quality control involves testing. Quality control
specialists test the manufacturing process at the beginning, middle and end to
ensure that the production quality remains the same throughout. If the specialist
discovers an issue at any point in the process, she works with the production team
to remedy the issue. Quality control specialists perform quality control tests for
services provided as well, evaluating the quality of a specific service at specified
intervals throughout the time of service. Testing provides quality results as of the
date of testing.
Monitoring
Monitoring consists of ongoing testing that the quality control specialist performs
on a regular basis. The specialist repeats the testing and records the results of each
test. After the specialist has performed several tests, he reviews the results and

43
looks for any trends in quality. If the quality declines, he increases the amount of
testing performed in that area. If the quality maintains or improves, he decreases
the amount of testing performed in that area. The quality control specialist
continues to monitor the trending of the results.
Auditing
Quality control specialists also spend time auditing the quality of a process which
the specialist doesn’t work with. The quality control specialist may be auditing the
work of the regular quality control work performed or auditing the quality of a
process without any current quality control work. When performing the audit, the
quality control specialist reviews the results reported by the regular quality control
workers to determine if they performed the original tests correctly.
Reporting
Periodically, the quality control specialist reports the quality results to
management. A high number of quality problems mean something is wrong with
the process and there may be many unhappy customers for the company.
Management reviews the number of quality problems and where they occur in the
process and take action to address the issue.

44
8. Tooling
Tooling is an important process in the production of automobiles. Think about all
the unique parts that come into play when a manufacturer creates a functioning
vehicle. Each of those parts is a piece of the puzzle that comes together to design
your automobile. From the fender to the deck lid, each part required to build the
recent version of the vehicle you drive is made by a tool that has been created
specifically for that part. When you think about all the vehicle designs that are on
the road today, you begin to see a picture of the large demand of MTI tooling. The
tooling industry is essential to the automotive industry. Each unique part needs
something designed to build it.
• Tooling is the process of designing and engineering the tools that are
necessary to manufacture parts or components. There are many different
types of tooling, of which the most common are: work holding tools, such as
jigs and fixtures; cutting tools for milling and grinding machines; dies for
cold forming, sheet metal, forging and extrusion machines; and welding and
inspection fixtures.
• The quality of a finished part, its properties, the speed and accuracy with
which it can be produced and the repeatability of manufacture in high
volume production runs, all depend on the precision and characteristics of
the tooling. So, for the best parts, tooling needs to be designed and
engineered to the highest quality.
• The cost of tooling will change from project to project because it depends on
so many variables. However, there is a common misconception that tooling
is an expensive and sometimes cost-prohibitive process. In fact, thanks to

45
modern engineering techniques the tooling costs for CNC machining and
precision cold forming are relatively low in most cases.
• Ensuring high-quality tooling requires a wide range of factors to be
considered. For example: the tolerances required in the finished part, as
these will affect the configuration of the tooling; mechanical strength and
rigidity of the tool, as this is essential to ensure workpiece accuracy,
repeatability and quality; cutting tool strength, which has to be sufficient to
withstand machining forces, especially in high volume production; and
more.
9. Material Management
Material management covers all aspects of material costs, supply and utilization.
The functional areas involved in material management usually include
purchasing, production control, shipping, receiving and stores.
The following functions are assigned for material management:
1. Production and Material Control:
Production manager prepares schedules of production to be carried in future. The
requirements of parts and materials are determined as per production schedules.
Production schedules are prepared on the basis of orders received or anticipated
demand for goods. It is ensured that every type or part of material is made available
so that production is carried on smoothly.

46
2. Purchasing:
Purchasing department is authorized to make buying arrangements on the basis of
requisitions issued by other departments. This department keeps contracts with
suppliers and collects quotations etc. at regular intervals. The effort by this
department is to purchase proper quality goods at reasonable prices. Purchasing is a
managerial activity that goes beyond the simple act of buying and includes the
planning and policy activities covering a wide range of related and complementary
activities.
3. Non-Production Stores:
Non-production materials like office supplies, perishable tools and maintenance,
repair and operating supplies are maintained as per the needs of the business. These
stores may not be required daily but their availability in stores is essential. The non-
availability of such stores may lead to stoppage of work.
4. Transportation:
The transporting of materials from suppliers is an important function of materials
management. The traffic department is responsible for arranging transportation
service. The vehicles may be purchased for the business or these may be chartered
from outside. It all depends upon the quantity and frequency of buying materials.
The purpose is to arrange cheap and quick transport facilities for incoming materials.

47
5. Materials Handling:
It is concerned with the movement of materials within a manufacturing
establishment and the cost of handling materials is kept under control. It is also seen
that there are no wastages or losses of materials during their movement. Special
equipment’s may be acquired for material handling.
6. Receiving:
The receiving department is responsible for the unloading of materials, counting the
units, determining their quality and sending them to stores etc. The purchasing
department is also informed about the receipt of various materials.
7.Inventory Arrangement and Control:
In the cosmopolitan world of today, the inventory arrangement would mean the
purchase of materials to be stored before entering the production stage or sold out,
such that the stock cost is zero.
There are three kinds of inventories: a) raw material, b) purchased goods, and c)
finished components. Their inventory control is the responsibility of the materials
management department, production department and the sales department. It is
always important to ensure that inventory at different levels is maintained, the raw
materials are available at each level and that there is proper flow of materials from
one production facility to another at all levels in a manufacturing firm.

48
10.Security
Tata Motors hire private security guards to protect and secure the office building.
These private security guards serve an important role within the corporate structure,
helping to eliminate theft, head off problems and ensure that corporate property is
secure.
Admission Control
Security officers normally have a desk at or near the front of the building. This
generally allows them to control access to the building. This may be in the form of
direct control, such as having to open or close a door to admit people, or having to
use a key to allow people to go up in an elevator. It may be in the form of requiring
people to check in at the security desk and receive a visitor's badge, or requiring
people to sign in and out of a building.
Surveillance
Security guards and personnel often perform surveillance functions within a
company. They may monitor security cameras to determine whether there are any
potential problems. By monitoring the security cameras and the building itself,
security personnel can watch for signs of break-in or for other problems, such as fire,
a burst sprinkler or something else that might cause damage.

49
11. Frame
• It is the supporting component of automobile vehicle.
• It is the foundation for carrying the engine, transmission system & steering
system by means of spring, axle, rubber pads etc.
• The frame is made of box, tubular channels or U-shaped section, welded or
riveted together.
Function of Frame
• To support chassis component and the body.
• To withstand the static and dynamic load of different component of chassis.
• To withstand load of the body.
• To carry load of passenger/goods carried in body.
• To withstand stresses caused due to uneven road conditions.
• To withstand force caused due to turning of vehicle and sudden braking or
acceleration.

50
PRODUCTS
TRUCKS
TATA PRIMA TATA SIGNA
TATA SE 1613
TATA LPT

51
SPORTS UTILITY VEHICLES
NEXON NANO
STORME HARRIER

52
TATA MUNICIPAL SOLUTION
TATA LPT REFUSE
TATA ROAD SWEEPER
Tata LPK 909-5 CUM TIPPER
TATA ACE HOPPE

53
TATA CARGO
TATA ACE TATA YODHA
PASSENGER TRANSPORTATION

55
MACHINE DETAILS
SIMATIC S7-1500 SPECIFICATIONS
Standard CPUs
CPU 1511-1 PN CPU 1513-1 PN CPU 1515-2 PN
Type Standard CPU Standard CPU Standard CPU
Dimensions 35 x 147 x 129 mm 35 x 147 x 129 mm 70 x 147 x 129 mm
Spare part availability
after product
discontinuation
10 years 10 years 10 years
Temperature range 0 … 60 °C 0 … 60 °C 0 … 60 °C
Display

56
Screen diagonal 3.45 cm 3.45 cm 6.1 cm
Command execution
time
Bit operation 0.06 µs 0.04 µs 30 ns
Word operation 0.072 µs 0.048 µs 36 ns
Fixed-point operation 0.096 µs 0.064 µs 48 ns
Floating-point operation 0.384 µs 0.256 µs 192 ns
Memory
Work memory 150 KB for
program 1 MB
for data
300 KB for program
1.5 MB for data
500 KB for program
3 MB for data
Load memory/mass
storage, max.
32 GB
(via SIMATIC memory
card)
32 GB
(via SIMATIC memory
card)
32 GB
(via SIMATIC memory
card)
Backup, max. Program on SIMATIC
memory card
(maintenance-free)
Program on SIMATIC
memory card
(maintenance-free)
Program on SIMATIC
memory card
(maintenance-free)
I/O
I/O address area, max. 32/32 KB 32/32 KB 32/32 KB
Process image 32 KB 32 KB 32 KB
Digital channels 262 144 262 144 262 144
Analog channels 16 384 16 384 16 384
Centralized
• I/O integrated in CPU No No No
• I/O modules on CPU Yes Yes Yes
Distributed
• I/O modules on
PROFIBUS
Yes (via CM) Yes (via CM) Yes (via CM)
• I/O modules on
PROFINET
Yes Yes Yes

57
Bit memories, timers,
counters, blocks
Bit memories 16 KB 16 KB 16 KB
S7 timers 2048 2048 2048
S7 counters 2048 2048 2048
IEC timers/counters Yes Yes Yes
Number of elements1)
2000 2000 6000
HMI

59
SPECIFICATIONS OF SERVO DRIVE
Ground Terminals

60
General Drive Specifications
Permissible Frequency 50/60 Hz ±5%
Encoder Resolution / Feedback
Resolution
2500 lines / 10000 ppr
Control of Main Circuit SVPWM (Space Vector Pulse Width Modulation)
Control
Tuning Modes Easy / Auto / Manual
Dynamic Brake Built-in control
Analog Monitor Outputs (2) Monitor signal can be set by parameters (Output voltage
range: ±8V; Resolution: 12.8 mV/count)
8 Programmable Digital Inputs
(45 selectable functions)
Servo enable, Alarm reset, gain switching, Pulse counter
clear, Fault stop, CW/CCW over-travel
Internal parameter selection, Torque limit activation,
Velocity limit activation, Control mode selection
Scalable Encoder Output Encoder signal output A, /A, B, /B, Z /Z, Line Driver
5 Programmable Outputs
(9 selectable indicators)
Servo ready, Servo On, Low velocity, Velocity reached,
In Position, Torque limiting, Servo fault,
Electromagnetic brake control, Home search completed
Communication Interface RS-232 / RS-485 / RS-422 / Modbus ASCII & RTU up
to 115k Baud
Protective Functions Overcurrent, Overvoltage, Undervoltage, Overload,
Excessive velocity/position error, Encoder error,
Regeneration error, Communication error
Installation Site Indoor location (free from direct sunlight), no corrosive
liquid and gas
(far away from oil mist, flammable gas, dust)
Altitude 1000m [3281 ft] above sea level – maximum

61
Operating Temperature 0 to 55 °C [32 to 131 °F] (If operating temperature is
above 55°C, forced cooling is required).
For long-term reliability, the ambient temperature of Sure
Servo systems should be under 45°C (113°F).
Storage Temperature -20° to 65°C (-4° to 149°F)
Humidity 0 to 90% (non-condensing)
Vibration 9.81 m/s2
(1G) less than 20Hz, 5.88 m/s2
(0.6G) 20 to 50
Hz
Protection IP 20
Agency Approvals CE; UL Certified (U.S. and Canada)
SERVO MOTOR

63
MY WORK AS A TRAINEE
I joined TATA Motors as a summer trainee in the session 10th
of June to 14th
of
August, my duty as a summer trainee firstly was to feel what the real industry is,
starting from the BIW Shop where the cowl welding was done then to the paint shop
where the cowl and cab were automatically painted by highly efficient and precise
robots, the paint shop is fully automatic. After visiting the BIW shop, I went to the
frame factory. Where I came to know Frame, factory makes frame(chassis) for the
truck from coils of metal. Followed by that the frame shop
was to be viewed in detail where I had spent my more than two weeks inspecting
processes as well as calibrating new things and methods. As a trainee I was given
the project in frame factory where the frame is being manufactured.

64
DAILY OVERVIEW OF INTERNSHIP ACTIVITIES

65
PROJECT DURING COP-TRAINING
Project Name: -
Flowchart of Servo EMC Heft Fixture
Objective: -
To make a flowchart of the working of Servo EMC Heft Fixture.
Location: -
Frame Factory, TATA Motors Jamshedpur.
Project duration: -
Flowchart of Servo EMC Heft Fixture
10th
June 2019 – 14th
August 2019.
Team Members -
T. DEEP - B. Tech 2nd
Year
Niraj Prasad - B. Tech 3rd
Year
Surya Pratap - B. Tech 3rd
Year
Mohammed Sheikh - B. Tech 3rd
Year
Shishupal Tiwari - Diploma 3rd
Year

67
LITERATURE REVIEW
PLC is an intelligent system of modules for replacing relay-based logic. PLCs are
often programmed in ladder logic which is the wiring up of relay contacts and coils
on screen. Some of relay contacts are tied up with inputs and some are with outputs
from real world. The program incorporates timers, counters and arithmetic
operations which couldn’t (easy) with just relays. The working of PLC is also
mentioned by author. Along with the PLC, SCADA database is used for graphical
view of process monitoring from operator station in the central control room. The
history of automation from manual control, with logic gates, electrical control with
logic gates up to PLC is given by author. PLC eliminates the physical wiring of the
control devices. The advantages of PLCs are enlisted by author like reduced space,
energy saving, modular replacement, easy trouble shooting, error diagnostic
programmer, economical, greater life and reliability. A SCADA system used to
gather data from sensors and instruments and transmit data at a central site for
control or monitoring. The collected data is viewed on one or more SCADA host
computers. The implementation of PLC and SCADA system is described by authors.
The authors concluded with the statement that remote and safe operation and
monitoring, flexibility, scalability and power modular structure can be Logic
Controllers. In this paper they highlight the concepts, working, advantages and
practical applications of Programmable Logic Controllers. Also, they have made
comparison of PLC with other control systems. The term Programmable Logic
Controller defined by the National Electrical Manufacturers Association (NEMA)

68
such as “A digitally operating electronic apparatus which uses a programmable
memory for the internal stage of instructions for implementing specific functions
such as logic, sequencing, timing, counting etc. through digital or analog
input/output modules, various types of machines or processes”. They mentioned that
there are six basic components of PLC such as I/O modules, processor, power
supply, memory unit, network interface and programming units. The authors have
mentioned about the programming and working of PLC. Also, they have made the
comparison of PLCs with other control systems.
PROGRAMMABLE LOGIC CONTROLLER
Introduction To PLC
What does PLC stand for?
• PLC-Programmable Logic Controller

69
• PLC implements logic control functions by means of a program.
• Definition
A digitally operating electronic apparatus which uses a programming memory for
the internal storage of memory for the internal storage of instructions for
implementing specific functions such as logic, sequencing, timing, counting and
arithmetic to control through digital or analog modules, various types of machines
or process.
Fig.: PLC system in a rack, left-to-right: power supply unit (PSU), CPU, interface module
(IM) and communication processor (CP).

70
PLC Origin
• Developed to replace relays in the late1960s.
• Costs dropped and became popular by 1980s.
• Costs dropped and became popular by 1980s.
Programmable Controller Development
• 1968- Programmable concept developed
• 1974 -Use of several(multi) processors within a PLC-timers and counters;
arithmetic operations;12K of memory and1024 I/O points.
• 1976 -Remote input/output system introduced 1977 Microprocessors-based
PLC introduced
• 1980-IntelligentI/O modules developed.
• 1983-Low-costsmall PLC’s introduced.
• 1985-Networking of all levels of PLC, computer and machine using SCADA
software.
Leading brand of PLC
1.Allen Bradley
2. Mitsubishi
3.Texas Instruments
4.General Electric
5.Westinghouse
6.Cutter Hammer
7.Square D
8. Siemens

71
INPUT DEVICE
Fig.: Input device
Limit
Push
Level
Flow
Thumbwheel

73
Major Components of a Common PLC
PROCESSOR
POWER
SUPPLY
I M
N O
P D
U U
T L
E
O M
U O
T D
P U
U L
T E
PROGRAMMING
DEVICE
From
SENSORS
Pushbuttons,
contacts,
limit switches,
etc.
T
oOUTPUT
Solenoids,
contactors,
alarms
etc.

74
COMPONENTS OF A COMMON PLC
Major Components of a Common PLC
• Power Supply: - Provides the voltage needed to run the primary
components.
• I/O Modules: - Provides signal conversion and isolation between the
internal logical level signals inside the PLC and field high level signal.
• Processor: - Provides intelligence to command and govern the activities of
the entire PLC systems.
• Programming Device: - Used to enter the desired program that will
determine the sequence of operation and control of process equipment or
driven machine.
• Self-test: Testing of its own hardware and software for
faults.
• Input scan: If there are no problems, PLC will copy all
the inputs and copy their values into memory.
• Logic solve/scan: Using inputs, the ladder logic program is solved once and
outputs are updated.
Self-test
Input scan
Logic scan

75
Output scan: While solving logic the output values are updated only in memory
when ladder scan is done, the outputs will be updated using temporary values
memory.
PLC OPERATION SEQUENCE
Programming Languages of PLC
• Most common languages encountered in PLC programming are:
• Ladder Logic
• Functional Block Diagram
• Sequential Function Chart
• Boolean mnemonics
Ladder Logic
Ladder logic is the main programming method used for PLCs. As mentioned before,
ladder logic has been developed to mimic relay logic. The decision to use the relay
logic diagrams was a strategic one. By selecting ladder logic as the main
programming method, the amount of retraining needed for engineers and trades
people was greatly reduced. Modern control systems still include relays, but these
Output
scan

76
are rarely used for logic. When a voltage is applied to the input coil, the resulting
current creates a magnetic field. The magnetic field pulls a metal switch (or reed)
towards it and the contacts touch, closing the switch. The contact that closes when
the coil is energized is called normally open. The normally closed contacts touch
when the input coil is not energized. Relays are normally drawn in schematic form
using a circle to represent the input coil. The output contacts are shown with two
parallel lines. Normally open contacts are shown as two lines, and wil be open (non-
conducting) when the input is not energized. Normally closed contacts are shown
with two lines with a diagonal line through them. When the input coil is not
energized the normally closed contacts will be closed (conducting).
The main ladder logic symbols represent the elements:
Advantages Of PLC
• Reliability.
• Flexibility in programming and reprogramming.
• Cost effective for controlling complex systems.
• Small physical size, shorter project time.
make contact
break contact
relay coil

77
• High speed of operation.
• Ability to communicate with computer systems in the plant.
• Ease of maintenance /troubleshooting.
• Reduced space.
• Energy saving
Disadvantages of PLCsdevices are pro
• Manufacturer can’t be used in combination with parts of another
manufacturer.
• Limited design and cost option
• Fixed Circuit Operations.
• PLCs manufacturers offer only closed architectures.
APPLICATION
• Robots manufacturing and control
• Car park control
• Train control station system
• Food processing
• Materials handling
• Machine tools
• Conveyer system

78
Fig.: PLC system in a rack, left-to-right: power supply unit (PSU), CPU,
interface module (IM) and communication processor (CP).

79
HUMAN MACHINE INTERFACE
A complete program may contain thousands of rungs, evaluated in sequence.
Typically, the PLC processor will alternately scan all its inputs and update outputs,
then evaluate the ladder logic; input changes during a program scan will not be
effective until the next I/O update. A complete program scan may take only a few
milliseconds, much faster than changes in the controlled process.

80
HMI functionality
Human Machine Interface (HMI)
Graphical object state presentation, lists, reports
Operator Command handling
change binary commands, set points
Alarm & Events
Record specified changes and operator actions
History data base
Keep a record of the process values and filter it
Logging
Keep logs on the operation of the automation system
Reporting
Generate incident reports

81
Fig.: HMI Block Diagram
Programmable controllers vary in their capabilities for a "rung" of a ladder diagram.
Some only allow a single output bit. There are typically limits to the number of series
contacts in line, and the number of branches that can be used. Each element of the
rung is evaluated sequentially. If elements change their state during evaluation of a
rung, hard-to-diagnose faults can be generated, although sometimes (as above) the
technique is useful. Some implementations forced evaluation from left-to-right as
displayed and did not allow reverse flow of a logic signal (in multi-branched rungs)
to affect the output.
A human–machine interface usually involves peripheral hardware for the INPUT and
for the OUTPUT. Often, there is an additional component implemented in software,
like e.g. a graphical user interface.
The user interface or human–machine interface is the part of the machine that
handles the human–machine interaction. Membrane switches, rubber keypads and

82
touch screens are examples of the physical part of the Human Machine Interface
which we can see and touch.
In complex systems, the human–machine interface is typically computerized. The
term human–computer interface refers to this kind of system. In the context of
computing, the term typically extends as well to the software dedicated to control
the physical elements used for human-computer interaction.
The engineering of the human–machine interfaces is enhanced by
considering ergonomics (human factors). The corresponding disciplines are human
factors engineering (HFE) and usability engineering (UE), which is part of systems
engineering.
Tools used for incorporating human factors in the interface design are developed
based on knowledge of computer science, such as computer graphics, operating
systems, programming languages. Nowadays, we use the expression graphical user
interface for human–machine interface on computers, as nearly all of them are now
using graphics.
HMI Functionality

83
Operator workplace: three main functions
What is an alarm, an event?
Alarm and Event (A&E) consider changes occurring in the plant (process) or in the
control system that are worth recording (operator actions, configuration changes,)
Recorded changes can be of three kinds:
➢ informative: no action required
➢ (e.g. "production terminated at 11:09")
➢ warning: plant could stop or be damaged if no corrective action is taken
"soon" (e.g. "toner low")
➢ blocking: the controller took action to protect the plant and further operation
is prevented until the reason is cleared (e.g. "paper jam")

84
What triggers an alarm?
➢ Binary changes of process variables (individual
bits), some variables being dedicated to alarms.
➢ Reception of an analog variable that exceeds
some threshold (upper limit, lower limit), the
limits being defined in the operator workstation.
Elements of the operator workstation
alarms
logging
plant
simulatio
mimic
instructor desk
process data
actualization
alarms
processing
state
logging
trend
processing
proces
data base

86
Fig.: HMI ON AC SERVO MOTOR

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SERVO DRIVE
Fig: REXROTH Control Drives
A servo drive is a special electronic amplifier used to power electric
servomechanisms. A servo drive monitors the feedback signal from the
servomechanism and continually adjusts for deviation from expected behavior.
A servo drive receives a command signal from a control system, amplifies the signal,
and transmits electric current to a servo motor in order to produce motion
proportional to the command signal. Typically, the command signal represents a
desired velocity, but can also represent a desired torque or position. A sensor

88
attached to the servo motor reports the motor's actual status back to the servo drive.
The servo drive then compares the actual motor status with the commanded motor
status. It then alters the voltage, frequency or pulse width to the motor so as to correct
for any deviation from the commanded status.[1]
In a properly configured control system, the servo motor rotates at a velocity that
very closely approximates the velocity signal being received by the servo drive from
the control system. Several parameters, such as stiffness (also known as proportional
gain), damping (also known as derivative gain), and feedback gain, can be adjusted
to achieve this desired performance. The process of adjusting these parameters is
called performance tuning.
Although many servo motors require a drive specific to that particular motor brand
or model, many drives are now available that are compatible with a wide variety of
motors.

89
SERVO MOTOR
A servomotor is a rotary actuator or linear actuator that allows for precise control
of angular or linear position, velocity and acceleration.[1]
It consists of a suitable
motor coupled to a sensor for position feedback. It also requires a relatively
sophisticated controller, often a dedicated module designed specifically for use with
servomotors.
Servomotors are not a specific class of motor although the term servomotor is often
used to refer to a motor suitable for use in a closed-loop control system.
Servomotors are used in applications such as robotics, CNC machinery or automated
manufacturing.

90
A servomotor is a closed-loop servomechanism that uses position feedback to
control its motion and final position. The input to its control is a signal (either
analogue or digital) representing the position commanded for the output shaft.
The motor is paired with some type of encoder to provide position and speed
feedback. In the simplest case, only the position is measured. The measured position
of the output is compared to the command position, the external input to the
controller. If the output position differs from that required, an error signal is
generated which then causes the motor to rotate in either direction, as needed to
bring the output shaft to the appropriate position. As the positions approach, the error
signal reduces to zero and the motor stops.
The very simplest servomotors use position-only sensing via a potentiometer and
bang-bang control of their motor; the motor always rotates at full speed (or is
stopped). This type of servomotor is not widely used in industrial motion control,
but it forms the basis of the simple and cheap servos used for radio-controlled
models.
More sophisticated servomotors use optical rotary encoders to measure the speed of
the output shaft[2]
and a variable-speed drive to control the motor speed.[3]
Both of
these enhancements, usually in combination with a PID control algorithm.

91
TOTALLY INTEGRATED AUTOMATION
(TIA) is a strategy (philosophies/architecture) in the automation technology, which
was developed since 1996 by Siemens Automation and Drives. This strategy defines
the interaction of extensive single components, tool (SW) and the services (spare
part service, etc.) to achieve an Automation solution. The interaction performs
integration across the four automation levels of the automation pyramid:
• Management level
• Operator’s level
• Controller’s level
• Field level
The consistency of TIA offers a simplification and cost savings to companies
involved in the value chain (OEM, System integration planner and end customer).

92
Sub definition: automation is composed of the essentials of the drives (frequency
converter + motor), a programmable logic control as well as a Panel to the
visualization.
S7-1500 simatic TIA portal
The S7-1500 is the latest generation PLC first announced in November 2012. It is
the eventual successor to the S7-300 and S7-400 PLC ranges, although these
products will remain current products until at least 2020. The S7-1500 provides the
following features and benefits;
• PROFINET port as standard
• Integrated Security
• Integrated Technology including Motion Control and PROFIdrive
• Integrated System Diagnostics
Simatic s7-1500 plusTIA portal
The SIMATIC® S7-1500 Advanced Controller sets new standards in system
performance and usability. The seamless integration of the SIMATIC S7-1500
controller into the Totally Integrated Automation Portal (TIA Portal) offers
advantages such as shared data management, a uniform operating concept and
centralized services. This makes the use of universal functions particularly easy. The
controller is quick and easy to install and connect, and with its quick system response
times, it boosts productivity at the wave of a hand. For you, this means more
flexibility in handling, shorter time-to-market, and a fast rate of return on your plant.

93
DETAILED STUDY OF FRAME FACTORY
1. Frame factory makes frame(chassis) for the truck from coils of metal.
2. Metal comes in the form of coils stacked in storage area.
3. A worker takes one coil roll through lift and places it in decoiling section.
4. Decoiling is done through two straightener machines.
5. One straightener is places at the inlet and the other one at the outlet.
6. Straighter machine use servo motors to decoil and straighten the metal in the
form of sheets.
7. These servo motors are powered by ceramic drives and also connected to an
encoder that is used to give feedback and also control the servo via S7400
CPU.
8. Laser is used to calculate the speed of moving metal sheet after straightening
from the first straighter, through this calculation the sheet is cut at a specific
length.
9. The cutting of the sheets is done through a method called shearing.
10.After shearing these sheets are moved on a conveyor belt.
11.Walmer scales are fixed to these conveyor belts to check the straightness of
the sheets.
12.Walmers scales send signals to the operator if the sheet is positive camber,
negative camber, or straight.
13.This data is used by the second straightener machine to correct the sheets.
14.This correction of sheet is known as edge wise correction.
15.Again, two walmer scales are used to check the upper, lower cartesian to
calculate mean cartesian and cross checked with the third scale.
16.Generally, the equation used is c=(a+b)/2.
17.The three scales are also known as gauges.
18.Cameras are used to check the scratches and other defects in the sheet, if any
defect is found then it is rejected.
19.All these steps are automatic and are monitored using a SCADA system.

94
20.DC electromagnets are used to pick up the metal sheets and put them aside.
21.Good quality sheets are stacked on one side, bad ones on the other.
22.All the above steps are done together at one place called Polar zone.
23.This zone can be divided in three domains.
24.Electronic- this has CPU, control card, drivers.
25.Electric- this has choke, transformer, relays, breaking resistors.
26.Mechanical-this has hydraulic cylinders, accumulator, pressure gauges.
27.All the above machines are controlled and monitored by SCADA monitoring
system.
28.After polar zone, sheets come in stacks to magnetic traverse.
29.Magnetic traverse has 10 magnets and moves the sheets in LIFO order to the
infeed conveyor and the sheet is pushed to the centre notching, bending or
forming is done.
30.Notching means making holes and cutting the plates.
31.After this the sheets are removed throughout feed side conveyor and quality.
check is done.
32.Dura vision software is used to check and count the numbers of holes in the
sheet.
33.It scans the sheet in segment to make a whole image, and holes in each
segment is checked.
34.RAMP system is used to give the frame its final shape. It has two die’s,
upper and lower die. Number of blocks make up one die.
35.Upper die is attached to the ramp and punching strokes are used to shape the
sheets.
36.The frames are fed to shot blasting machine which sprays silica to remove
the upper corroded layer.
37.After this the sheets are sent to LMCD (Long Member Cathode
Decomposition) for electrolytic painting and are fed to ovens to dry the
paints.
38.When they come out the sheets are sent to assembly area where frames for
chassis is made.

95
PROJECT : FLOWCHART OF SERVO EMC HEFT FIXTURE
PROCESS
1. At starting the long-frame member goes through the process of installation
of load detection & notification.
2. Firstly, the frame long member is paved to the heft fixture area by the lifting
tackles attached to hoist hook which helps in lifting heavy frame long
members.
3. After being placed at area of heft fixture area, the operators tighten the frame
member with screws as required.
4. In this we observe a CPU of model S7-1500 which is the latest among S7-
300, S7-400.
5. And then the real work starts, as one of the operator switches on the forward
button.
6. We observe REXROTH CONTROLLER CARD which provide Input
information to CPU.
7. There is one green colour card which takes DIDO.
8. The process starts from here, our main motive is to see the working of heft
fixture.
9. The frame is passed from the assembly line. The operator working on that
station used host took to carry these long frame members and pass into heft
fixture plane.
10.In this plane, it is divided into 8 servo drive panel.
11.As the long frame member is laid on that plane. One of the operators pushes
the forward button on the EBI switch. When the button is pushed, the servo
drive connects to the long frame member. With this connection. The
CYCLE POSITION FORCE POSITION VELOCITY is being viewed at
the HMI SCREEN.
12.With the company demand using the servo drive, respective long frame is
being shaped into its following cycle position.

96
13.After this HEFT FIXTURE PROCESS. The frame member is passed into
another substation using PNEUMATIC SENSOR.
Fig.: Diagram of frame long member of TATA Trucks

98
Fig.: Overall Working Diagram

101
MY INTERNSHIP EXPERIENCE
The Tata Motors is considerably huge, very appealing, and colorful all around with
the display of various cars, trucks and newly launched TATA cars and other
commercial vehicles.
Duration in weeks. No. of days/week. Timings
• 9 weeks and 2 days 9 AM – 4 AM
Accommodation: how, where, how was it?
This being situated in Jamshedpur there is enough P.G available 5 kms away
from the industry. I preferred staying at my own house.
First impression, First day, formalities etc.
Right from the first day, there were absolutely no formalities. Not much introduction
been done. The work was briefed to me and straight away intern would start with
the work.
The intern at the Tata Motors Legal Department is expected to have rapport with
everyone in the office on your own and team up with various other departments in

102
the office including the passenger vehicle division and commercial vehicle division,
because the legal department requires the data from them.
The intern would be introduced to the H.R Department with whom the work has to
be coordinate with regard to the project given to us.
Main tasks
The interns at Tata Motors are considered to be same as that of every other employee.
But as of the work is concerned it is seen that there is not much pressure.
In the legal department, the intern is expected to be aware of the various legal
aspects. Anyone who works with the legal team is not expected to be fully
conversant with the provisions of the Consumer Protection Act, but at least the
least minimum knowledge is expected.
The Nature of work in legal department was to maintain various files and check on
the progress of cases from the southern region as this office being the regional office
for southern region. There are various procedures followed in maintenance of files,
and periodic summary reports are to be sent to the head office at Mumbai.
The various other tasks were entering data in the excel sheet maintained by the Legal
Department and various columns are to be prepared. There are systematic methods
being adopted, which the interns are strictly expected to adhere to.

103
The TATA Motors have many ware houses situated in various distinct places and
there are so many employees working at ware house and this very own office and
Legal Department are so keen in adhering to various Labor related laws.
So, the interns would be given tasks of researching on various Labor laws and Acts
such as Sexual Harassment prohibition in Work place, and other new Acts so that
the company would not be at default in any way. There would be constant discussion
taking place one on one with H.R. Department as to various Laws and its better
implementation is concerned.
Intern’s progress is constantly checked at Tata Motors and their opinions and
suggestions and academic knowledge would be checked there during various daily
discussions. Finally, the interns are asked to make a presentation on certain Labor
related issues or on any Acts.
Work environment, people:
The environment is generally relaxed and has a steady pace throughout the day
though the other departments are too busy, as of Legal Department is concerned,
they are pretty relaxed.
The colleagues are very friendly and they patch up with interns very easily in some
way or other. The work environment is totally chilled as the interns are treated one
among them.

104
There happens lot of friendly chit chat happening and the interns can get every
possible assistance from the senior and other members any time and they are ready
to help any time.
People stay for long hours at and ready to compromise even after office hours if any
assistance is required. There is no compromise been done as to the quality of
customer service, for which TATA Motors is known for.
There are so many opportunities for refreshments as the Industry is located in such
a prime place Jamshedpur City. Lunch, food, coffee, awesome variety refreshments
served.
Best things?
I was treated so well during the stay. There is lots of encouragement been done.
There is constant concern towards the interns as to their work load is concerned and
least pressure is given. There is no way skipping of lunch or any refreshments. The
intern would be forced to take up refreshments and food on time. There are no strict
rules as to the working hours are concerned for the intern.
There is good amount of bonding been created as there would be constant hang
outs and interactions takes place and lot of suggestions been given.
Bad things
All is good. Nothing was bad Tata Motors, Jamshedpur from the point of view of an
intern.

105
Stipend month
There was no stipend given to me, but wait you are not been sent home empty
handed either. There is a hell lot of gifts given to interns, which again depends on
your presentation. Once you crack your presentation, you can take home gifts for
sure from TATA Motors
.
Biggest lessons:
As a student I would have felt good studying various Industrial machines and there
might be times where I have felt proud about various new responsibilities and Laws.
But when you get to experience the actual working of the corporate field you field
it is totally different.
Academics have nothing to do with their functioning. Interns might get disheartened
as well when various compliances are not been followed at all what we see in books.
But what is expected of you to just gain experience from this very corporate office
where you are interning during your stay and take back home hell lot of memories,
whether they are bitter truth or money in the money in the bank.
Don’t lose hope if you don’t receive any stipend for your hard work, at the end of
the day it is the experience and lessons and memories for your record is what it all
matters.
I would rate the experience 9.0/10.

106
IMPROVEMENT DURING CO-OP TRAINING
• Interpersonal
• Communication
• Collaboration
• Time management
• Adaptability
• Critical Thinking
• Initiative
• Receptiveness
• Technical Proficiency
• Research analysis
LEARNING DURING CO-OP TRAINING
As I go into the "real world" having this internship experience was good for me to
start out as a professional.
I learned responsibilities of working: being on time, dressing professionally,
working hard, and having supervisors etc. is all part of having a job. I am very
aware that I will be starting out at the bottom of any company that I work for only
to work myself up. I know that I am starting all over and I am looking forward to
that. Having an internship only gives me more of a competitive edge because I got
experience from that.
Open communication was one of the strongest and most apparent skills that I learned
during my internship. When I first started interning, I was intimidated and nervous
to ask too many questions because I didn’t want to admit that I didn’t understand or

107
that I needed extra help with something. Luckily, I got over that fear quickly because
asking questions is the only way to learn what you are really supposed to be doing.
I found that my boss and fellow staff members appreciated it more if I asked too
many questions to make sure I really understood what it was doing and that I did it
correctly. If I had not worked with such cooperative and helpful people, I probably
would have been too intimidated to ask questions in my next job. Now that I know
it is not bad to ask questions, I won’t have to struggle with it in my future job.
Without open communication between everyone in an office, I don’t see how any
work can be done."
• I learned that customer service is hard. You cannot please everyone. There
are people in this world that are simply difficult.
• I have learned that stressing over little things will not get me anywhere.
• I have learned to work well as a team and that without my counterparts the
work would not get done.
• Another aspect that I learned throughout my internship is to never be afraid
to ask lots of questions. By asking questions I got answers.
• The internship taught me exactly all of the required skills and tasks needed
to have a career in my field.
• Understand of PLC and all aspects of inputs & outputs system.
• Understand of HMI and its interaction with PLC.
• Evaluate, analysed and designed a flow chart of Servo Heft Fixture.
• As an intern, I learned to collaborate with other interns and company
employees. This ability to communicate and relate well to others is certainly
important for collaboration, as is the capacity to work with others toward a
common goal. As a part of team, I have understood my own strengths and

108
weaknesses so I know I can best contribute, as well as be aware of how i can
bring out the best in others.
• This experience finally opened my eyes to the real world. I will be the first
to admit that I am not the most responsible person, but I have come to
realize that responsibility sets a good employee apart from an excellent
employee. I am in this internship because of my lack of willingness to get up
and get an internship earlier in the school year, but everything happens for a
reason."
• "As a whole I believe that this internship was successful in furthering my
knowledge of a career in the field of marketing. While being immersed in a
company 40 hours a week for two and half months, I saw the pressure of
deadlines, importance of appearance, the value of being a self-motivator and
the joy of loving your job.
LIMITATION
In undertaking this study, a number of problems were faced. Thus, the study has
several limitations. The limitations are:
a) Lack of knowledge:
As a student, in the research field, I have no past practical experience of PLC, HMI,
data processing, data analyzing, integrating and presenting. So, it is a limiting factor
for obtain accurate information.
b) Lack of time -For the time limitation I could not gather more information to
justify exact condition. The time constraints are limiting factors.
e) Employee willingness

109
Most of the employee of the industries were engage at their work. So, they could not
give me enough time to fill up questionnaire. Also, they are not willing or afraid to
provide appropriate data.
ABBREVIATIONS USED
• VIN – Vehicle Identification Number
• CNG – Compressed Natural Gas
• HLA – Head Lamp Aimer
• FIP – Fuel Injector Pump
• PLC – Programmable Logic Controller
• R/B test – Roll and Brake Test
• ABS – Anti Locking Brake System
• CMVR – Common Motor Vehicle Rules
• FA – Front Axle
• R/T Axle – Rear/Tandem Axle
• HCBS – High Capacity Buses Service
• TMML – Tata MARCOPOLO Motors Ltd.
• BIW - Body in White
• TML – TATA MOTORS LTD.

110
REFERENCES
The following is the reference list for any further information:
• http://www.insulatorsindia.com/
• http://www.hindusthanurban.com/
• http://www.amci.com/tutorials/tutorials-what-is-programmable-
logiccontroller.asp
• https://en.wikipedia.org/wiki/Programmable_logic_controller
• http://www.allaboutcircuits.com/textbook/digital/chpt-6/programmable-
logiccontrollers-plc/
• http://www.plcdev.com/how_plcs_work

111
CONCLUSION
In this project, we have seen all the operation of frame factory and the operation of
station number 7 seeing the procedure of HEFT Fixture. We learned how to use
TIA Portal software and saw how to program in ladder programming. We have
seen different components and their usage. Overall view of the program and
different sections were used, such as tags etc. It was big experience in creation of
the projects using PLC.

TATA MOTORS, JAMSHEDPUR.

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