tata-proj

Submitted by- SWAPNIL SRIVASTAVA
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PROJECT REPORT ON
PRODUCTION ENGINEERING
DEPARTMENT
TATA MOTORS LTD, LUCKNOW
SUBMITTED BY:-
SWAPNIL SRIVASTAVA
B.Tech (ME) 2012-2016
Raj Kumar Goel Institute of Technology (UPTU), Ghaziabad
UNDER THE GUIDENCE OF:
Mr. MAYUR GANDHI
(-TCF Logistics Centre)
TATA MOTORS LTD. LUCKNOW

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DECLARATION
This is to certify that this project report on “Production Engineering
Department” is the bona-fide work of Swapnil Srivastava student of
B.Tech Mechanical Engineering Department, Raj Kumar Goel
Institute of Technology (UPTU) Ghaziabad who carried out his project
under my supervision in Tata Motors Lucknow.
His performance was commendable throughout the training period. The
project assigned to him was completed within the specific period, i.e.
from 23rd
June 2015 to 23rd
July 2015.
We wish him success in the future and believe that this training will help
him in his goals ahead.
This is to be certified that the above statement made by the student is correct to
the best of our knowledge and belief.
Mr. Irfan Habib
-Manager SCM
TATA MOTORS LTD.LUCKNOW
Mr. Mayur Gandhi Mr. Prashant Pandey
-Manager Logistics Centre Talent Acquisition - HR
TATA MOTORS LTD. LUCKNOW TATA MOTORS LTD. LUCKNOW

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ACKNOWLEDGEMENT
I would like to pay my gratitude to all those who guided and have been with me
throughout my training tenure without whom I could not have completed this
project.
I am very thankful to my project guide Mr. Mayur Gandhi for guiding throughout
this duration and Mr. Irfan Habib for sharing his knowledge with me. Also a
special thanks toMr. Vibhu Satyamfrom TATA Prolife for being coordinative to
all aspects of my tenure at TATA MOTORS.
I would also thank all the operators working in the TATA plant and my training
colleagues with whom I developed a special bond.
Also my sincere thanks to Mr. Prashant Pandey and all the staff members of
TATA MOTORS for providing me the oppurtunity to add a new dimension in my
knowledge by being trained in this esteemed organization.
SWAPNIL SRIVASTAVA

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ABSTRACT
The title of my project is “Production Engineering Department”. This is
basically a case study on the PE Department of TATA motors which is an
important part of any industry. Not only in TATA Motors but in any industry either
manufacturing or assemby all for the seamless working require the PE
Department which createsall the fixures and templates for any department or
even any other plant. Production engineering is a combination of manufacturing
technology with management science. A production engineer typically has a wide
knowledge of engineering practices and is aware of the management challenges
related to production. The goal is to accomplish the production process in the
smoothest, most-judicious and most-economic way.
In industry, once the design is realized, production engineering concepts
regarding work-study, ergonomics, operation research, manufacturing
management, materials management, production planning, etc., play important
roles in efficient production processes. These deal with integrated design and
efficient planning of the entire manufacturing system, which is becoming
increasingly complex with the emergence of sophisticated production methods
and control systems.
This department is not only needed but in actual without this the functioning of
any plant would become a lot difficult. This is very necessary and useful.

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Industry Profile – TATA Motors
Brief Profile
TATA MOTORS LTD.
Type Public
Industry Automotive
Founded 1945 by J. R. D. Tata
Headquarters Mumbai, Maharashtra, India
Area served Worldwide
Key people
Cyrus Pallonji Mistry (Chairman)
Ravi Kant (Vice Chairman)
Karl Slym (Managing Director)
Revenue US$ 32.67 billion (2012)
Employees 59,759 (2012)
Subsidiaries Jaguar Land Rover, Tata Daewoo, Tata Hispano
Website www.tatamotors.com
History
TATA Motors Limited is India's largest automobile company, with consolidated revenues of
₹1,65,654 crores ($32.5 billion) in 2011-12. It is the leader in commercial vehicles in each
segment, and among the top in passenger vehicles with winning products in the compact,
midsize car and utility vehicle segments. It is also the world's fourth largest truck and bus
manufacturer. The TATA Motors Group's over 55,000 employees are guided by the mission "to
be passionate in anticipating and providing the best vehicles and experiences that excite our
customers globally." Established in 1945, TATA Motors' presence cuts across the length and
breadth of India. Over 7.5 million Tata vehicles ply on Indian roads, since the first rolled out in
1954. The company's manufacturing base in India is spread across Jamshedpur (Jharkhand),
Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and
Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set up an industrial
joint venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce both Fiat

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and Tata cars and Fiat powertrains. The company's dealership, sales, services and spare parts
network comprises over 3,500 touch points.
TATA Motors, also listed in the New York Stock Exchange (September 2004), has emerged as
an international automobile company. Through subsidiaries and associate companies, TATA
Motors has operations in the UK, South Korea, Thailand, Spain, South Africa and Indonesia.
Among them is Jaguar Land Rover, 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. In 2006, TATA Motors formed a 51:49 joint venture with the Brazil-
based, Marco polo, a global leader in body-building for buses and coaches to manufacture fully-
built buses and coaches for India - their plants are located in Dharwad and Lucknow. In 2006,
TATA Motors entered into joint venture with Thonburi Automotive Assembly Plant Company of
Thailand to manufacture and market the company's pickup vehicles in Thailand, and entered
the market in 2008. TATA Motors (SA) (Proprietary) Ltd., TATA Motors' joint venture with Tata
Africa Holding (Pty) Ltd. set up in 2011, has an assembly plant in Rosslyn, north of Pretoria.
The plant can assemble semi knocked down (SKD) kits, light, medium and heavy commercial
vehicles ranging from 4 tonnes to 50 tonnes.
TATA Motors is also expanding its international footprint, established through exports since
1961. The company's commercial and passenger vehicles are already being marketed in
several countries in Europe, Africa, the Middle East, South East Asia, South Asia, South
America, CIS and Russia. It has franchisee/joint venture assembly operations in Bangladesh,
Ukraine, and Senegal. The foundation of the company's growth over the last 66 years is a deep
understanding of economic stimuli and customer needs, and the ability to translate them into
customer-desired offerings through leading edge R&D. With over 4,500 engineers, scientists
and technicians the company's Engineering Research Centre, established in 1966, has enabled
pioneering technologies and products. The company today has R&D centres in Pune,
Jamshedpur, Lucknow, Dharwad in India, and in South Korea, Spain, and the UK.

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It was TATA Motors, which launched the first indigenously developed Light Commercial Vehicle
in 1986. In 2005, TATA Motors created a new segment by launching the Tata Ace, India's first
indigenously developed mini-truck. In 2009, the company launched its globally benchmarked
Prima range of trucks and in 2012 the Ultra range of international standard light commercial
vehicles. In their power, speed, carrying capacity, operating economy and trims, they will
introduce new benchmarks in India and match the best in the world in performance at a lower
life-cycle cost.
TATA Motors also introduced India's first Sports Utility Vehicle in 1991 and, in 1998, the Tata
Indica, India's first fully indigenous passenger car.
In January 2008, TATA Motors unveiled its People's Car, the Tata Nano. The Tata Nano has
been subsequently launched, as planned, in India in March 2009, and subsequently in 2011 in
Nepal and Sri Lanka. A development, which signifies a first for the global automobile industry,
the Nano brings the joy of a car within the reach of thousands of families.
The TATA Motors Culture
TATA Motors is equally focussed on environment-friendly technologies in emissions and
alternative fuels. It has developed electric and hybrid vehicles both for personal and public
transportation. It has also been implementing several environment-friendly technologies in
manufacturing processes, significantly enhancing resource conservation.
Through its subsidiaries, the company is engaged in engineering and automotive solutions,
automotive vehicle components manufacturing and supply chain activities, vehicle financing,
and machine tools and factory automation solutions.
TATA Motors is committed to improving the quality of life of communities by working on four
thrust areas - employability, education, health and environment. The activities touch the lives of
more than a million citizens. The company's support on education and employability is focused
on youth and women. They range from schools to technical education institutes to actual
facilitation of income generation. In health, the company's intervention is in both preventive and
curative health care. The goal of environment protection is achieved through tree plantation,
conserving water and creating new water bodies and, last but not the least, by introducing
appropriate technologies in vehicles and operations for constantly enhancing environment care.
With the foundation of its rich heritage, TATA Motors today is etching a refulgent future.

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Subsidiaries and Joint-
Ventures
Tata Daewoo
In 2004, TATA Motors acquired Daewoo
Commercial Vehicle Company of South Korea.
The reasons behind the acquisition were:
1. Company's global plans to reduce domestic
exposure. The domestic commercial vehicle
market is highly cyclical in nature and prone
to fluctuations in the domestic economy. TATA Motors has a high domestic exposure of
~94% in the MHCV segment and ~84% in the light commercial vehicle (LCV) segment.
Since the domestic commercial vehicle sales of the company are at the mercy of the
structural economic factors, it is increasingly looking at the international markets. The
company plans to diversify into various markets across the world in both MHCV as well as
LCV segments.
2. To expand the product portfolio TATA Motors recently introduced the 25MT GVW Tata
Novus from Daewoo‟s (South Korea) (TDCV) platform. Tata plans to leverage on the strong
presence of TDCV in the heavy-tonnage range and introduce products in India at an
appropriate time. This was mainly to cater to the international market and also to cater to
the domestic market where a major improvement in the Road infrastructure was done
through the National Highway Development Project.
Tata Daewoo is the second-largest heavy commercial vehicle manufacturer in South Korea.
TATA Motors has jointly worked with Tata Daewoo to develop trucks such as Novus and World
Truck and buses including Globus and StarBus
Tata Hispano
Tata Hispano Motors Carrocera, S.A. is a bus and coach cabin manufacturer based in
Zaragoza, Aragon, Spain and a wholly owned
subsidiary of TATA Motors. Tata Hispano has
plants in Zaragoza, Spain and Casablanca,
Morocco. TATA Motors first acquired a 21% stake
in Hispano Carrocera SA in 2005, and acquired the
remaining 79% for an undisclosed sum in 2009,
making it a fully owned subsidiary, subsequently
renamed Tata Hispano.

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Jaguar Land Rover
Jaguar Land Rover PLC is a British premium automaker headquartered in Whitley, Coventry,
United Kingdom and has been a wholly owned subsidiary of TATA Motors since June 2008,
when it was acquired from Ford
Motor Company. Its principal activity
is the development, manufacture
and sale of Jaguar luxury and sports
cars and Land Rover premium four
wheel drive vehicles. It also owns
the currently
dormant Daimler, Lanchester and Rover brands.
Jaguar Land Rover has two design centres and three assembly plants in the UK. Under Tata
ownership, Jaguar Land Rover has launched new vehicles including the Range Rover Evoque,
Jaguar F-Type and the fourth-generation Range Rover.
Tata Marcopolo
Tata Marcopolo is a bus manufacturing joint
venture between TATA Motors (51%) and
the Brazil-based Marcopolo S.A. (49%). The
joint venture manufactures and assembles
fully built buses and coaches targeted at
developing mass rapid transportation
systems. It utilises technology and expertise
in chassis and aggregates from TATA
Motors, and know-how in processes and
systems for bodybuilding and bus body design
from Marcopolo. Tata Marcopolo has launched a low-floor city bus which is widely used by
Chennai, Coimbatore, Delhi, Hyderabad, Mumbai, Lucknow, Pune, Kochi, Trivandrum and
Bengaluru transport corporations. Its manufacturing facility is based in Dharwad and Lucknow.
Fiat India Automobiles
TATA Motors also formed a joint venture with Fiat and gained access to Fiat‟s diesel
engine technology. TATA Motors sells Fiat cars in India through a 50/50 joint venture Fiat
Automobiles India Limited, and is looking to extend its relationship with Fiat and Iveco to other
segments.

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Business overview
TATA Motors has diversified in to a range of activities all related to the automobile industry.
Through its subsidiaries, the company is involved in engineering and automotive products,
construction equipment manufacturing, automotive vehicle components manufacturing and
supply chain activities, machine tools and factory automation products, high-precision tooling,
electronic components for automotive and computer applications, and automotive retailing and
service operations. The company's manufacturing base is spread across India. In the east they
are based in Jamshedpur (Jharkhand). Pune (Maharashtra) is their main centre for the west. In
the north, they are present in Lucknow (Uttar Pradesh) and Pantnagar (Uttarakhand). A new
plant to manufacture Nano which was being constructed in West Bengal has been moved
Sanand in Gujarat.
TATA Motors focuses on Research and Development and has over 2,500 engineers and
scientists working for the company‟s Engineering Research Centre. The company has R&D
centres in Pune, Jamshedpur, Lucknow, in India, and in South Korea, Spain, and the UK. It has
developed the first commercially viable prototype of air power car. On 25th July 2008, it also
announced to launch the electric version of Nano in Europe by Dec 2009. The company‟s
dealership, sales, services and spare parts network comprises over 3500 touch points; TTM
also distributes and markets Fiat branded cars in India.
TATA Motors operates in four main automobile segments which cover the range of products in
the automobile segments in India.
Passenger Cars: This segment accounts
for 30.5% of the total production volume
During FY2008, 182,292 units of gasoline and
diesel engine versions were manufactured and
sold. This division also distributes Fiat branded
cars in India. TATA Motors has a presence in
the compact car, mid-sized car and station
wagon segment of the market in the form of
Indica, Indigo and Indigo Marina and their variants. In FY2008, the passenger car industry grew
by 11.9% in India, but the TATA Motors sales in this segment declined by 7.3% due to no new
product launches. The market share of TATA Motors in this segment declined from 15.6% to
13.3%. All the passenger cars are manufactured at plants at Pimpri and Chinchwad district in
Maharashtra. TATA Motors has launched "Nano", an affordable family car with a price tag of
₹1,10,000 for the developing world. The project was delayed as the public opposition and
political problems forced the management to abandon the plant site at Singur, West Bengal and
shift it to Sanand, Gujarat.

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Utility Vehicles: TATA Motors entered the utility vehicle with the launch of Tata Sumo in
1994. Later it also entered SUV segment with the launch of Tata Safari in 1998. This segment
accounts for 8.4% of the total production volume. The sales in this segment were 47,530 units,
a decline 0.8% as compared to 47,892 units in FY2007. The overall market share in this
category is 20.1%. TATA Motors lost 2% of the market share due to lack of any new, product or
a variant of the existing product in this segment. All the utility vehicles are manufactured at
plants in Pimpri and Chinchwad district in Maharashtra.
Light Commercial Vehicles: TATA Motors manufactures light commercial vehicles
including pickup trucks, trucks and buses with gross vehicle weight of between 0.7 ton and 7.5
tons. This segment grew by 17.2% growth to 147,316 units sold in the Indian domestic market
in FY2008 and constituted 29.1% of the total
units sold. TATA Motors entered this
category by indigenously developing a low
priced product Ace (mini-truck) with a 0.7 ton
payload in fiscal 2006. In FY2008, TATA
Motors launched two other products, Magic a
passenger variant of Ace and Winger. It also
announced to introduce CNG variant of the
Ace, the Tata Cargo Panel Van, a lifestyle
pickup truck (Xenon XT) and an office concept vehicle at the Auto Expo 2008 in India. TATA
Motors has a market share of 64.2% in this segment. The light commercial vehicles are
manufactured at Pantnagar plant in Uttarakhand.
Medium and Heavy Commercial Vehicles: TATA Motors manufactures medium
and heavy commercial vehicles which include trucks, buses, dumpers and multi-axle vehicles
with GVW of between 9 tons to 49 tons. In addition, through Tata Daewoo Commercial Vehicle
Company Limited, or TDCV, a wholly-owned subsidiary in South Korea, TATA Motors
manufactures high horsepower trucks ranging from 220 horsepower to 400 horsepower,
including dump trucks, tractor-trailers, mixers and cargo vehicles. This segment constituted 32%
of the total volumes in FY2008. During the same period it declined by 4.2% to 165,619 units as
compared to FY2007. The decline was due to the lack of availability of vehicle finance from
outside sources and constraints in the components and aggregates supply chain. TTM has a
market share of 64.17% in this segment. In India, TATA Motors manufactures the Medium and
Heavy Commercial Vehicles in manufacturing plants at Jamshedpur, Jharkhand and Lucknow,
Uttar Pradesh.

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Global Challenges
TATA Motors has some distinct advantages in comparison to other multi-national competitors.
There is definite cost advantage as labour cost is 8-9% of sales as against 30-35% of sales in
developed economies. TATA Motors has extensive backward and forward linkages and it is
strongly interwoven with machine tools and metals sectors. Tata Group's strong expertise in the
IT based engineering solution for products and process integration has helped TATA Motors.
India has one of the world's largest auto component industry noted for its world class
capabilities. There is huge demand in domestic markets due to infrastructure developments and
TATA Motors is able to leverage its knowledge of Indian market. There are favourable
Government policies and regulations to boost the auto industry.
However, major multi-national automakers are moving their operations to India to cut costs.
Volvo, a manufacturer of trucks, buses, cars, construction equipment, and aero engines, had
entered in India in 1998. Its main focus is in the area of fully built buses. In India, it has focused
on providing economical transport solutions in consonance with its values of safety, quality, and
environmental care. Its competitive advantage is its high technology which makes the vehicle a
very comfortable option to travel through. Its trucks are reputed for their performance and
economy and are the flag bearers in their production activities in India. It is still operating in the
niche market of high end buses where the Tata compete through its Hispano Carrocera and
Marcopolo buses.
The Government of India last announced an automobile policy in December 1997. The policy
required majority-owned subsidiaries of foreign car firms to invest at least US$50 million in
equity if they wished to set up manufacturing projects in India. It also forced them to take on
export obligations to fund their auto part imports and required them to submit to a schedule for
increasing the share of locally made parts in their cars. Mere car assembling operations were
not welcomed.
An Indian cabinet panel will soon consider a new automobile policy that aims to set fresh
investment guidelines for foreign firms wishing to manufacture vehicles in the country.
Investments in making auto parts by a foreign vehicle maker will also be considered a part of
the minimum foreign investment made by it in an auto-making subsidiary in India. The move is
aimed at helping India emerge as a hub for global manufacturing and sourcing for auto parts.
The policy sets an export target of $1 billion by 2005 and US$2.7 billion by 2010. The policies
adopted by Government will increase competition in domestic market, motivate many foreign
commercial vehicle manufactures to set up shops in India, whom will make India as a
production hub and export to nearest market. Thus TATA Motors Commercial Vehicles will have
to face tough competition in near future, which might affect its growth negatively.

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Competition in Heavy Vehicles
Mahindra and Mahindra: M&M has formed a 51:49 joint venture called Mahindra
International with ITEC, USA (parent Navistar International), to manufacture commercial
vehicles and to bolster its position in the business. ITEC is the leader in medium and heavy
trucks and buses in North America, and is the world's largest manufacturer of medium-duty
diesel engines. Mahindra International aims to have a presence across the commercial vehicles
market (6-35 tonnes GVW) with variants of passenger transport, cargo and specialised load
applications and is likely to start producing medium/heavy commercial vehicles from FY09.
Force Motors: Force Motors has paired up with MAN in a 70:30 joint venture to
manufacture high-tonnage and specialty vehicles, such as long-haul trucks, tippers, tractor
trailers and multi-axle vehicles in the 16-32 tonne range at its Pithampur plant, with an initial
capacity of 24,000 units per annum and at an investment of ₹7 billion. The joint venture plans to
sell nearly half of its production in the domestic market, while the rest is to be exported to the
Middle East, Turkey, Russia, Asia and Africa. Further, the two companies have formed another
JV to manufacture buses in India from end-2007.
Ashok Leyland: Ashok Leyland recently acquired the truck unit of Czech Republic-based
Avia for US$35m. Avia manufactures 6-9 tonne LCVs and has a capacity of 20,000 units per
annum. The acquisition has given ALL direct access to an entire range of Avia trucks, Avia‟s
press shop with dies and tools, welding lines, state-of-the-art paint shop and R&D facilities.
Ashok Leyland has also entered into technology agreements with Hino Motors of Japan and ZF
of Germany to complement its in-house R&D efforts and developing complementary
components and aggregates.

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Competition in Passenger Cars
Maruti Suzuki India: Maruti Suzuki India Limited is a subsidiary of Suzuki Motor
Corporation. It was formerly known as Maruti Udyog Limited. The Group's principal activity is to
manufacture, purchase and sale of Motor Vehicles and Spare parts. The Group is a subsidiary
of Suzuki Motor Corporation. The other activities of the Group comprises of dealership network
of Pre-Owned Car Sales, Fleet Management and Car Financing. The Group also provides
services like framing of customized car policies, economical leasing of cars, maintenance
management, registration and insurance management, emergency assistance and accident
management. The product range includes ten basic models with more than 50 variants. The
Group has operations in over 1220 cities with more than 2628 outlets and also exports cars to
other countries. It also exports its products to Asia, Africa, and South and Latin America.
Hyundai Motor Company: Based in Seoul, South Korea, Hyundai Motor Company
manufactures and distributes motor vehicles and parts worldwide. It offers passenger cars,
recreational vehicles and commercial vehicles, including light commercial vehicles; medium and
heavy duty trucks; special vehicles, such as refrigerated van truck, dry van truck, wing body
truck, and trailer wing body/bottle carriers; medium and large size buses; and bare chassis.
Honda: Headquartered in Tokyo, Honda Motor Co., Ltd., together with its subsidiaries
develops, manufactures and distributes motorcycles, automobiles, and power products
worldwide. Its motorcycle business manufactures motorcycles, all-terrain vehicles, and personal
watercrafts. Honda‟s motorcycle line consists of sports, business, and commuter models. Its
automobile business offers passenger cars, multiwagons, minivans, sport utility vehicles and
mini cars. The company also offers various financial services to its customers and dealers. In
addition, it manufactures various power products, including power tillers, portable generators,
general-purpose engines, grass cutters, outboard engines, water pumps, snow throwers, power
carriers, power sprayers, lawn mowers, and lawn tractors. Honda sells its products through
various outlets, wholesalers, and independent retail dealers.
Toyota: Headquartered in Toyota City, Japan, Toyota Motor Corporation operates in the
automotive industry worldwide. It designs, manufactures, assembles, and distributes passenger
cars, recreational and sport-utility vehicles, minivans and trucks, and related parts and
accessories. It also offers hybrid vehicles. Its products also comprise conventional engine
vehicles, including subcompact and compact cars, mini-vehicles, passenger vehicles,
commercial vehicles, auto parts, mid-size models and luxury models. In addition, Toyota offers
sports and specialty vehicles, recreational and sport-utility vehicles, pickup trucks, minivans and
cab wagons, trucks and buses. Further, the company provides finance to dealers and their
customers for the purchase or lease of Toyota vehicles.

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TATA Motors Vehicle range
Conventional Full forward Semi forward
Conventional Control Chassis:
 All controls (Accelerator, clutch & brake) are behind the engine.
 Less noise and vibrations in cabin.
 More safety to the driver.
 Visibility is poor.
Full Forward Control Chassis:
 All controls mounted in front of engine.
 Better visibility.
 Getting more loading area.
 Safety of the driver is less.
Semi forward Control Chassis:
 All controls mounted by the side of engine.
 More safe for driver and passenger.

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Light commercial vehicles
 Tata 207 DI single cab:497 SP, diesel and direct injection engine, vacuum-assisted
hydraulic dual-circuit breaks with tandem master cylinder.
 Tata 207 DI crew cab:497 SP, diesel, direct-injection engine with vacuum-assisted
hydraulic dual-circuit breaks with tandem master cylinder.
 SFC 407 Ex turbo truck:497 SP turbo (India 2000) engine, vacuum-assisted hydraulic
dual-circuit breaks with tandem master cylinder.
 SFC 407 turbo truck:497 SP turbo engine with vacuum-assisted hydraulic dual-circuit
breaks with tandem master cylinder; available in cab load-body, cab chassis, truck cowl
and bus cowl versions.
Intermediate commercial vehicles
 LPT 1109 turbo truck: 497 turbo four-cylinder engine with dual-circuit full air S-Cam
brakes.
 LP 1109 turbo truck: 497 turbo four-cylinder engine with dual-circuit full air S-Cam
brakes.
Medium and heavy commercial vehicles
 LPT 1615 TC turbo heavy-duty truck: Cummins 6 BT
5.9 TC water-cooled, turbo-charged diesel engine with
6 inline cylinders, dual-circuit full air S-CAM service
brakes.
 SE 1613 TC turbo truck:Cummins 6 BT 5.9 TC water-
cooled, turbo-charged diesel engine. With 6 inline
cylinders and dual-circuit full air S-CAM service brakes.
 LPT 1613 TC turbo truck: Cummins 6 BT 5.9 TC water-cooled, turbo-charged diesel
engine with 6 inline cylinders and dual-circuit full air S-CAM service brakes.

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 LPT 2515 TC turbo truck: Cummins 6 BT 5.9 TC water-cooled, turbo-charged inter
cooled diesel engine with 6 inline cylinders and dual-circuit full air S-CAM service
brakes.
 LPT 2516 TC: With Cummins 6 BT AA 5.9 TC water-cooled, turbo-charged, inter-cooled
diesel engine with 6 inline cylinders and dual-circuit full air S-CAM service brakes.
Buses
 SFC 407 turbo mini- bus: 497 SP turbo water-cooled direct injection diesel engine with
vacuum-assisted dual circuit hydraulic with tandem master cylinder.
 LPO 1510 CGS bus (CNG bus): 6B 5.9 CNG NA engine with 6 inline cylinders, fully
duplicated full air S-CAM brake system.
 LP / LPO 1510 Bharat stage II bus: 697 NA engine with 6 inline cylinders, fully
duplicated full air S-CAM brake system.
 LPO 1616 TC inter luxury Bharat stage II bus:With Cummins 6 BT AA 5.9 TC water-
cooled, turbo-charged, inter-cooled diesel engine and 6 inline cylinders and dual-circuit
full air S-CAM service brakes.

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Defense vehicles
 Tata 407 (4x4) soft-top troop carrier: 4 SP turbo engines with vacuum-assisted
independent hydraulic brakes.
 Tata 407 / (4x2) hard-top troop carrier: 4 SP TC engine with vacuum-assisted
hydraulic dual circuit breaks and tandem master cylinder (exhaust brake optional).
 Tata SD 1015 TC (4x4): Cummins 6 BT engine with air over hydraulic breaks with
independent hydraulic circuit for front and rear.
 Tata LPTA 1621 TC (6x6): Cummins 6 BT engine with dual circuit full air S-CAM brakes
and provision for trailer brakes.
PLANT LOCATION

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TATA Motors - Lucknow Plant
Overview
TATA Motors Lucknow is one of the youngest production facilities among all the TATA Motors locations
and was established in 1992 to meet the demand for Commercial Vehicles in the Indian market. The
state-of-the-art plant is strongly backed by an Engineering Research Centre and Service set-up to
support with latest technology and cater to the complexities of automobile manufacturing. Fully Built
Vehicle business, which is one of the fast growing areas of business, is also established in Lucknow.
The plant rolls out commercial vehicles and is specialised in the designing and manufacturing of a range
of modern buses which includes Low-floor, Ultra Low-floor, CNG & RE Buses.
TATA Motors Lucknow is a third manufacturing unit of Tata Engineering and Locomotive Company. This
unit covers an area of 600 acres. In this unit the assembly of chassis and spare parts takes place. On 14th
January 1992 the recruitment of operators started in Lucknow plant. On 25th
June induction of Engineers
(first phase) started which also included ITI's and Occupancy of administration office of assembly shop in
September 1992. First vehicle rolled out from Lucknow plant on 20th
October 1992 which was LP 1210
52. Construction of MRS finished on 6th
January 1993. It took approximately 9 years since the
conception of the plan and to rollout the first vehicle from this latest manufacturing facility of TATA
Motors. Plant Head Mr. Rajnish Julka, currently heads this Unit.
The Lucknow facility also specializes in manufacturing HCBS (High capacity Bus System) buses. In light of
Company’s aggressive growth plans, the plant is currently in expansion phase and production at
Lucknow would grow manifold in near future.

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Currently, the following manufacturing and assembly units exist within the plant:
 Assembly Line 1
 ERC Proto Shop
 PE and Transmission shop
 Integral Bus Factory (IBF)
Assembly Line
The assembly lines in TATA Motors, Lucknow are slat conveyors with roller chains whose speed can be
varied between 0.1 to 2.2 m/min. The length of slat conveyor for MCV line is 76.2 mts. and can
accommodate a maximum of 24 vehicles. The Length of slat conveyor for LCV Line is 68.85 mts. and can
also accommodate a maximum of 24 vehicles.
The HCV/MCV/LCV assembly line is semi-automated and is divided into 3 sections:
 Frame Shop
 Trim/Cowl Line
 Main Assembly Line
Frame Shop
Long members from Jamshedpur plant are supplied by means of trailers and unloaded in the Frame
Shop. Then the long members are transferred to punching area by roller conveyor. In the punching area,
holes are punched by punching guns, using metal templates. Then long members are transferred to
preparation area by using roller conveyor. In the preparation area, reinforcements and spring brackets
are screwed or riveted, as required.
Then both LH and RH long members are
transferred to the Heft fixture using special
tackle, where they are assembled along with
the cross members. Pneumatic clamping force
is used to hold the assembly while tightening.
After clamping, further operations like
screwing and riveting are carried out. Then the
frame is transferred to a conveyor which has
six stations for further bolting and riveting.
Then the frame is inspected and corrected if any discrepancy is found, then transferred to the pre-
cleaning area where it is ground to remove any burr or sharp edges using Pneumatic Sander.
 Assembly Line 2
 Assembly Line 3
 Paint Shop
 Body-In-White (Welding Shop)

21
Then the frame is transferred to the paint booth where it is painted with Denitrol, followed by the
baking oven. The frame is baked for 15 min at 120o
C. After baking, it is transferred to the prepared
frame storage area. From here, frames are fed to the main chassis assembly line.
Trim/Cowl Line
Cowl is the front portion of the chassis which has driver seat, engine hood, steering wheel, head lights,
instrument cluster, indicators, Retarder ECU, accelerator, brake and clutch pedals and other electrical
connections. Bare cowls are received from Paint Shop in pallets. Their assembly is done here.
The Cowl Cx is divided into two areas:
Bare Cowl Rectification area: The cowls that are received have to be rectified before dropping them on
to the assembly lines. The following processes are done here:
Cowl line: The cowl line is in the form of an endless conveyor on
which fixtures called pilots are attached. The fixtures are of such a
type that they can accommodate all kinds of cowls and FES. The line
starts with the dropping of the cowl on the conveyor. Fitment of all
parts is then carried out on the structure. The line ends with the
inspection, testing and unloading of the cowl on the last station.
Main Assembly Line
The main assembly line consists of 19 stations, from frame dropping
to engine starting. Aggregates like front axle, rear axle, engine etc. are inwarded from Jamshedpur or
Pune; while the rest of the components are supplied by vendors. Some parts are supplied as it is,
whereas others have to sub assembled before fitment on the respective chassis. There is an aggregate
area along the chassis line where sub assembly of parts is done.

22
Productivity Service Department
Productivity: The rate at which a company produces goods or services in relation to the
amount of materials and number of employees needed. This is usually expressed in ratios of
inputs to outputs. That is (input) cost per (output) good/service. For calculation purpose,
expression of productivity is-
Productivity = Output/ Input
Output may be classified as: Input may be defined as:
Parts & product Money
Services Material
Brand/Image/Identity Machine
Satisfaction Man Hours
Victory/ success Methods
Wastage of any type Land
Pollutants of any type, etc
Roles and Responsibility of PSD:-
1. Measures and monitoring of productivity.
2. Work system design, assessment and resource requirement.
3. Custodianship for overall nos. For all types of personnel in the establishment (permanent,
temporary, trainees, job trainees, apprentices)
4. Measures and monitor productivity of plant, cascading of targets and facilitate achievements
of targets.
5. Based on strategy and organization structure define organizational process, systems, work
flow for attaining of plant‟s objectives.
6. Based on the above, defined work content and role of each position.
7. Study area wise resource requirement in line with productivity targets and work assessment.

23
Eastern complex
Tata Motors Ltd. Lucknow has total plant area of 600 acres of which 280 acres are covered in the
western part called Western Block which has a present production capacity of 120 vehicles per day and
now they have planned to increase its daily production capacity to 520 vehicles by extension which is
already going in the form of eastern complex on the other side of ‘Dewa’ road covering the remaining
320 acres. The production capacity of this new assembly plant will expected to be 320 vehicles per day.
The eastern complex would have longest conveyor line of India i.e. 375meters.This eastern complex will
have two conveyers formed by the combination of single chain conveyor and double chain slat
conveyor. These conveyors are named as ‘Line-2’ and ‘Line-3’ (Line-1 is the name given to the conveyor
at western complex). There is also a provision of a future expansion in form of ‘Line-4’ and ‘Line-5’ and
two more trim lines to cater their cowl/cab needs.Line-2’ and‘Line-3’ will be composed of 30 stations of
12.5 meters each in comparison to the 19 stations in the existing line. The complete assembling activity
for the vehicle chassis will be done in these 30 stations. The assembly of cowl/cab will be catered by the
two trim lines, which will be composed of 34 and 40stations respectively. Apart from this, it would also
have the biggest paint shop, which will be dedicated for the painting of cowls and cabs along with the
BIW (Body in White) shop. Presently the cowls are being received from the Jamshedpur which carries a
lot of extra transportation charges will now be seized with the start of Eastern Complex. Moreover in
the Eastern Complex there are many other changes made for the efficient working on the line. Firstly
the line will accommodate the assembling of chassis of various types of MCV`s and HCV`s up to the
upcoming model WORLD TRUCK of TATA. All the equipments and tools etc. will operate over-head so as
to make the more floor surface available and reducing hindrance on the shop floor. Platforms for
accommodating different types of over-head equipments and machines are hanged to the top with
various beams and hangers. Also the aggregates which are the heavy parts required during the chassis
assembly (Engine, Axles, and Cab etc.) will now be moved from storage to the fitment station through
EMS (Electric Monorail System) which will freeze the movement of fork-lifters on the shop floor.
Moreover the docking stations are built aside the wall to dock the material from outside in front of the
station in which that part will go to the assembly line directly. Above all the main thing is that the flow
of work is made in efficient & systematic way to enhance the productivity with the increased safety.

24
DifferentmodelsofCVassembledinLucknowplantare:
1.207 DI-MOBILE
2. SFC 407 (Semi Forward Control) CLB/COWL
3. SFC 407 F/L (27 & 31 WB)
4. SFC 709
5. LP 709 (Laden Passenger)
6. LPT 709 (Laden Passenger Truck)
7. LP/LPT 407
8. LP 407(TT)(Twin Tires)
9. LP 407 CNG
10. LPO1512 TC (Laden Passenger Overhung- Tata Cummins Engg.)
11. LPT 1613 TC
12. LPT 1613 CMVR (CMVR Engines)
13. LPO 1520 CNG
14. LPT 2515 TC Ex
15. LPT 3118 TC BS II
16. RE 1615 SLF (Semi Lower Floor)
17. LPO 1510 CNG
18. LP 1510 TC/CMVR
19. LPO 1510CMVR
20. SE 1613 CMVR
21. LPO 1616(EURO 1, EURO 2 & PNEU. SUSP.)
22. LPO 1651 ULF (HCBS)
23. LPO 1623 ULF (HCBS)

25
What Is Production Engineering?
Production engineering develops processes for turning raw materials into a finished
item. Read on to learn more about this field and the responsibilities associated with it.
Schools offering Industrial Engineering degrees can also be found in these popular
choices. Production engineering is a combination of manufacturing technology with
management science. A production engineer typically has a wide knowledge of
engineering practices and is aware of the management challenges related to
production. The goal is to accomplish the production process in the smoothest, most-
judicious and most-economic way. Production engineering encompasses the application
of castings,machining processing, joining processes, metal cutting & tool design,
metrology, machine tools, machining systems, automation, jigs and fixtures, and die and
mould design and material science and design of automobile parts and machine
designing and manufacturing. Production engineering also overlaps substantially with
manufacturing engineering and industrial engineering.
In industry, once the design is realized, production engineering concepts regarding
work-study, ergonomics, operation research, manufacturing management, materials
management, production planning, etc., play important roles in efficient production
processes. These deal with integrated design and efficient planning of the entire
manufacturing system, which is becoming increasingly complex with the emergence of
sophisticated production methods and control systems.
OVERVIEW
Production engineering refers to the intricate design and careful planning that goes into
creating a product. Such a process can be quite broad, incorporating everything from
the initial use of raw materials to the final products made available to consumers as
large-scale durable goods.

26
Production Engineering Division (PE)- TATA
Production Engineering Division (PE), a captive division of Tata Motors,
started operations in 1965. Located at Tata Motors' Pune plant, by far this
is the largest tool room in India spread across 30,000 m2 area with a
modern and highly-equipped set up along with experienced engineers and
specialists to manufacture sheet
metal and foundry tools at all levels of
complexity. PE's commercial
operations started in 2001-2002 and
since then have done tooling works
for several OEM and Tier 1
companies in India and Europe.
With knowledge of vehicle level
fitments and engineering in tool
making, which is an added benefit to
its customers, PE division is aiming to
reduce project risks and efficiently
manage timelines. PE plays a very important role in BIW tooling of Tata
Motors Limited through its New Product Development process. PE's
product portfolio comprises Stamping Dies (Press Tools), Sheet-Metal
Fixtures, Inspection Fixtures and Gauges, Foundry Tooling and
Thermoforming Moulds.

27
Vision, Mission & Core Values

28
Z&B SURFACE GRINDER-
CNC 84 Horizontal Surface Grinder
Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely used
abrasive machining process in which a spinning wheel covered in rough particles
(grinding wheel) cuts chips of metallic or non-metallic substance from a workpiece,
making a face of it flat or smooth. Surface grinding is the most common of the grinding
operations. It is a finishing process that uses a rotating abrasive wheel to smooth the
flat surface of metallic or non-metallic materials to give them a more refined look or to
attain a desired surface for a functional purpose. The surface grinder is composed of an
abrasive wheel, a work holding device known as a chuck, and a reciprocating or rotary
table. The chuck holds the material in place while it is being worked on. It can do this
one of two ways: ferromagnetic pieces are held in place by a magnetic chuck, while
non-ferromagnetic and non-metallic pieces are held in place by vacuum or mechanical
means. A machine vise (made from ferromagnetic steel or cast iron) placed on the
magnetic chuck can be used to hold non-ferromagnetic work pieces if only a magnetic
chuck is available.

29
Factors to consider in surface grinding are the material of the grinding wheel and the
material of the piece being worked on. Typical workpiece materials include cast iron
and mild steel. These two materials don't tend to clog the grinding wheel while being
processed. Other materials are aluminium, stainless steel, brass and some plastics.
When grinding at high temperatures, the material tends to become weakened and is
more inclined to corrode. This can also result in a loss of magnetism in materials where
this is applicable. The grinding wheel is not limited to a cylindrical shape and can have
a myriad of options that are useful in transferring different geometries to the object
being worked on. Straight wheels can be dressed by the operator to produce custom
geometries. When surface grinding an object, one must keep in mind that the shape of
the wheel will be transferred to the material of the object like a reverse image. Spark
out is a term used when precision values are sought and literally means "until the
sparks are out (no more)". It involves passing the workpiece under the wheel, without
resetting the depth of cut, more than once and generally multiple times. This ensures
that any inconsistencies in the machine or workpiece are eliminated.
DESCRIPTION
 Maximum grinding length 800 mm
 Maximum grinding width 400 mm
 Electromagnetic table 600 x 400 mm
 Control CNC Siemens Simatic Op 26

30
TECHNICAL SPECIFICATIONS
 Based on the proven design principles of the Grinder series A this machine offers
a large variety of functions due to the NC-Superplus-D control and covers many
more applications
 Grinding area 500 x 250 mm or 800 x 400 mm
 Spindle drive 7.5/11/13/22 kW
 Distance table to spindle centreline:
 600 bmm to 700 mm
 Above all the STARLINE series E guarantees for productivity, simple operation
philosophy, high righty of the entire systems and provides excellent value for
money
 This machine features a half enclosure with sliding door
 The NC-Superplus-D control widens the machining applications as compared to
the Grinder series A as follows a „variety of different dressing programs with
compensation, possibilities for calibration (straight side dressing),backing-off
(angled side dressing) including wheel management, a wide selection of software
modules are available upon request
Lubricants are sometimes used to cool the workpiece and wheel, lubricate the interface, and
remove scrap(chips). It must be applied directly to the cutting area to ensure that the fluid is not
carried away by the grinding wheel. Common lubricants include water-soluble chemical fluids,
water soluble oils, synthetic oils, and petroleum-based oils. The type of lubrication used
depends on the workpiece material and is outlined in the table below.
Types of lubricants used for grinding based on workpiece material
Workpiece material Lubricant
Aluminium Heavy duty oil
Brass Light duty oil
Cast iron Heavy duty emulsifiable oil, light duty chemical and synthetic oil
Mild steel Heavy duty water-soluble oil
Stainless steel Heavy duty emulsifiable oil, heavy duty chemical and synthetic oil
Plastics Water-soluble oil, dry, heavy duty emulsifiable oil, light duty chemical and synthetic oil

31
MAGNETIC-BED
The job is fixed using a fixture over a magnetic bed which makes it impossible to move
or even vibrates, and is important as while grinding the surface the job might attain high
momentum and could be destructive so is fixed rightly.
CONTROL

32
BFW CONVENTIONAL MILLING-
Knee Type Milling Machine
Milling is the most common form of machining, a material removal process, which can
create a variety of features on a part by cutting away the unwanted material. The milling
process requires a milling machine, workpiece, fixture, and cutter. The workpiece is a
piece of pre-shaped material that is secured to the fixture, which itself is attached to a
platform inside the milling
machine. The cutter is a
cutting tool with sharp
teeth that is also secured
in the milling machine and
rotates at high speeds. By
feeding the workpiece
into the rotating cutter,
material is cut away from
this workpiece in the form
of small chips to create
the desired shape. Milling
is typically used to
produce parts that are not
axially symmetric and
have many features, such
as holes, slots, pockets,
and even three
dimensional surface
contours. Parts that are
fabricated completely
through milling often include components that are used in limited quantities, perhaps for
prototypes, such as custom designed fasteners or brackets. Another application of
milling is the fabrication of tooling for other processes. For example, three-dimensional
molds are typically milled. Milling is also commonly used as a secondary process to add
or refine features on parts that were manufactured using a different process. Due to the
high tolerances and surface finishes that milling can offer, it is ideal for adding precision
features to a part whose basic shape has already been formed.

33
RIGID STRUCTUREThe rigid structure enables smooth, vibration-free machining. The
rigid spindle housing, cross ribbed box type column structure, and the closed box-type
knee design facilitate optimum chip removal and surface finish.
WORK SPINDLE- Optimum spacing of precision taper roller bearings enables vibration-
free cutting. The bearing pre-loading is adjusted through a common nut.
COOLANT- An electric pump mounted at the rear of the machine base ensures copious
flow of coolant to the work zone. The coolant is discharged into the built-in coolant tank
in the machine base.
LUBRICATION- Central lubrication for guide-ways and lead-screws, splash lubrication
for speed and feed gears.
GUIDES- The table, the cross-slide, and the knee, slide over dovetail guideways, which
are amply dimensioned to withstand machining load.
FEED & TRANSVERSE- Power-operated feed in longitudinal and cross directions for
standard Size 1 machine, rapid feed in longitudinal direction optional. Power operated
feed and rapid traverse in longitudinal, cross, and vertical directions for Size 2 and Size
3.5 models.
MOTORISED OVERARM- MOA is supplied with vertical milling head for Size 2 and Size
3.5 machines. The MOA comes with an independent drive motor of 3 kW (4 HP) power.
The spindle is provided with 12 speeds in the range 45-2,000. Since the MOA itself is
used as overarm for mounting
the arbor support bracket.
TABLE DRIVE- Lead-screw with
two nuts for backlash-free
setting Feed selection by sliding
gear drive Reversal of
movement direction through
motor reversal Dead accurate
stoppage through brake clutch
hange-over and rapid traverse
feed through multi-disc clutch.

34
CHARACTERISTICS
 The width of the chip starts from zero and increases as the cutter finishes slicing.
 The tooth meets the workpiece at the bottom of the cut.
 Upward forces are created that tend to lift the workpiece during face milling.
 More power is required to conventional mill than climb mill.
 Surface finish is worse because chips are carried upward by teeth and dropped in front
of cutter. There's a lot of chip re-cutting. Flood cooling can help!
 Tools wear faster than with climb milling.
 Conventional milling is preferred for rough surfaces.
 Tool deflection during Conventional milling will tend to be parallel to the cut.
There are two major classes of milling process:
 In face milling, the cutting action occurs primarily at the end corners of the
milling cutter. Face milling is used to cut flat surfaces (faces) into the workpiece,
or to cut flat-bottomed cavities.
 In peripheral milling, the cutting action occurs primarily along the circumference
of the cutter, so that the cross section of the milled surface ends up receiving the
shape of the cutter. In this case the blades of the cutter can be seen as scooping
out material from the work piece. Peripheral milling is well suited to the cutting of
deep slots, threads, and gear teeth.

35
MACHINE LAYOUT

36
CHEVALIER SURFACE GRINDER-
FSG-1228ADIII Automatic Precision Grinder
The highly advanced ADII series of automatic precision surface grinding machines are a
result of the on-going and extensive research and development program at
CHEVALIER In addition to improved accuracies, quality, and machine life, the overall
design of the machine incorporates ergonomics; all operating handwheels,levers,stroke
setting devices, and the pendant control panel are arranged to allow ease of operation,
therefore, working efficiency is increased.
A surface grinder is a machine tool used to provide precision ground surfaces, either to a
critical size or for the surface finish.The typical precision of a surface grinder depends
on the type and usage, however ±0.002 mm (±0.0001 in) should be achievable on most
surface grinders.The machine consists of a table that traverses both longitudinally and
across the face of the wheel. The longitudinal feed is usually powered by hydraulics, as
may the cross feed, however any mixture of hand, electrical or hydraulic may be used
depending on the ultimate usage of the machine (i.e., production, workshop, cost). The
grinding wheel rotates in the spindle head and is also adjustable for height, by any of
the methods described previously. Modern surface grinders are semi-automated, depth
of cut and spark-out may be preset as to the number of passes and, once set up, the

37
machining process requires very little operator intervention.Depending on the workpiece
material, the work is generally held by the use of a magnetic chuck.
SPECIFICATION
DESCRIPTION FSG-1224ADIII FSG-1632ADIII FSG-1640ADII
Table Size 300x600mm 400x800mm 400x1000mm
(11 3/4"x23
5/8")
(15 3/4"x31 1/2") (15 3/4"x39 3/8")
Max. Grinding Length (Longitudinal) 610mm (24") 810mm (32") 1015mm (40")
Max. Grinding width (Crosswise) 305mm (12") 405mm (16")
Max. Distance from Table Surface to Spindle
Centerline
620mm (24 7/16 ")
Standard Magnetic Chuck Size 300x600mm
(11 3/4"x23
5/8")
400x800mm (15
3/4"x31 1/2")
400x1000mm
(15 3/4"x39 3/8")
Longitudinal Movement of Table Longitudinal Travel,
Hydraulic
650mm (25 5/8") 850mm (33 7/16") 1050mm (41
5/16")
Max Travel (Manual) 700mm (27 1/2") 900mm (35 3/8") 1100mm (43
1/4")
Table speed, variable 5~25m/min (16~82fpm)
Cross Transverse Travel Rapid travel (Approx.) 60Hz/3.5m/min (12fpm), 50Hz/2.9m/min (10fpm)
Auto transverse increment 3~32mm (1/8-1 1/4")
Max.automatic travel 12" (305mm) 405mm (16")
Max. manual travel 350mm (13 3/4") 460mm (18")
Handwheel per revolution 6mm (0.25")
Handwheel per graduation 0.1mm (0.0025")
Micro
feed
per revolution 0.1mm (0.005")
per graduation 0.001mm (0.00005")
Wheelhead vertical infeed Auto infeed 0.001~0.04mm (0.00005" ~0.002")
Rapid travel (Approx.) 500mm/min (25 ipm)
Standard Grinding Drive Speed 60Hz/1750rpm,50Hz/1450rpm
Power Rating 5HP/4P
Standard Grinding Wheel Diameter 355mm (14")
Width 50mm (2")
Bore 127mm (5")
Floor Space (Lx Wx H) 2950x 3340x 4280x
1490x2080mm 1730x2080mm 1730x2080mm
(116"x59"x81 7/8 (139"x68"x81 7/8 ") (158"x68"x76")

38
OPTONAL-
 Machine lamp.
 Grinding wheel.
 Chuck controller.
 Wheel flange.
 Parallel dressing attachment
(manual type).
 Dual face dresser adapter for
mounting diaformdresser.
 Universal wheel guard &
nozzle.
 Balancing stand with levellingbubble .
 Balancing stand (roller type).
 Single face dresser.
 Electromagnetic chuck.
 Over-the-wheel auto. Straight line dressing & compensation device.
 Parallel dressing attachment (hydraulic).
 Rotary diamond dresser .
 Single side water baffle saddle locking device frequency converter for spindle.
 Dust collector.
 Coolant system with double filter.
 Coolant system with auto. Paper feeding device & magnetic separator (with 1roll
of paper).
 Coolant system with auto. Paper feeding device (with 1 roll of paper).
 Coolant system with manual paper feeding device
MACHINE LAYOUT

39
CONVENTIONAL LATHE-
Four Jaw Chuck Conventional Lathe Machine
A lathe is a machine tool which rotates the workpiece on its axis to perform various
operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning,
with tools that are applied to the workpiece to create an object which has symmetry
about an axis of rotation. Lathes are used in woodturning, metalworking, metal spinning,
thermal spraying, parts reclamation, and glass-working. Lathes can be used to shape
pottery, the best-known design being the potter's wheel. Most suitably equipped
metalworking lathes can also be used to produce most solids of revolution, plane
surfaces and screw threads or helices. Ornamental lathes can produce three-
dimensional solids of incredible complexity. The workpiece is usually held in place by
either one or two centres, at least one of which can typically be moved horizontally to
accommodate varying workpiece lengths. Other work-holding methods include clamping
the work about the axis of rotation using a chuck or collet, or to a faceplate, using
clamps-or-dogs.

40
Examples of objects that can be produced on a lathe include candlestick holders, gun
barrels, cue sticks, table legs, bowls, baseball bats, musical instruments (especially
woodwind instruments), crankshafts, and camshafts.
Lathes have allowed man to reshape, machine and manufacture many precision
cylindrical components made of various types of metal, wood, plastics, and other
materials. Without the lathe, man would still be trying to produce cylindrical components
in some crude fashion or another. However, because of advanced technology, the lathe
has allowed man to become an important asset in developing and machining many
precision components needed to operate and function in many areas of our industrial
complex.

41
TATA Motors has a 4 jaw manual centring lathe machine, which could
be widely used for several operations and is self-sufficient for a wide
range of jobs. Although it is old but does all the work precisely as has
no electrical component or CNC grid so problem occurs. It is water
resistant and coolant/lubricant tray makes the flow continuous.
LATHE MACHINE TOOLS
MODES OF USES
When a workpiece is fixed between the headstock and the tail-stock, it is said to be "between
centres". When a workpiece is supported at both ends, it is more stable, and more force may be
applied to the workpiece, via tools, at a right angle to the axis of rotation, without fear that the
workpiece may break loose. When a workpiece is fixed
only to the spindle at the headstock end, the work is
said to be "face work". When a workpiece is supported
in this manner, less force may be applied to the
workpiece, via tools, at a right angle to the axis of
rotation, lest the workpiece rip free.

42
LATHE OPERATIONS

43
GOODWAY CNC TURNING-
POWER LATHE CNC FOR BETTER PRECISION
A metal lathe or metalworking lathe is a large class of lathes designed for precisely
machining relatively hard materials. They were originally designed to machine metals;
however, with the advent of plastics and other materials, and with their inherent
versatility, they are used in a wide range of applications, and a broad range of materials.
In machining jargon, where the larger context is already understood, they are usually
simply called lathes, or else referred to by more-specific subtype names (toolroom lathe,
turret lathe, etc.). These rigid machine tools remove material from a rotating workpiece
via the (typically linear) movements of various cutting tools, such as tool bits and drill
bits. The design of lathes can vary greatly depending on the intended application;
however, basic features are common to most types. These machines consist of (at the
least) a headstock, bed, carriage, and tailstock. Better machines are solidly constructed
with broad bearing surfaces (slide-ways) for stability, and manufactured with great
precision. This helps ensure the components manufactured on the machines can meet
the required tolerances and repeatability.
Various other codes are also used. A CNC machine is operated by a single operator
called aprogrammer. This machine is capable of performing various operations
automatically and economically. With the declining price of computers and open source
CNC software, the entry price of CNC machines has plummeted. Computer numerical
controlled (CNC) lathes are rapidly replacing the older production lathes (multispindle,
etc.) due to their ease of setting, operation, repeatability and accuracy. They are
designed to use
modern carbide
tooling and fully use
modern processes.
The part may be
designed and the tool
paths programmed by
the CAD/CAM
process or manually
by the programmer,
and the resulting file

44
uploaded to the machine, and once set and trialled the machine will continue to turn out
parts under the occasional supervision of an operator. The machine is controlled
electronically via a computer menu style interface, the program may be modified and
displayed at the machine, along with a simulated view of the process. The
setter/operator needs a high level of skill to perform the process, however the
knowledge base is broader compared to the older production machines where intimate
knowledge of each machine was considered essential. These machines are often set
and operated by the same person, where the operator will supervise a small number of
machines (cell).
The design of a CNC lathe varies with different manufacturers, but they all have some
common elements. The turret holds the tool holders and indexes them as needed, the
spindle holds the workpiece and there are slides that let the turret move in multiple axis
simultaneously. The machines are often totally enclosed, due in large part to
occupational health and safety (OH&S) issues.
With rapid growth in this industry, different CNC lathe manufacturers use different user
interfaces which sometimes makes it difficult for operators as they have to be
acquainted with them. With the advent of cheap computers, free operating systems
such as Linux, and open source CNC software, the entry price of CNC machines has
plummeted.

45
Feed mechanisms
Various feed mechanisms exist to feed material into a lathe at a defined rate.
Bar feeder
A bar feeder feeds a single piece of bar stock into the cutting machine. As each part is
machined, the cutting tool creates a final cut to separate the part from the bar stock, and
the feeder continues to feed the bar for the next part, allowing for continual operation of
the machine.
Bar loader
A bar loader is a variation on the bar feeder concept in that multiple pieces of bar stock
may be fed into a hopper, and the loader feeds each piece as necessary.
CONTROL UNIT CHUCK
There are many variants of lathes within the metalworking field. Some variations are not
all that obvious, and others are more a niche area. For example, a centering lathe is a
dual head machine where the work remains fixed and the heads move towards the
workpiece and machine a center drill hole into each end. The resulting workpiece may
then be used "between centers" in another operation
PRODUCT

46
ITL POWER SAW-
POWER BAND TYPE SAW FOR LARGE LATERAL SECTIONS
A hacksaw is a fine-toothed saw, originally and principally for cutting metal. They can
also cut various other materials, such as plastic and wood; for example, plumbers and
electricians often cut plastic pipe and plastic conduit with them. There are hand saw
versions and powered versions (power hacksaws). Most hacksaws are hand saws with
a C-shaped frame that holds a blade under tension. Such hacksaws have a handle,
usually a pistol grip, with pins for attaching a narrow disposable blade. The frames may
also be adjustable to accommodate blades of different sizes. A screw or other
mechanism is used to put the thin blade under tension. Panel hacksaws forgo the frame
and instead have a sheet metal body; they can cut into a sheet metal panel further than
a frame would allow. These saws are no longer commonly available, but hacksaw blade
holders enable
standard
hacksaw blades
to be used
similarly to a
keyhole saw or
pad saw.
Power tools
including
nibblers, jigsaws,
and angle
grinders fitted
with metal-cutting
blades and discs
are now used for
longer cuts in
sheet metals. A
power hacksaw
(or electric
hacksaw) is a
type of hacksaw that is powered either by its own electric motor or connected to a
stationary engine. Most power hacksaws are stationary machines but some portable
models do exist; the latter (with frames) have been displaced to some extent by
reciprocating saws such as the Sawzall, which accept blades with hacksaw teeth.
Stationary models usually have a mechanism to lift up the saw blade on the return
stroke and some have a coolant pump to prevent the saw blade from overheating.
Power hacksaws are not as commonly used in the metalworking industries as they once
were. Bandsaws and cold saws have mostly displaced them. While stationary electric
hacksaws are not very common, they are still produced. Power hacksaws of the type
powered by stationary engines and line shafts, like other line-shaft-powered machines,
are now rare; museums and antique-tool hobbyists still preserve a few of them.

47
PROPERTIES
• Cutting arm of high tension bearing capacity with preloaded adjustable antifriction
ball bearings
• Cutting arm guided in vertical plate, self lubricated due to grease packing.
• Protected from atmosphere.
• 6 cutting speeds with dual speed motor (Optional).
• Infinitely variable feed rate and positive hydraulic cutting pressure.
• Motorized hydraulic pump for faster approach of blade to job.
• Full cutting efficiency by positive feed pressure.
• Forward cutting operation by hydraulic pressure.
• New tech HSS bi-metal blade with a tooth hardness of 67 HRC can also be used.
• In case of hydraulic failure, blades & job are saved automatically.
PRODUCTS OF ITL

48
RADIAL DRILLING MACHINE-
Self-Feeding Radial Drilling Heavy Duty Machine
A radial drilling machine or radial arm press is a geared drill head that is mounted on an
arm assembly that can be moved around to the extent of its arm reach. The most
important components are the arm, column, and the drill head. The drill head of the
radial drilling machine can be moved, adjusted in height, and rotated. Aside from its
compact design, the radial drill press is capable of positioning its drill head to the work
piece through this radial arm mechanism. This is probably one of the reasons why more
machinists prefer using this type of drilling machine. In fact, the radial drilling machine is
considered the most
versatile type of drill
press. The tasks that a
radial drilling machine
can do include boring
holes, countersinking,
and grinding off small
particles in masonry
works.Although some
drill presses are floor
mounted, the most
common set-up of
radial arm drill presses
are those that are
mounted on work
benches or tables. With
this kind of set-up, it is
easier to mount the drill
and the work pieces.
There is no need to
reposition work pieces
because the arm can extend as far as its length could allow. Moreover, it is easier to
manoeuvre large work pieces with the radial arm drilling machine. Large work pieces
can be mounted on the table by cranes as the arm can be swivelled out of the way.

49
Here are some of the major parts of the radial arm drilling machine:
Column -is the part of the radial arm drill press which holds the radial arm which can be
moved around according to its length
Arm Raise - adjusts the vertical height of the radial arm along the column
On/Off Button - is the switch that activates and deactivates the drill press
Arm Clamp - secures the column and the arm in place
Table - is the area where the work pieces are fed and worked on
Base - is the radial arm drill press part that supports the column and the table
Spindle - is the rotated part of the drill press which holds the drill chuck used in holding
the cutting tool.
Drill Head - is the part of the drill press that penetrates through the material or work
piece and drill through the specific hole size
Radial Arm - holds and supports the drill head assembly and can be moved around on
the extent of its length
There are a number of advantages of using the radial arm drill press. One of these
advantages is the amount of area that it can cover which is only dependent on the
length of the arm. Another advantage is the considerable size of work that it can handle
since the arm can
actually swivel out of
the working area
allowing cranes and
derricks to place
work pieces on the
table. Finally, less
effort is required
during the drilling
process because the
arm assembly
seemingly is doing
all that is needed for
specific tasks to be
completed.

50
RADIAL DRILL LAYOUT
DRILLING OPERATIONS
 Threading
 Reaming
 Drilling
 Counter Sinking
 Boring
 Counter Boring
 Tapping
 Trepanning
 Spot Facing
Drill Bit of size 0.2 – 102mm Is used. Coolant used is soluble oil mixed with water,
basically fatty, immersive oils etc.

51
STUDER S242-
CNC CYLINDERICAL GRINDER
This is the Studer CNC Grinder which is capable of grinding the job whatsoever
internally or externally both simultaneously. With a tolerance of 1 micron the machine is
capable of grinding basically cylindrical jobs mostly with the internal and external
grinding wheels. The input is entered in the form of G-Code according to the job. Two
Third bore required for minimum diameter of the job.
BENEFITS
The S242combined machine
tool ideally combines the
technologies of cylindrical
grinding and hard turning.
Thanks to its design concept,
it can easily cope with both
processes. Consequently, it
enables highly efficient hard
fine machining of shafts and
chucking components with a
high manufacturing quality,
production reliability and the desired surface quality in a single clamping. It is interesting
not only for high-volume production but also for small batch sizes and single parts.
INNER GRINDING WHEELS CONTROL

52
TECHNICAL SPECIFICATIONS
 Distance between centres 400/800/1000 mm
 Swing diameter 180 mm
 Synchronous tailstock with selectable axial clamping pressure for workpiece drive
definable for each workpiece in the workpiece program
 Multiple in-process gauging. Individual workpiece positions and diameters are stored in
the workpiece program.
 Machine bed with inclined design (machining plane 45°) made from GRANITAN®
 Standardized interfaces for loader and peripheral devices
 Automated part handling system (option)
 Easy programming thanks to StuderWIN
 Full enclosure with sliding door
 The modular kit system enables customer-specific designs
 Large range of accessories

53
MACHINE
LAYOUT

54

55
DECKEL MAHO-
GILDEMEISTER DMU 80 T MACHINING CENTER-UNIVERSAL
One of the most efficient machines in the PE Shop at Tata, Lucknow is this Universal Milling
Machine of Deckel Mahobrought up nearly 15years ago from Germany, has an automatic
changer which according to the need changes the tool instantaneously. This is hence a CNC
machine works on several Servo motors functioning to 4axles in 5 side machining. Consists of
two heads- upper & lower; which can be easily interchanged for horizontal or vertical milling
activity. The table below on which the job is been placed rotates hence for the better job finish
and precision is much greater than any other milling. The only demerit is that a very huge job
can‟t be machined on it because of the smaller size of the machine. The job must be kept
150mm distance from the tool. The coolant system is automated as to cool the tool precisely
and act as lubrication for the machining. The machine has firstly to be entered with the proper
G-Code (CNC program) according to the job specification manually and then the further
automated milling machine does everything.
Most CNC milling machines (also called machining centres) are computer controlled vertical
mills with the ability to move the spindle vertically along the Z-axis. This extra degree of freedom
permits their use in die sinking, engraving applications, and 2.5D surfaces such
as relief sculptures. When combined with the use of conical tools or a ball nose cutter, it also

56
significantly improves milling precision without impacting speed, providing a cost-efficient
alternative to most flat-surface hand-engraving work.
CNC machines can exist in virtually any of the forms of manual machinery, like horizontal mills.
The most advanced CNC milling-machines, the multiaxis machine, add two more axes in
addition to the three normal axes (XYZ).[8] Horizontal milling machines also have a C or Q axis,
allowing the horizontally mounted work piece to be rotated, essentially allowing asymmetric
and eccentric turning. The fifth axis (B axis) controls the tilt of the tool itself. When all of these
axes are used in conjunction with each other, extremely complicated geometries, even organic
geometries such as a human head can be made with relative ease with these machines. But the
skill to program such geometries is beyond that of most operators. Therefore, 5-axis milling
machines are practically always programmed withCAM.
The operating system of such machines is a closed loop system and functions on feedback.
These machines have developed from the basic NC (NUMERIC CONTROL) machines. A
computerized form of NC machines is known as CNC machines. A set of instructions (called a
program) is used to guide the machine for desired operations. Some very commonly used
codes, which are used in the program, are:
G00 - Rapid Traverse
G01 - linear interpolation of tool.
G21 - Dimensions in metric units.
M03/M04 - spindle start (clockwise/counter clockwise).
T01 M06 - Automatic tool change to tool 1
M30 - program end.
Various other codes are also used. A CNC machine is operated by a single operator called
aprogrammer. This machine is capable of performing various operations automatically and
economically.
With the declining price of computers and open source CNC software, the entry price of CNC
machines has plummeted.

57
TOOLS LAYOUT

58
BFW MACHINE-
CNC MILLING MACHINE VERTICAL
Milling is the machining process of using rotary cutters to remove material[1] from a
workpiece advancing (or feeding) in a direction at an angle with the axis of the tool.[2][3]
It covers a wide variety of different operations and machines, on scales from small
individual parts to large, heavy-duty gang milling operations. It is one of the most
commonly used processes in industry and machine shops today for machining parts to
precise sizes and shapes.
Milling can be done with a wide range of machine tools. The original class of machine
tools for milling was the milling machine (often called a mill). After the advent of
computer numerical control (CNC), milling machines evolved into machining centers
(milling machines with automatic tool changers, tool magazines or carousels, CNC
control, coolant systems, and enclosures), generally classified as vertical machining
centers (VMCs) and horizontal machining centers (HMCs). The integration of milling into
turning environments and of turning into milling environments, begun with live tooling for
lathes and the occasional use of mills for turning operations, led to a new class of
machine tools, multitasking machines (MTMs), which are purpose-built to provide for a

59
default machining strategy of using any combination of milling and turning within the
same work envelope. A metal lathe or metalworking lathe is a large class of lathes
designed for precisely machining relatively hard materials. They were originally
designed to machine metals; however, with the advent of plastics and other materials,
and with their inherent versatility, they are used in a wide range of applications, and a
broad range of materials. In machining jargon, where the larger context is already
understood, they are usually simply called lathes, or else referred to by more-specific
subtype names (toolroom lathe, turret lathe, etc.). These rigid machine tools remove
material from a rotating workpiece via the (typically linear) movements of various cutting
tools, such as tool bits and drill bits. The design of lathes can vary greatly depending on
the intended application; however, basic features are common to most types. These
machines consist of (at the least) a headstock, bed, carriage, and tailstock. Better
machines are solidly constructed with broad bearing surfaces (slide-ways) for stability,
and manufactured with great
precision. This helps ensure
the components
manufactured on the
machines can meet the
required tolerances and
repeatability.
NC milling is a specific form
of computer numerical
controlled (CNC) machining. Milling itself is a machining process similar to both drilling
and cutting, and able to achieve many of the operations performed by cutting and
drilling machines. Like drilling, milling uses a rotating cylindrical cutting tool. However,
the cutter in a milling machine is able to move along multiple axes, and can create a
variety of shapes, slots and holes. In addition, the work-piece is often moved across the
milling tool in different directions, unlike the single axis motion of a drill.
CNC milling devices are the most widely used type of CNC machine. Typically, they are
grouped by the number of axes on which they operate, which are labeled with various
letters. X and Y designate horizontal movement of the work-piece (forward-and-back
and side-to-side on a flat plane). Z represents vertical, or up-and-down, movement,
while W represents diagonal movement across a vertical plane. Most machines offer
from 3 to 5 axes, providing performance along at least the X, Y and Z axes. Advanced

60
machines, such as 5-axis milling centers, require CAM programming for optimal
performance due to the incredibly complex geometries involved in the machining
process.
Computer numeric controlled machining centers are used to produce a wide range of
components, and tooling costs involved have continued to become more affordable. In
general, large production runs requiring relatively simple designs are better served by
other methods, although CNC machining can now accommodate a wide range of
manufacturing needs. CNC milling centers are ideal solutions to everything ranging from
prototyping and short-run production of complex parts to the fabrication of unique
precision components. Virtually every type of material that can be drilled or cut can be
machined by a CNC mill, although most of the work performed is done in metal. As with
drilling and cutting, the proper machine tools must be selected for each material in order
to avert potential problems. The hardness of the work-piece material, as well as the
rotation of the cutting tool must all be factored before beginning the machining process.

61
The operating system of such
machines is a closed loop system and
functions on feedback. These
machines have developed from the
basic NC (NUMERIC CONTROL)
machines. A computerized form of NC
machines is known as CNC machines.
A set of instructions (called a program)
is used to guide the machine for
desired operations. When combined
with the use of conical tools or a ball
nose cutter, it also significantly
improves milling precision without
impacting speed, providing a cost-
efficient alternative to most flat-surface
hand-engraving work
MACHINE LAYOUT

62
TANAKA GAS CUTTER-
GAS CUTTER AND PHOTO TRACER TYPE
Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding
in the U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld
and cut metals, respectively. French engineers Edmond Fouché and Charles Picard
became the first to develop oxygen-acetylene welding in 1903. Pure oxygen, instead of
air, is used to increase the flame temperature to allow localized melting of the workpiece
material (e.g. steel) in a room environment. A common propane/air flame burns at about
2,250 K (1,980 °C; 3,590 °F), a propane/oxygen flame burns at about 2,526 K (2,253
°C; 4,087 °F), and an acetylene/oxygen flame burns at about 3,500 °C (6,330 °F).
Oxy-fuel is one of the
oldest welding
processes, besides
forge welding. Still
used in industry, in
recent decades it has
been less widely
utilized in industrial
applications as other
specifically devised
technologies have
been adopted. It is still
widely used for
welding pipes and tubes, as well as repair work. It is also frequently well-suited, and
favoured, for fabricating some types of metal-based artwork. As well, oxy-fuel has an
advantage over electric welding and cutting processes in situations where accessing
electricity (e.g., via an extension cord or portable generator) would present difficulties; it
is more self-contained, and, hence, often more portable.
Butane, like propane, is a saturated hydrocarbon. Butane and propane do not react with
each other and are regularly mixed. Butane boils at 0.6 °C. Propane is more volatile,
with a boiling point of -42 °C. Vaporization is rapid at temperatures above the boiling
points. The calorific (heat) values of both are almost equal. Both are thus mixed to attain
the vapour pressure that is required by the end user and depending on the ambient

63
conditions. If the ambient temperature is very low, propane is preferred to achieve
higher vapour pressure at the given temperature.
Propane does not burn as hot as acetylene in its inner cone, and so it is rarely used for
welding Propane, however, has a very high number of BTUs per cubic foot in its outer
cone, and so with the right torch (injector style) can make a faster and cleaner cut than
acetylene, and is much more useful for heating and bending than acetylene. The
maximum neutral flame temperature of propane in oxygen is 2,822 °C (5,112 °F).
Propane is cheaper than acetylene and easier to transport. Like propylene, most
propane tips are of a two-piece design. Propane often gets unfair criticism because it
really needs changing the torch (from an equal pressure torch to an injector torch) and
not just changing the tip to get the best performance. Most torches are equal pressure
and designed for gases, such as acetylene, which are lighter than oxygen. Propane is a
great deal heavier and runs much better through a low-pressure injector torch with a
setting from a few ounces to about two pounds per square inch when cutting.

64

65
MUFFLE FURNACE-
HEAT TREATMENT PROCESS OF THE METAL
A muffle furnace (sometimes, retort furnace) in historical usage is a furnace in which the
subject material is isolated from the fuel and all of the products of combustion including
gases and flying ash. After the development of high-temperature electric heating
elements and widespread electrification in developed countries, new muffle furnaces
quickly moved to electric designs. Today, a muffle furnace is (usually) a front-loading
box-type oven or kiln for high-temperature applications such as fusing glass, creating
enamel coatings, ceramics and soldering and brazing articles. They are also used in
many research facilities, for example by chemists in order to determine what proportion
of a sample is non-combustible and non-volatile (i.e., ash). Some digital controllers
allow RS232 interface and permit the operator to program up to 126 segments, such as
ramping, soaking, sintering, and more. Also, advances in materials for heating
elements, such as molybdenum disilicide, can now produce working temperatures up to
1,800 degrees Celsius (3,272 degrees Fahrenheit), which facilitate more sophisticated
metallurgical applications. The term muffle furnace may also be used to describe
another oven constructed on many of the same principles as the box type kiln
mentioned above, but takes the form of a long, wide, and thin hollow tube used in roll to
roll manufacturing processes. Both of the above mentioned furnaces are usually heated
to desired temperatures by conduction, convection, or blackbody radiation from
electrical resistance heating elements. Therefore there is (usually) no combustion
involved in the temperature control of the system, which allows for much greater control

66
of temperature uniformity
and assures isolation of
the material being heated
from the by-products of
fuel combustion.
An Automatic Oil Muffle
Furnace, circa 1910.
Petroleum is contained in
tank A, and is kept under
pressure by pumping at
intervals with the wooden
handle, so that when the
valve B is opened, the oil
is vaporized by passing
through a heating coil at
the furnace entrance, and
when ignited burns
fiercely as a gas flame.
This passes into the
furnace through the two
holes, C, C, and plays
under and up around the
muffle D, standing on a
fireclay slab. The doorway
is closed by two fireclay
blocks at E.

67
TOOL HEIGHT MACGINE-
TOOL HEIGHT MEASURING MACHINE
Basically used to measure the tool length before the usage of the tool and even every
time after the tool was used. The tool gets rusted or been grinded while getting been
used. This is basically very important for the CNC machines as they do require the
actual length of the tool for the further numerical calculations and the measurements.

68
Case Study I: - Oil Sumps for Engines
This Case study gives an insight on how the part design can be
simplified by optimization in virtual tryout / simulation. Oil sumps of
various Tata Motors projects were made feasible using virtual tryout
tools. The learning from these exercises were documented to enable
product designers to design oil-sumps to engine requirements in
shortest possible virtual tryout loops.
The exercise made possible Implementation of 3-Ply Sandwich
material for special NVH (Noise, Vibrations and Harshness)
application in one of the Oil Sumps.

69
Case Study II: - Head Lamp Cover for a Tata
Mini Truck
Initial Head lamp cover was made up of 2 stamping parts joined by
spot welding. Due to number of joints the head lamps cover was
prone to leakages. After studying various possible solutions a cost-
effective, single piece design had been proposed and implemented
successfully.

70
Case Study III: - Simultaneous Engineering
for Manufacturing Feasibility
As per the Simultaneous Engineering concept, all design activities
should occur simultaneously, the overall goal being that the
concurrent nature of these processes significantly reduces project
implementation time while increasing productivity and product quality.
The success of Simultaneous Engineering lies in allowing errors and
redesigns to be discovered early during the design process when the
project is still in a more abstract and digital realm. By locating and
fixing these issues early, the design team can avoid costly errors as
the project moves to more complicated computational models and
eventually into the physical realm.

71
Case Study IV: Dimensional Variation
Analysis (DVA) of Using 3DCS Software on
CATIA V5 R19 Platform
Dimensional Variation Analysis helps in closing the gap between
engineering investigation and manufacturing quality assurance. The
challenge is to integrate such components without experiencing
significant production problems so as to reduce costs and deliver
products in the market faster and better. By leveraging the
advantages of 3DCS CatiaV5, variation analysis, reduction of
assembly flow time and recurring costs resulting from rework and
adjustments late in the production cycle can be achieved.

72
LEARNING
From this Production Engineering Department Case Study we can learn
few very basic and important learning‟s. That the PE department is really
very important and is the only which consists of a lot of machines and
equipment for the manufacturing processes.
PE's commercial operations started in 2001-2002 and since then have
done tooling works for several OEM and Tier 1 companies in India and
Europe.
With knowledge of vehicle level fitments and engineering in tool making,
which is an added benefit to its customers, PE division is aiming to reduce
project risks and efficiently manage timelines.
PE plays a very important role in BIW tooling of Tata Motors Limited
through its New Product Development process.
PE's product portfolio comprises Stamping Dies (Press Tools), Sheet-Metal
Fixtures, Inspection Fixtures and Gauges, Foundry Tooling and
Thermoforming Moulds.

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