Sant Prasad Tyagi

PROJECT REPORT ON REDUCTION OF HUB PLAY COMPLAIN IN ASSEMBLY LINE OF

HVAL, TATA MOTORS (JAMSHEDPUR)

SUBMITED BY:SANTPRASAD TYAGI

2

ND

DIPLOMA IN ENGINEERING (Mechanical) YEAR, DAYALBAGH EDUCATIONAL INSTITUTE, DEEMED UNIVERSITY AGRA (U.P.)

HV AX LES LIM ITED C/ O TATA MO TORS LIM ITED Telco Campus, Jamshedpur 831 010

CERTIFICATE

This is to certify that the project report entitled REDUCTION OF HUB PLAY IN REAR AXLE ASSEMBLY LINE is done by Mr. SANTPRASAD TYAGI, second year student of DAYALBAGH EDUCATIONAL INSTITUTE, AGRA (U.P.) pursuing Diploma in Mechanical Engineering during the summer of 2009 for the partial fulfillment of the project as a Vocational Trainee at HV AL, TATA MOTORS , Jams he dp ur.

Mr. SURANJAN CHATTERGEE ( Asst. General Manager) H.V. AXLE Ltd. TATA MOTORS JAMSHEDPUR (JHK.)

ACKNOWLDGEMENT Whenever I start a new work from the grass root level,to make that work a huge success there is involvement of many other people whose encouragement works as strength to complete the new work. Similarly I have started my project and many people played a vital role in its fulfillment. So I would like to acknowledgment my sincere thanks to all the people whose support made my project a success. First of all I would like to thanks Mr. SURANJAN CHATTERGEE (AGM) who gave us this opportunity to carry out this project and had been a constant source of inspiration. Without his support this project would have been an impossible task. I also extend my gratitude and thanks to Mr.SAGAR MAHAJAN (Manager in SQA Dept.) & Mr. Satish Gupta (Technical officer) for there constant support and guidance throughout the tenure of this project. I would also like to pay the words of thanks to the all line managers who took out time from their hectic schedule to give the skill matrix & for their suggestions, which enable me to come out with a conclusion. I would like to thanks all the people of H.V.A.L. who helped me directly or indirectly in completion of my project.

THANKING YOU: SANTPRASAD TYAGI

Contents  Acknowledgement  TATA Motors  Heavy Vehicle Axles Ltd.  Supplier Quality Assurance  Hub Play  Reduction of Hub Play  Conclusion  Photo Gallery

SALIENT STATISTICS TATA MOTORS, JAMSHEDPUR  TOTAL AREA OF JAMSHEDPUR:

1780 ACRES

 TOTAL AREA OF WORKS:

580 ACRES

 COVERED AREA OF WORKS:

217 ACRES

 LENGTH OF ROADS INSIDE WORKS:

30

 AREA OF COLONEY:

1200 ACRES

 POPULATION OF COLONEY:

35000(APPROX.)

 TEMPERATURE:  AVERAGE RAINFALL:

45.5-DEGREE CEL. (MAX) 6.7-DEGREE CEL. (MIN) 99 CM

 LONGITUDE:

86.12-DEGREE EAST

 LATITUDE:

22.47-DEGREE NORTH

 ALTITUDE:

159m.ABOVE SEA LEVEL (TATANAGAR)

 GEOGRAPHICAL LOCATION:

MILES

JHARKHAND (EAST SINGHBHUM)

ORGANISATIONAL STRUCTURE OF TATA MOTORS LIMITED (JSR)

TATA MOTORS LIMITED

CVBU

PUNE

HVAL

HRD

PCBU

JSR

LKU

TML

ERC

 CVBU  PCBU  TML  HVAL  HVTL  TTL  TELCON  HRD  ERC  APPC  PL-I  PL-II  PL-III  VD  AM

PUNE

HVTL

APPC

: : : : : : : : : : : : : : :

PL-I

PL-II

TTL

PL-III VD

TCL

AM

Commercial Vehicle Business Unit Public Carrier Business Unit Tata Motors Limited Heavy Vehicle Axle Limited Heavy Vehicle Transmission Limited Tata Technologies Limited Tata Constructions Human Resource Department Engineering and Research Center Auto Production Planning and Control Plant-1(Vehicle assembly line) Plant-2(Engine division) Plant-3(Cab/Cowl manufacturing unit) Vehicle Dispatch Auto Manufacturing

Tata Motors Limited

Tata Motors Limited is India's largest automobile company, with standalone revenues of Rs. 25,660.79 crores (USD 5.5 billion) in 2008-09. It is the leader in commercial vehicles in each segment, and among the top three in passenger vehicles with winning products in the compact, midsize car and utility vehicle segments. The company is the world's fourth largest truck manufacturer, and the world's second largest bus manufacturer. The company's 23,000 employees are guided by the vision to be "best in the manner in which we operate, best in the products we deliver, and best in our value system and ethics." Established in 1945, Tata Motors' presence indeed cuts across the length and breadth of India. Over 4 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) and Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set up an industrial joint venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce both Fiat and Tata cars and Fiat powertrains. The company is establishing a new plant at Sanand (Gujarat). The company's dealership, sales, services and spare parts network comprises over 3500 touch points; Tata Motors also distributes and markets Fiat branded cars in India. 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 was 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, with an option to acquire the remaining stake as well. Hispano's presence is being expanded in other markets. In 2006, it formed a joint venture with the Brazil-based Marcopolo, a global leader in body-building for buses and coaches to manufacture fully-built buses and coaches for India and select international markets. 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. The new plant of Tata Motors (Thailand) has begun production of the Xenon pickup truck, with the Xenon having been launched in Thailand at the Bangkok Motor Show 2008. 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 and South America. It has franchisee/joint venture assembly operations in Kenya, Bangladesh, Ukraine, Russia and Senegal. The foundation of the company's growth over the last 50 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 2,000 engineers and scientists, 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, in India, and in South Korea, Spain, and the UK. It was Tata Motors, which developed the first indigenously developed Light Commercial Vehicle, India's first Sports Utility Vehicle and, in 1998, the Tata Indica, India's first fully indigenous passenger car. Within two years of launch, Tata Indica became India's largest selling car in its segment. In 2005, Tata Motors created a new segment by launching the Tata Ace, India's first indigenously developed minitruck. In January 2008, Tata Motors unveiled its People's Car, the Tata Nano, which India and the world have been looking forward to. The Tata Nano has been subsequently launched, as planned, in India in March 2009. A development, which signifies a first for the global automobile industry, the Nano brings the comfort and safety of a car within the reach of thousands of families. The standard version has been priced at Rs.100,000 (excluding VAT and transportation cost). Designed with a family in mind, it has a roomy passenger compartment with generous leg space and head room. It can comfortably seat four persons. Its monovolume design will set a new benchmark among small cars. Its safety performance exceeds regulatory requirements in India. Its tailpipe emission performance too exceeds regulatory requirements. In terms of overall pollutants, it has a lower pollution level than two-wheelers being manufactured in India today. The lean design strategy has helped minimise weight, which helps maximise performance per unit of energy consumed and delivers high fuel efficiency. The high fuel efficiency also ensures that the car has low carbon dioxide emissions, thereby providing the twin benefits of an affordable transportation solution with a low carbon footprint. In May 2009, Tata Motors ushered in a new era in the Indian automobile industry, in keeping with its pioneering tradition, by unveiling its new range of world standard trucks. 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. The years to come will see the introduction of several other innovative vehicles, all rooted in emerging customer needs. Besides product development, R&D is also focussing on environment-friendly technologies in emissions and alternative fuels. Through its subsidiaries, the company is engaged in engineering and automotive solutions, construction equipment manufacturing, automotive vehicle components manufacturing and supply chain activities, machine tools and factory automation solutions, high-precision tooling and plastic and electronic components for automotive and computer applications, and automotive retailing and service operations.

Company Profile It has been a long and accelerated journey for Tata Motors, India's leading automobile manufacturer. Some significant milestones in the company's journey towards excellence and leadership. Milestones

1 945

•

Tata Engineering and Locomotive Co. Ltd. was established to manufacture locomotives and other engineering products.

1 948

•

Steam road roller introduced in collaboration with Marshall Sons (UK).

1 954

•

Collaboration with Daimler Benz AG, West Germany, for manufacture of medium commercial vehicles. The first vehicle rolled out within 6 months of the contract.

1 959

•

Research and Development Centre set up at Jamshedpur.

1 961

•

Exports begin with the first truck being shipped to Ceylon, now Sri Lanka.

1 966

•

Setting up of the Engineering Research Centre at Pune to provide impetus to automobile Research and Development.

1 971

•

Introduction of DI engines.

1 977

•

First commercial vehicle manufactured in Pune.

1 983

•

Manufacture of Heavy Commercial Vehicle commences.

1 985

•

First hydraulic excavator produced with Hitachi collaboration.

1 986

•

Production of first light commercial vehicle, Tata 407, indigenously designed, followed by Tata 608.

1 989

•

Introduction of the Tatamobile 206 - 3rd LCV model.

1 991

• • •

Launch of the 1st indigenous passenger car Tata Sierra. TAC 20 crane produced. One millionth vehicle rolled out.

1 992

•

Launch of the Tata Estate.

1 993

•

Joint venture agreement signed with Cummins Engine Co. Inc. for the manufacture of high horsepower and emission friendly diesel engines.

1 994

• • •

Launch of Tata Sumo - the multi utility vehicle. Launch of LPT 709 - a full forward control, light commercial vehicle. Joint venture agreement signed with M/s Daimler - Benz / Mercedes - Benz for manufacture of Mercedes Benz passenger cars in India. Joint venture agreement signed with Tata Holset Ltd., UK for manufacturing turbochargers to be used on Cummins engines.

•

1 995

•

Mercedes Benz car E220 launched.

1

•

Tata Sumo deluxe launched.

1 997

• •

Tata Sierra Turbo launched. 100,000th Tata Sumo rolled out.

1 998

• • •

Tata Safari - India's first sports utility vehicle launched. 2 millionth vehicle rolled out. Indica, India's first fully indigenous passenger car launched.

1 999

• •

115,000 bookings for Indica registered against full payment within a week. Commercial production of Indica commences in full swing.

2 000

• • • • • •

First consignment of 160 Indicas shipped to Malta. Indica with Bharat Stage 2 (Euro II) compliant diesel engine launched. Utility vehicles with Bharat 2 (Euro II) compliant engine launched. Indica 2000 (Euro II) with multi point fuel injection petrol engine launched. Launch of CNG buses. Launch of 1109 vehicle - Intermediate commercial vehicle.

2 001

• • • • • •

Indica V2 launched - 2nd generation Indica. 100,000th Indica wheeled out. Launch of CNG Indica. Launch of the Tata Safari EX Indica V2 becomes India's number one car in its segment. Exits joint venture with Daimler Chrysler.

2 002

2 003

• Unveiling of the Tata Sedan at Auto Expo 2002. Tata Motors has several joint venture, subsidiary and • Petrol version of Indica V2 launched. • Launch ofcompanies: the EX series in Commercial vehicles. associate • • • • • •

Launch of the Tata 207 DI. 2,00,000th Indica rolled out. 5,00,000th passenger vehicle rolled out. Jaguar Land Rover Launch of the Tata Sumo'+' Series Launch of the Tata Indigo. TataEngineering Technologies (TTL) and itswith subsidiaries Tata signedLtd. a product agreement MG Rover of the UK.

•  • •

Launch the Tata SafariEquipment Limited Edition. Telco of Construction Co. Ltd. (Telcon) The Tata Indigo Station Wagon unveiled at the Geneva Motor Show. On 29th July, J. R. D. Tata's birth anniversary, Tata Engineering becomes Tata HV Axles Ltd. (HVAL) Motors Limited. 3 millionth vehicle produced. First CityRover rolled out HV Transmissions Ltd. (HVTL) 135 PS Tata Safari EXi Petrol launched Tata SFC 407 EX Turbo launched



• •  • •

2 004

 TAL Manufacturing Solutions Ltd. (TAL)

• • • • • • • • • •

2 005

• •

Tata Motors unveils new product range at Auto Expo '04. New Tata Indica V2 launched Sheba Properties Ltd.Commercial (Sheba) Vehicle Co. Ltd. sign investment Tata Motors and Daewoo agreement Indigo AdventMotors unveiled(India) at Geneva Motor Show Concorde Ltd. (Concorde) Tata Motors completes acquisition of Daewoo Commercial Vehicle Company Tata LPT 909 EX launched TataDaewoo Daewoo Commercial Company Ltd (TDWCV) Tata Commercial VehicleVehicle Co. Ltd. (TDCV) launches the heavy duty truck 'NOVUS' , in Korea Sumo VictaCarrocera launched S. A. (HC) Hispano Indigo Marina launched Tata Motors lists on the NYSE Tata Motors rolls out the 500,000th Passenger Car from its Car Plant Facility in Pune The Tata Xover unveiled at the 75th Geneva Motor Show

Tata Motors acquires 21% stake in Hispano Carrocera SA, Spanish bus manufacturing Company • Tata Ace, India's first mini truck launched • Tata winsInsurance JRD QV award for business excellence. TataMotors Motors Broking & Advisory Services Ltd • The power packed Safari Dicor is launched • Introduction of Indigo SX series - luxury variant of Tata Indigo  Tata Motors European Technical Centre plc • Tata Motors launches Indica V2 Turbo Diesel. • One millionth passenger car produced and sold • Inauguration of new factoryLimited at Jamshedpur for Novus Tata Motors Finance • Tata TL 4X4, India's first Sports Utility Truck (SUT) is launched • Launch of Tata Novus Tata Motors • Launch of NovusThailand range of medium trucks in Korea, by Tata Daewoo Commercial Co. (TDCV)  Vehicle Tata Marco polo Motors Ltd (TMML) •

2 006

• • • • • • • • • •

(TMIBASL)

Tata Motors vehicle sales in India cross four million mark TataMotors Motors(SA) Proprietary Ltd premium (TMSA)Indigo & X-over concept at Tata unveils new long wheel base Auto Expo 2006 Indica Xeta launched TMLV2 Distribution Company Ltd (TDCL) Passenger Vehicle sales in India cross one-million mark Tata Motors and Marcopolo, Brazil, announce joint venture to manufacture fully built buses & coaches for India & markets abroad Tata Motors first plant for small car to come up in West Bengal Tata Motors extends CNG options on its hatchback and estate range M.L. Bapna TDCV develops South Korea's first LNG-Powered TractorTrailer CEO (HVAL & HVTL) Tata Motors and Fiat Group announce three additional cooperation agreements Tata Motors introduces a new Indigo range

Ashesh Jamaiyar (HVAL) • Construction COO of Small Car plant at Singur, West Bengal, begins on January 21 • New 2007 Indica V2 range is launched • Tata Motors launches the longwheel base Indigo XL, India's first stretch R R Mishra A K Panda limousine AGM (FABU) to Indigo sedan and estate range AGM (Rear Axle Fctory) • Common rail diesel (DICOR) engine extended • Tata Motors and Thonburi Automotive Assembly Plant Co. (Thonburi),

PROFILE OF

2 007

HV AXLES LIMITED

announce formation of a joint venture company in Thailand to manufacture, S Mohanty Suranjan Chatterjee assemble and market pickup trucks. AGM (Central Materials) AGM (Central Quality) • Roll out of 100,000th Ace • Tata-Fiat plant at Ranjangaon inaugurated • Launch of a new Upgraded range of its entry level utility vehicle offering, the R P Singh D N Tripathi Tata Spacio. AGM (PPC) AGM – (P&A & IR) • CRM-DMS initiative crosses the 1000th location milestone • Launch of Magic, a comfortable, safe, four-wheeler public transportation mode,

developed on the Ace platform Dipan Sengupta P K Sinha • Launch of Winger, India’s only maxi-van Div Mngr Div Mngr (HR & PSD) (Central Maintenance ) of Joint Venture in India • Fiat Group and Tata Motors announce establishment • Launch of the Sumo Victa Turbo DI, the new upgraded range of its entry-level utility vehicle, the Sumo Spacio U Macwana • Tata Motors launches Indica V2 Turbo with dual airbags and ABS AGM (Logistics & Stores) • •

2 008

• • • • • • •

Launch of new Safari DICOR 2.2 VTT range, powered by a new 2.2 L Direct Injection Common Rail (DICOR) engine. P K Choudhury Rollout of the one millionth passenger car off the Indica platform.

AGM (Planning, PE,NPI,ERC, Ext Business,

Ace plant at Pantnagar (Uttarakhand) begins production. Indica Vista – the new generation Indica, is launched. Tata Motors' new plant for Nano to come up in Gujarat. Tarun Gupta Latest common rail diesel offering- the Indica V2 DICOR, launched.AGM (Finance & Excise) Indigo CS (Compact Sedan), world’s first sub four-metre sedan, launched. Launch of the new Sumo -- Sumo Grande, which combines the looks of an S. Aich SUV with the comforts of a family car. AGM (Projects, IDM Tata Motors unveils its People's Car, Nano, at the ninth Auto Expo.

• • • • •

Tata Motors signs definitive agreement with Ford Motor Company to purchase Jaguar and Land Rover. Tata Motors completes acquisition of Jaguar Land Rover. Tata Motors introduces new Super Milo range of buses. Tata Motors is Official Vehicle Provider to Youth Baton Relay for The III Commonwealth Youth Games Pune 2008. Indica Vista – the second generation Indica, is launched.

PROFILE OF HV AXLES LTD. H V Axles Ltd., a subsidiary of Tata Motors, was formed in March 2000. Earlier it used to be the Axle Division of Telco (Tata Engineering), Jamshedpur,

.

The manufacturing facilities of HVAL are located in the industrial belt of Jamshedpur in the state of Jharkhand, 250 kms from Kolkata, India's leading metro city and is well connected by air, road and rail to major cities/ locations.

Starting operations in 1954 (creation of Telco), today HVAL is the market leader in medium & heavy commercial vehicle axles in India with an installed capacity of over 3.6 lakh axles per annum. The company’s product range includes Front Steer Axles (both Live and Normal), Rear Drive Axles and Dummy / Trailer Axles. It is currently the sole supplier of M & HCV Axles to the Jamshedpur and Lucknow plants of Tata Motors.

VISION OF HV AXLES LTD. To be a benchmark stand alone M & HCV Axles manufacturer, rated as number one in the CV Industry in India & among the recognized top five globally in terms of Volume, Durability, Reliability, Revenues, Cost & Product range, with lowest ownership cost of products, offering a first overhaul life of more than three lakh kilometers and achieving 10% revenue from an expanded customer base by 20102011. MISSION OF HV AXLES LTD. To provide superior value for money to customers through quality and cost effective Axles and related Products & Services To achieve sustainable growth by continuously seeking new business opportunities/challenges, employing contemporary technologies and maintaining a high performance work culture. CORE VALUE OF HV AXLES LTD. Integrity, Customer Focus, Corporate Citizenship, Passion for Engineering

Product of HVAL

Live Front Axle

All dimensions are in mm.

SL.NO. DIMENSION

DRG NO.

DRG NO.

HVA – 610

HVA - 1210

1

SPRING C / C DISTANCE

840

840

2

SPRING SADDLE - HOLE SIZE

17 DIA

17 DIA

3

DISTANCE FROM ANCHORPLATE (BRAKE) FACE TO17 DIA HOLE ON SPRINGSADDLE

430

430

4

HOLES ON SPRING SADDLE FOR U BOLT MOUNTING :

23

23

HOLE DIA

153

153

SPACE BETWEEN BOLTS U BOLT CENTRE

89

89

5

HUB BEARINGS SIZE (OD X ID ):

125 X 85.72 & 133.274 125 X 85.72 & 133.274 X 70 X 70

6

HUB LUBRICATION

GREASE

GREASE

7

WEIGHT OF AXLE (Kg)

415

435

8

GROUND CLEARANCE (With 9 X 20 Tyres)

281

281

9

TUBE SEC. & SIZE

CIRCULAR - OD : 120 , ID : 87

CIRCULAR - OD : 120 , ID : 87

10

BRAKES :

405 DIA X 100 WIDE DUAL AIR OVER HYDRAULIC

405 DIA X 100 WIDE DUAL AIR OVER HYDRAULIC

11

DRUM / WHEEL PCD :

275

275

12

WHEEL RIM FIXING DIA :(mm)

218.7

218.7

13

WHEEL BOLTS :

M 20 X 2.5 ( 8 N0S. )

M 22 X 2.5 ( 8 N0S. )

14

TRACK

1760

1991

15

RATED LOAD ( Kg )

4060

4060

16

TOE IN

0-3

0-3

17

RATED OUTPUT TORQUE IN FORWARD DIRECTION ( mKg ) PEAK / CONTINUOUS:

670 / 200

670 / 200

18

RATIO & DIA OF CROWN WHEEL & PINION

37 / 7 , 41 / 6 , 41 / 7 ( 345 mm DIA )

41 / 6 , 41 / 7 ( 345 mm DIA )

19 QTY / SPEC. OF OIL: 3.5 Litre ( 85 W 140 ) NOTE: Specifications are subject to change without notice.

4.35 Litre ( 85 W 140 )

Supplier Quality Assurance Quality Policy HV Axles Ltd. is committed to maximizing customer satisfaction and striving to achieve the goal of excellence by continual improvement through manufacture and sale of reliable, safe, cost effective and quality products as well as services of international standards, by using environmentally sustainable technologies for improving levels of efficiency and productivity within its plant & ancillaries. HV Axles Ltd. also has a commitment towards improving the quality of life of its employees, both within and outside its plant and offices, through improved work practices and social welfare schemes.

1 Environmental Policy HV Axles Ltd. is committed to minimize the adverse impact of its products, operations and services on the environment. Towards this end it shall strive to: (i) Establish sound environmental objectives and targets and a process of reviewing them. (ii) Comply with all applicable legal / regulatory and other environmental requirements. (iii) Use of environmentally sustainable technologies and practices for prevention of pollution and the continual improvement in environmental performance (iv) Conserve natural resources and energy by minimizing their consumption and wastage. (v) Minimizing waste generation, maximizing resource efficiency, recycling of material & preventing pollution. (vi) Building awareness across all sections of the workforce on environmental issues.

Supplier Quality system requirements General Requirements The ISO / TS 16949:2002 Standard is the foundation for the development of this manual. All automotive material suppliers to HV Axles Ltd. must comply with this standard and their related documents.

A minimum of ISO 9000 certification is required by all suppliers. All calibration Labs and test sources must be accredited to NABL (National Accreditation Board for Laboratories) or certified by TML/HV Axles Ltd. Third party registration to the applicable quality standard is evidence of conformance. HV Axles Ltd. also reserves the right to require self-assessment or assessment by an HV Axles Ltd. representative. Formal corrective actions in the standardized 8D are required from the supplier for any deficiencies / defect observed during inspection or assembly. The same has to be submitted within 15 days. These requirements of manual are part of the purchase order or contract issued by HV Axles Ltd. Acceptance of the purchase order/contract constitutes acceptance of the requirements of this manual. Additional quality requirements for parts, material and services specified on the purchase order, contract, drawings or specifications must be satisfied and take precedence over the requirements of this manual. Prior approval in writing from HV Axles Ltd. would be mandatory for suppliers for any hange in their approved process. Failure to comply with quality system requirements may result in suspension of supply and will require objection clearance from HV Axles Quality department before restoring the supplies HV Axles Ltd. reserves the right to revise this manual at any time without prior notice.

Supplier Selection Selection of a new supplier is done based on the assessment of supplier’s infrastructure, financial position, machine & tools, inspection facilities, availability of technical persons etc.

Third Party Certification HV Axles Ltd. shall perform supplier quality management system development with the goal of supplier conformity with ISO/TS 16949:2002. Conformity with ISO 9001: 2000 is the first step in achieving this goal. 2009, Hv Axles Ltd. Jamshedpur All rights reserved, Reproduction prohibited without written approval Unless otherwise specified by HV Axles Ltd., the suppliers to HV Axles Ltd. shall be third party registered to ISO 9001: 2000 by an accredited third party certification body. A roadmap for moving to ISO/TS16949:2002 is expected from each supplier.

Approved Raw Material Source All suppliers must procure raw materials from sources approved by HV Axles Ltd. / Tata Motors. For approved source see Appendix B

Control of Inspection, Measuring and Test Equipment The suppliers must have established and documented procedures to control, calibrate and maintain inspection, measuring and test equipment and devices used to demonstrate the conformance of product to the specified requirements. Inspection, measuring and test equipment should be used in a manner that ensures that the measurement uncertainty is known and is consistent with the required measurement capability.

Sub-Contractor Control

The supplier shall be responsible for any sub-contracted (outsourced or alternate) process and will have final approvals or inspection in place to ensure that all subcontracted components conform to specifications dictated by the drawings. Prior to any sub-contracting activity the supplier shall communicate to HV Axles Ltd. in writing & thereafter carry out fresh PPAP.

Declaration of Responsible Person by supplier It is the responsibility of the Supplier to report to HV Axles Ltd. the names of key individuals who are responsible for delivering a quality product to HV Axles Ltd.. There must be someone available with authority to make necessary decisions. Such person(s) of the supplier shall be responsible for signing minutes of meetings, giving authorization for lifting / scrapping nonconforming material etc. Any change in this responsibility shall be reported to HV Axles Ltd. immediately.

Sample Acceptance process Supplier’s business initiation takes place with the submission of the sample (2-5 nos) with all related documents. The sample is accepted or rejected based on its conformance to drawing and other requirements conformance as mentioned in 2.11 A sample checking report is made and a copy is made available to the vendor. All suppliers of production part materials are required to submit a PPAP to HV Axles Ltd. & receive approval prior to beginning of regular dispatches

PHOTO GALLERY OF H.V.A.L. PRODUCT

ASSEMBLY LINE

CONCLUSION The project assigned to me during my summer training in HV Axles Ltd was “REDUCTION OF HUB PLAY COMPLAIN IN ASSEMBLY LINE” At the time of starting of project rejection of axle due to hub play had increased from 5 axle per day to approx 20 axles per day out of 350 axles manufactured. To understand and reduce this complain I was given formal training of 10 days at Metrology lab to understand checking procedure and after that attached to supplier quality assurance group to analyze complain through Fish Bone diagram and to reduce the complain by finding root cause and closing it through effective CAPA. Main finding of my project was as follows:  Process followed in assembly at HV Axles were ok  Spacer tube quality was not ok and variations were found in some parameter which was critical from assembly and functional point of view. After controlling the variation it was observed that there was 80% reduction in hub play complain. This project had not been completed with such a great output if I have not got technical and functional support from Supplier Quality assurance group and other related departments.