INPLANT TRAINING REPORT

03.12.2014 - 18.12.2014

NAME: V.JAYAPRAKASH

ROLL NO: 11A118

BRANCH: AUTOMOBILE ENGINEERING

COLLEGE: KARPAGAM COLLEGE OF ENGINEERING

PROJECT LEAD: MR. VIDYA BHUSHAN PRASAD

DEPARTMENT HEAD:MR.PRASANTA SWAIN

TRAINING CO-ORDINATOR: MR. SURIYANARAYANAN.N

DECLARATION

I hereby declare that the report work entitled “IN PLANT TRAINING

REPORT” submitted to KARPAGAM COLLEGE OF ENGINEERING,

COIMBATORE is a record of an original work done by me at Daimler India

Commercial Vehicles private limited.

Date: Signature of student

BONAFIDE CERTIFICATE

This is to certify that the In-Plant training report is

a bonafide record of work done by

JAYAPRAKASH V

Register No: 11A118

B.E AUTOMOBILE ENGINEERING

KARPAGAM COLLEGE OF ENGINEERING

COIMBATORE

Mr. Suriyanarayanan Mr. Karunakaran

Mr. Prasanta Swain

TRAINING COORDINATOR PLANT- HR

Department Head

PREFACE

Currently I am pursuing a Bachelor’s degree in

Production Engineering at PSG COLLEGE OF TECHNOLOGY. I

am in my third year and therefore I would like to go for an In-

Plant Training in an established industry. The reason I

choose to do my training in Daimler is because I wanted to

benefit myself from the experience of knowing the

German way of running an industry, their industrial

culture, methodologies and ultimately gaining knowledge. I

wanted to do my training to experience the international

business across the world and to learn about an industry in

the global market, improve and develop new sets of skills.

My main goal is to improve my technical knowledge in

engineering and industries. This is why I choose to follow my

training here which helps me to learn and develop new sets

of skills and to experience working abroad.

In this report I will describe my experiences during my

training period. The report contains an overview of the

company and the activities, tasks and projects that I have

worked on during my training. Writing this report, I also will

describe and reflect my learning objectives and personal

goals that I have set during my training period.

ACKNOWLEDGEMENT

I owe a great thanks to many people who supported me

during the project. For this opportunity I thank:

Mr. Suriyanarayanan N (Training incharge and

internship coordinator):

I want to thank him for guiding me right from the

beginning, explaining about industry life and helping me out

with my doubts, in spite of his busy schedule. I would also

like to thank for allocating his time for showing and

explaining us about the entire Daimler plant.

Mr. VIDYA BHUSHAN PRASAD (Project Lead)

I would like to thank him, for being friendly and

constantly motivating me during my project sessions and

clearing my technical doubts, despite of his busy schedule.

My deep sense of gratitude to Mr. Karunakaran (Plant HR),

Mr. Mohan Raj (Plant HR – Head), Mr. Prasanta

Swain(EOL and FBV head) ,Mr. Swaminathan.G (Safety

department) and Mr. Ramesh priyan K V (safety

department), Daimler India Commercial Vehicles Pvt. Ltd.

Thanks and appreciation to the people and operators at the

company for their support.

I would also like to thank my department HOD, my

institution and faculty members without whom this training

would be a distant dream. I also extend my heartfelt thanks

to my family and well-wishers.

SYNOPSIS:

EXECUTIVE SUMMARY

COMPANY PROFILE

PROJECT UNDERTAKEN ON 5’S IMPROVEMENT IN FBV.

TRAINING DESCRIPTION

CONCLUSION

EXECUTIVE SUMMARY:

Daimler AG  is a German multinational automotive corporation.

Daimler AG is headquartered in Stuttgart, Baden-Württemberg,

Germany. By unit sales, it is the thirteenth-largest car

manufacturer and second-largest truck manufacturer in the world.

In addition to automobiles, Daimler manufactures buses and

provides financial services through its Daimler Financial Services

arm.

As of 2014, Daimler owns or has shares in a number of car, bus,

truck and motorcycle marques including Mercedes-Benz,

Mercedes-AMG, Smart Automobile, Freightliner, Western Star,

Thomas Built Buses, Setra, BharatBenz, Mitsubishi Fuso, MV

Agusta as well as shares in Denza, KAMAZ, Beijing Automotive

Group, Tesla Motors, and Renault-Nissan Alliance. The Maybach

marque was closed at the end of 2012, but was revived in

November 2014 as "Mercedes-Maybach", an ultra luxury edition

of the Mercedes-Benz S-Class.

COMPANY PROFILE

There is a great desire among Indian customers for a

world-Q class truck which they can proudly call their own.

The need of the hour is a truck that will give them a high

value on their investment. With this perspective, Daimler AG

incorporated Daimler India Commercial Vehicles (DICV) as a

wholly-owned subsidiary in 2008, in order to create world-

class products, to be manufactured indigenously in

partnership with Indian suppliers.

Currently, Daimler is present in the Indian market with the

Mercedes-Benz brand of trucks. Beginning 2012, DICV

initiated production of commercial vehicles under the

uniquely Indian brand ‘BharatBenz’. Towards this objective,

DICV had invested Rs.4,400 crores in establishing a state-of-

the-art manufacturing plant at Oragadam near Chennai,

including an extensive research & development arm.

Subsequent to the launch of an all new brand "BharatBenz",

DICV set to take its vision and mission into the market. After

a successful Premiere of its trucks in March 2012, DICV

inaugurated its state-of-the art plant at Oragadam, near

Chennai, in April 2012. Later, in June 2012, it began

production of the Heavy-duty trucks. This was followed by a

slew of dealerships that were inaugurated. On 26 September

2012, DICV launched its Heavy-duty trucks after an intense

period of testing. February 2013, witnessed the launch of the

Light/Medium duty range. . DICV also launched the new

FUSO range of trucks at its plant on 23 May 2013, as part of

its well-coordinated Asia Business Model.

Daimler India Commercial Vehicles Pvt. Ltd (DICV), a 100%

wholly owned subsidiary of Daimler AG, on 10th July 2013,

rolled out the 5000th truck from its plant at Oragadam, near

Chennai. DICV is stabilizing its production line of all its

launched models. Currently, DICV produces the 2523, 3123,

2528, 914, 1214 & 1217 (Heavy, Medium/Light-duty rigid &

tipper trucks) with several variants.

ON MARCH 6TH 2014, Daimler laid the foundation stone for its

new bus plant.The new Bus manufacturing plant is spread

across an area of 27.91 acres will be constructed within the

existing premises of DICV. The bus plant will manufacture

and assemble buses under the Mercedes-Benz and

BharatBenz brands and will be completed by the 2nd quarter

2015. The DICV plant in Oragadam will thus be the only

Daimler Truck plant worldwide, that manufactures three

brands of Trucks and Buses, as well as engines under one

roof. Daimler India buses will be offered in 9t, 16t and above

16t categories in both front and rear engine configurations.

An investment of INR 425 Cr has been earmarked for the bus

project in India for an installed capacity of 1500 units in the

initial phase. The capacity can be further expanded to 4000

units subsequently. On 10th April 2014, Daimler’s BharatBenz

trucks rode on high gear and crossed 10,000 units sale. In

the beginning of 2014, Daimler achieved the following:

Crosses sale of 1,000 units in a month in March 2014

Sales up by 67.4% in the first quarter of 2014

Gains 5.3% Market Share in the addressable market

above 9T segment

STUDY ON 5’S:

5’S basic powerful tool for improving quality.

5’S is fundamental clean up of the work environment .

Clean up leads to improved efficiencies improved quality

and reduced costs.

5’S is a technique that provides the foundation for visual

management.

THE 5’S :

SORT.

SET IN ORDER.

SHINE.

STANDARDIZE.

SUSTAIN.

SORT:

1. Sort through items in the area.

2. Keep what is needed.

3. Eliminate what is not needed.

4. Reduce the number of items to the quantity.

SORT CHECKLIST:

Review and use the Item Disposition List as the criteria for

red tagging.

Gather needed supplies, including Red Tags.

Set up a red tag Holding area. Mark the location, identify a

red tag holding area manager, write and post standards and

rules for disposition.

Create and implement initial sort plan to purge the for

unnecessary items.

Fill out a log sheet listing all items removed from the area.

Continue to Sort, through Red Tagging,as the other 5S

System steps are implemented.

SET IN ORDER:

Analyse the current situation by updating the Workplace

Scan Display Checklist.

Target specific issues.

Decide where things belong.

Make it visually obvious where and how things belong.

SET IN ORDER CHECKLIST:

Determine the criteria for relocating out of place items.

Identify and gather needed supplies (bins, labels, tags,

colour tapes, etc).

SHINE:

Check to see if everything is in its place.

Check to see if you need to replace anything.

Check everything; see if deep cleaning, repair, or

replacement is needed.

Shine and inspect through cleaning every shift.

SHINE CHECKLIST:

Systematically determine targets and assignments.

Determine appropriate cleaning methods.

Get the right tools and supplies.

Perform initial cleaning of targets.

STANDARDIZE:

Identify and categorize a condition to standardize.

Assign responsibilities for condition maintenance.

Maintain and monitor those conditions.

STANDARDIZE CHECKLIST:

Prepare the standardization chart.

Identify standardization issues.

Identify and attain desired conditions for Sort, Set in Order,

and Shine.

Make all standards clear and obvious.

Monitor and improve all standards.

SUSTAIN:

The first four pillars rely on sustain .

Stick to the rules to keep the workplace well-ordered

and run by agreed-upon standards.

Ensure that all workers have been trained in the

procedures.

SUSTAIN CHECKLIST:

Create a plan for Sustaining.

Ensure that you have management support for the

plan.

Inform everyone in the area about the 5S standards

and their purposes.

STATIONS IN FULLY BUILT VEHICLE:

STATION -1 (Chassis preparation).

STATION -2 (Load Body mounting).

STATION -3(U-Blot /Hydraulic /

Mudguard fitment).

STATION -4(Load body fastener

tightening).

STATION -5(SUPD & Wheel Choke

fitment).

STATION -6(Mudguard tightening).

STATION -7(Quality Gate & In-line

Rework).

Rework Bay-1.

Rework Bay-2.

Logistics bay-1.

Logistics bay-2.

STATION-1:

Chassis preparation for vehicle is done here for

both HDT (Heavy Duty Trucks) and MDT (Medium Duty Trucks)

Vehicles.

Operation:

1. Workers remove tail lamp by removing bolts .

2. Balata pasting. Balata is aligned properly along

the chassis.

3. Workers make note of time in and

Time out vehicle.

4. Documentation checking.

SAFETY MEASURE:

1. Safety gloves.

2. Safety shoes.

TOOLS USED:

1. Balata clam.

2. Torque wrench.

3. Cable tie cutter.

4. Ring spanner.

STATION-2:

Load body is mounted for both MDT and HDT at this

station where respective body for the vehicles are supplied

through logistics bay 1.

Operation:

From logistics bay 1 the body is carried to station

2 with a help of the crane and it is mounted to chassis and it is

literally clamped. The various types body mounted are rock, box

and Rigid.

SAFETY MEASURE:

1. Safety shoes.

2. Safety gloves.

3. Goggles.

4. Safety helmets.

STATION -3:

In this station clamping of U-Bolt and Mudguard fitment is

done.

Operation:

The workers clamp the U-blot by using tools like pneumatic gun

and spanners where the materials are supplied through Logistics

Bay. After clamping with the help of the tools the vehicle is

moved to next station using Easy mover.

TOOLS USED:

1. Torque wrench.

2. Ring spanner.

SAFETY MEASURE:

1. Safety shoes.

2. Safety gloves.

3. Safety helmets.

STATION-4:

In this station fitted load body fastener

tightening is done .

Operation:

The fitted load body is fastener tightening is

done using pneumatic gun and ring spanner along the chassis

and fitting of back light is done which is removed in the station 1 .

After clamping with the help of the tools the vehicle is moved to

next station using Easy mover.

TOOLS USED:

1. Torque wrench.

2. Ring spanner.

3. Spanner.

SAFETY MEASURE:

1. Safety shoes.

2. Safety gloves.

3. Safety helmets.

STATION -5:

In this station SUPD (Side Under Protective Device ) and Wheel

choke Fitment is done .

Operation:

Fitting protective guards along both sides of

vehicle and and fitting wheel choke along both sides . After

clamping with the help of the tools the vehicle is moved to next

station using Easy mover.

TOOLS USED:

1. Torque wrench.

2. Ring spanner.

3. Spanner.

SAFETY MEASURE:

1. Safety shoes.

2. Safety gloves.

STATION -6:

In this station the clamped mudguard is tightened and quality of

the mounted body is checked.

Operation:

The Mudguard tightening is done using

pneumatic spray gun and quality of the mounted body is checked

other than paint all the quality of the mounted body is checked

and after checking the quality it is moved to the next station.

TOOLS USED:

1. Torque wrench.

SAFETY MEASURE:

1. Safety shoes.

2. Safety gloves.

STATION -7:

In these station quality and In-line rework are

done.

Operation:

In this station minor rework which can done within 10

minutes are done at these station and quality of the mounted

body is checked . If quality is checked without any issues then

the vehicle comes under FTT. If it is not under the quality it is

moved to rework bay which doesn’t comes under FTT.

TOOLS USED:

1. Hammer.

2. Pneumatic spray gun.

SAFETY MEASURE:

1. Safety shoes.

2. Safety gloves.

REWORK BAY:

In this station major rework like painting are done both on the

body and along the chassis and inside the chassis. The rework

which cannot be done within 10 minutes are done here.

TOOLS USED:

1. Torque wrench.

2. Ring spanner.

3. Pneumatic spray gun.

4. Hammer.

SAFETY MEASURE:

1. Safety shoes.

2. Safety gloves.

3. Goggles.

LOGISTICS BAY:

Through Logistics Bay materials are supplied to the respective

station on the requirements for every station .

5’S Improvement In FBV Shop:

ARRANGEMENT ON PNEUMATIC HOSE PILLARTOOL

OLD LOOK NEW LOOK

OLD TOOL TROLLY FOR MATERIAL RELOOK

Before After

LOGISTIC KIT BOX AREA PAINTING FOR SURFACE MARKING

Before After

Before After

BELT & D-HOOK STORAGE

TROLLEY

SUPD TROLLEY

MODIFICATION

Before After

CONCLUSION:

Thus the training at DICV was successfully completed with the guidance of the training coordinator and FBV department. I personally gained some technical knowledge about commercial vehicles, their working, parts, process layout, industry and its management, the problems that arise while assembling even a minute part etc. I look forward to join this company if given an opportunity in the near future. And if I am recruited, I would assure that I will be proactive and work for the progress of this

esteemed company.