Industrial Training

at

General Motors India Pvt. Ltd.

VIVEK NIRWAL

GBPEC

PRODUCTION ENGG.

Batch:- 2011-2015

Content

1. General Motor Corporation

1.1 Introduction

1.2 Chevrolet history

2. General Motors India Pvt. Ltd.

2.1 GMI-HALOL

2.2 GMI products

2.3 Major areas in GMI

3. Project Done at GMI-HALOL

3.1 To increase productivity in paint shop

3.2 Defect analysis in Paint Shop

3.3 Process study and Time study in Paint Shop

Contd…

4. Aids to Manufacturing (Various approaches for efficient functioning of the organization)

4.1 Andon concept

4.2 kanban concept

4.3 kaizan concept

4.4 VIN Number

4.5 AGV

4.6 QCOS

4.7 PFMEA

5. Bibliography

• American multinational corporation

headquartered in Detroit, Michigan.

• Designs, manufactures, markets and

distributes vehicles and vehicle parts.

• Produces vehicles in 37 countries under ten

brands.

• Chevrolet, Buick, GMC, Cadillac, Opel,

Holden, Vauxhall, Wuling, Baojun, Jie Fang,

and UzDaewoo.

• Has strategic partnerships:

Fiat Auto Spa of Italy

Daimler Chrysler AG & BMW of Germany

Toyota Motor Corporation of Japan

Suzuki Motor Corporation of Japan

1.1 Introduction to General Motors

1.2 Chevrolet history

1909- Louis Chevrolet, William Durant came up with the car design

1911- Establishment of the Chevrolet Motors Car Company

1912- Chevrolet launched its “Classic Six”-Top speed of 65 mph

1914- Chevrolet “bowtie” logo appears for the first time

1918- First Chevrolet truck sold. Chevy joins GMC

1927- Chevrolet outsold Ford in the US by topping 1million units

1965- First to build over over 3 million cars and trucks in a single year

1979- A momentous year as Chevrolet rolled out its 100 millionth car

2014-Part of the global landscape selling more than 150 million cars.

2.1 General Motors India (Halol)

Incorporated on 15th August 1994

100% subsidiary of General Motors Corporation (GMC)

Site area : 172 Acres

Plant area : 68,000 m2

Total plant size : 44000 m2

Utilized area : 27000 m2

Start of Production : June 1996

Capacity : 1,80,000 unit / year

Management sys. : GM Global Manufacturing System

: ISO 9001

: ISO 14001

2.2 Products of General Motors India

(Halol,Vadodra)

1) CRUZE (J-300)

Pros

Chevrolet Cruze Pros :

1. Striking exterior appearance

2. Equipped with several impressive convenience aspects

3. Engine performance is good with decent acceleration and pick up

4. Available in both manual and automatic transmission gearbox

5. Level of safety standards are at par with other sedans

2) TAVERA (I-163)

Pros

Chevrolet Tavera Pros :

1. Spacious internal cabin

2. Less expensive price tag

3. Decent ground clearance

4. Dual tone exteriors

5. The 10-seater option

Contd…

3) ENJOY (CN-100)

Pros

Chevrolet Enjoy Pros:

1. Lavish interior space with luxurious seating arrangement

2. Ideal vehicle for families

3. Budget friendly price tag adds to the advantage

4. Fuel economy of diesel version is impressive

5. Utility aspects are at par with other MPVs

Contd…

2.3 Major Areas In GMI

General Motors India, Halol plant is divided into five major departments:

• I. Press Shop

• II. Body Shop

• III. Paint Shop

• IV. General Assembly

• V. QualityQuality

Press shop

Body shop

Paint shop

GA shop

I. Press Shop

Starting point of the car manufacturing process

Major equipment In use are:

A)- Dies

B)- Flywheels

C)- Robot Arms

D)- CNC Machines

Scope of work

Has function of converting blank metal sheets into different shapes as required

Produce the outer skin panels of I-163 & outer and inner panels for CN-100

These parts employ about 120 dies & 4 presses

These 4 presses are of :-

• 2250T- Press for forming or drawing operation

• 1000T- Press for trim operation

• 1000T- Press for trim and pierce operation

• 1000T- Press for final flanging operation

Employs a Die-spot press used for checking of dies

II. Body shop

Build of a car starts with body shop

Body parts are assembled by spot

welding

Body shop can be broadly divided

into two parts:

a) Weld Sub-Assembly (WSA) line

b) Body in White (BIW) line

Scope of work

Consists of three separate lines for I-163 Tavera, J-300 Cruze and CN-100 Enjoy

The BIW line consists of 20 stations required for the body to take the final shape

Final body passes through DRL station under the quality team

III. Paint Shop

Function of the paint shop is to provide an even coat of paint upon the car body

without any defects and with a luster or shine

From customer point of view, it is one of the most important processes

Paint shop is kept as a company secret in a number of automobile industries

Paint shop is further divided into:

: Metal Body Paint shop

: Plastic Part Paint shop

Paint Ingredients like binders, pigments, solvents, additives are added into paint to

enhance paint property

IV. General Assembly Shop

At GM, Halol currently there are two lines running parallel :

• Truck line (I-163) dedicated for production of Tavera

• T&J car line producing Cruze (J-300) and Enjoy (CN-100) simultaneously

On Truck line there are 38 stations, out of which 18 are on trim line and 20 are on

Chassis line

There are total 41 stations in T&J Car Line, out of which 21 are on trim line and 20

are on chassis line

In trim line the first 10 stations includes installation of electrical harnesses, floor mat,

roof mat, air ducts for intake, head lamps, parking lights, fluid lines etc

In next 10 stations suspension, gear box lever, cockpit, steering, wind shield (front

and rear), front and rear bumper etc

The car is then moved to the chassis line where the crucial parts of the car are bolted

and fitted in the body

The car gets tires, seats, and all sorts of fluids wherever required like brake fluid,

coolant, engine oil etc.

The final status of the car is checked by software called NGFTT (New generation

flashing testing tool).

Scope of work

The variants manufactured at GM , Halol are:-

• CN-100 Enjoy has three feature variants – LS, LT and LTZ varied into 6, 7

and 8 seated With two engine variants of Petrol and Diesel

• J-300 Cruze has two feature variants of – LT and LTZ with engine types as

Petrol and Diesel

• I-163 Tavera is the longest running production vehicle in the history of GMI,

It has feature variants of five types – Base, B1, B2, LT, and Ambulance with

diesel engine

GA shop thus handles volumes of production

Contd…

Trim Line Chassis Line

V. Quality Shop

Quality operation is divided into two parts:

DRL: To repair any defects that have been left out

: In case of a major fault the car is made offline and repaired , which is

referred as Direct Run Rate

SIP : (Standardized Inspection Process) After GA shop, it is checked visually and

passed through a series of test to assure its quality

: The following tests are carried out;-

Caster, Camber and Toe : The wheels checked using various sensors, and

accordingly altercations are made

Dynamic Vehicle Testing : The ECM (Engine Control Module) of the car is checked,

it is accelerated, braked for a specified

Squeak & Rattle : The vehicle on aspecially made track to check its feasibility on all

road conditions

Head Lamp Alignment : It is checked via a machine

Water Test : The vehicle is showered with water to check for leakages

Then goes to CARE (Customer Acceptance Review and Evaluation) line.

Contd…

DRL Line SIP Line/CARE Line

3. Project Done at GMI-Halol

3.1

To increase the productivity in paint shop

Observation 1:- The elpo and primer sandings are done by operators with the bare

sand papers

Harmful effects:-

• This may injure the fingers of operators

• It takes much time in sanding the body of car

Contd….

Recommendation:-

• Well suited sandpaper holder should be used to hold the sand paper

• Sandpaper holder for complex shapes should be used

• Operators should be given proper gloves to wear which reduces the chances

of injury to fingers

Contd…

Observation 2:-While painting the plastic parts in plastic part paint shop, only one

type of gun is used to paint the both smaller & larger parts which

causes the wastage of paint

Contd…

Recommendation:- A conical shape nozzle should be mounted on gun ends for

smaller parts like valence, osrvm, garnish and spoilers in order

to reduce the wastage of paint

• The new design is more ergonomic

Contd…

Observation 3:- The door fixtures are attached to body panel at station 0 in paint

shop just after elpo baking oven and at station 2 elpo sanding is

done to the doors

Recommendation :- The fixture trolley should move from fixture station to the door

sanding station no. 2 in order to save the cost of a station

Benefits :-

• This reduces the cost of electricity

• Reduces manpower

• Reduces downtime

Contd…

Observation 4:- Both side fixtures are kept on left side of body panel and fixtures

are thrown to the right sides of body.

Effects:-

• May cause damage to body

• It takes time to shift the fixture to respective sides

Recommendation:-

• There should be different trolleys for fixtures on respective sides

3.2 Defects analysis in Paint Shop

Defects generally found at body buffer:

Rust

Hairline crack

Contd…

Excess sealer

Chip

Contd…

Dent

Weld bud (spatter)

3.3 Process study in Paint Shop

Process flow (metal body paint shop):-

I) Pre-Treatment:- In this process the car is dipped in various tanks and held

at various angles to clean the body completely

Loading area

Spray wash

Immersion wash

DI wash spray

Activation

Immersion phosphate

ELPO

ELPO Oven

PT Line Flow Diagram

Contd…

Station 01 – Immersion degreasing: This process removes oil; metal and grease

from car body by immersing the entire car body in a degreasing solution

which is a basic solution of NaOH at a temperature of about 55 to 60’C

Station 02 – Spray rinse soft water : Here soft water is sprayed to remove

degreasing material (NaOH) from car body.

Contd…

Station 03 - Spray rinse activation: This process is used to activate car body by

freeing all ions from it before Phosphating

Station 04 - Spray Phosphate: Phosphating process takes place for rust prevention

and uniform paint concentration

`Contd…

(II) ELPO line – It is the process of depositing basic paint on all the car body parts.

Elpo process is Cathodic Electro Deposition process carried out to

prevent rust

Contd…

(iii) Oven - After the ELPO process the car is baked in oven to make the coating

bond strongly with the car body

– Oven has five zones: Radiation (190’C), Convection 1 (172’C),

Convection 2, Convection 3 and forced Cooling (60’C)

Contd…

(iv) Sealing – Here Sealant is applied to prevent water leakage and reduce

vibrations.

Apart from sealant, PVC is also applied in the underbody section to

prevent chipping and deadener is applied on the floor so as to

reduce vibrations and prevent inflow of engine heat.

Contd…

(v) Primer application - Before applying the final paint, primer is applied so that

the top coat can adhere strongly

Initially solvent wiping and tag rack wiping is done

manually so as to remove all accumulated dirt prior to

paint application

The inner parts of the car body undergo primer application

manually using electro static spray gun

The outer parts of the car body are applied with primer by

the help of three robots.

The last stage is flash off where the primer is dried and

finally sent to primer oven for baking

Contd…

(vi) Top coat application - Top coat is the final colour that has to be applied on the

car body.

It consist of two process Base coat and Clear coat

Clear coat is basically varnish is used to give a shining effect on the body

The last stage is flash off where the paint is dried and then sent to top coat

oven

In case of two coat models the process is repeated twice

Contd…

(vii) Finesse it and Cavity wax - Final touch up stage where the painted car body

is thoroughly inspected by the quality team for any damage of paint in terms of

scrapping, unevenness or shades and if required repairs are undertaken

Quality checks related to DRL, DRR, are done here before sending the painted car

body to General Assembly shop for final assembly

Wax is applied in the interior where paint cannot reach properly so as to avoid

rusting.

Contd…

Contd…

Process flow (Plastic part paint shop):-

• All the plastic parts such as bumpers, door handles,OSRVM, spoilers, grills,valence.

undergo the painting process

• Masking process is followed in case of bumpers which are not to be painted

completely

• The final stage is flash off to ensure the coat of paint to be permanent followed by

oven for baking

• The processes carried for primer and paint in this shop resemble those in the Metal

Body Paint shop

Flow diagram of PPPS

Oven baking

Sanding & Buffing Spot repair

Conductive Primer application

Top coat application Flash off

Unpacking

Wiping Loading

Contd…

Contd…

4. Aids to Manufacturing

4.1 Andon Concept

Refers to a system used to notify management, maintenance, and other workers of a

quality or process problem

Gives the worker the ability, and moreover empowers them, to stop production when

a defect is found, and immediately call for assistance

Common reasons for manual activation of the Andon are part shortage, defect

created or found, tool malfunction, or the existence of a safety problem

It facilitates the identification of the root cause of the problem

Some applications of the Andon concept provide a visual display of the status of a

run, or downtime tracking

Andon Board Control Switch Andon Board

4.2 Kanban Process

Kanban means signboard or billboard which is a scheduling system for lean and just-

in-time (JIT) production

Kanban is a system to control the logistical chain from a production point of view

Developed by Taiichi Ohno at Toyota

One method through which JIT is achieved

Part of an approach where the "pull" comes from the demand

Contd…

Ensures that intermediate stocks held in the supply chain are better managed, and

are usually smaller

Kanban cards are a key component of kanban and signal the need to move materials

within a manufacturing or production facility

Trigger the replenishment of that product, part, or inventory

Kanban cards therefore help create a demand-driven

system.

4.3 Kaizen

Refers to activities that continually improve all functions, and involves all employees

from the CEO to the assembly line workers

The cycle of kaizen activity can be defined as:

• Standardize an operation and activities,

• Measure the operation (find cycle time and amount of in-process inventory).

• Gauge measurements against requirements.

• Innovate to meet requirements and increase productivity.

• Standardize the new, improved operations.

• Continue cycle.

4.4 VIN Number

VIN Number (Vehicle Identification Number)

4.5 AGV (Auto Guided Vehicle)

Mobile robot that follows markers or wires in the floor, or uses vision, magnets, or

lasers for navigation

Used in industrial applications to move materials around a manufacturing facility or a

warehouse

Automatic guided vehicles can be grouped into four general types:-

• Tow vehicles (tuggers)

• Unit load carriers

• Carts

• Fork vehicles

Increase efficiency and reduce costs

by helping to automate a manufacturing

facility or warehouse

4.6 QCOS

Quality Control Operation Sheet

It is a sheet maintained for every operation taking place in every shop

Includes the the job name , part number, job number, name of tool used and tool

number

Also includes the time taken to do the job

Is important to maintain as in case of any fault, the inspection team can directly

revert back to the station where the job was done and look for the reason

It is easy to find which tool was not working well and thereby caused the problem

Essential part of the quality check procedure and acts as a powerful tool to maintain

quality standards

Contd…

4.7 PFMEA

Process Failure Mode Effects Analysis

Helps to establish the impact of the failure, and identify and prioritize the action items

with the goal of alleviating risk

PFMEA evaluates each process step and assigns a score on a scale of 1 to 10

Severity — Assesses the impact of the failure mode (the error in the process)

Occurrence — Assesses the chance of a failure happening

Detection — Assesses the chance of a failure being detected

RPN — Risk priority number = Severity * Occurrence *Detection

RPN=S*O*D

5. BIBLIOGRAPHY

Guidance by mentors

GMI ME department study material

Guidance by operators and workers

www.gm.com

www.wikipedia.com

www.google.com