By:- Rajat Pundir R

STUDY OF PROCESS &MAKING OF PROCESS SHEETS PLANT ENGINEERING DEPARTMENT This is the department on which I have worked on. It is an agency which takes care of the pre-engineering activities essentially for in-house components & assemblies of a New Product / New Project, Capacity Enhancement, New Technologies, Method / Process improvements & Engineering Changes to the existing products.

MAIN ACTIVITIES : Feasibility study / Budgeting & sanctions for any new Product / Project. Process design and Productionization of the Product & Projects. Plant & Shop Layouts Management. Facilities, Resource & Equipment Planning & Arrangement Tooling Design and Management Work Measurement, Line Balancing & Manpower Planning Productivity Management New Product introduction through APQP / MPDS route SAP and Process BOM Management KAIZEN Activities & Improvements

PLANT ENGINEERING FUNCTIONS Process Engineering Process Definition & Compliance Change Management Concern Resolution APQP for new Projects Process Improvements Industrial Engineering Work Measurements Manpower Planning Productivity Management Layouts Management Ergonomics & Improvements

INTRODUCTION TO BOLERO SHED BOLERO shed is a place where assembly of BOLERO 4- wheeler is done. This shed consist of: TRIM LINE FACIA LINE CHASSIS LINE ENGINE LINE MAIN LINE

TRIM LINE: Vehicle Body comes from Paint Shop & goes to Trim Line where various operations on body are carried out like Floor Carpet Fitment, Battery Fitment, Trim Pads Fitment, Body Doors Fitment, AC Fitment, Instrument Panel Fitment, Tapping of seat holes, Car Roof Covering, Fitment of various Harnesses for Vehicle’s Electrical Functions, etc. FACIA LINE: Vehicle’s Facia after getting separated from Body goes to Facia Line where various Operations are carried out on Facia like AC Condenser fitment, Air Deflector Fitment, Reservoir Fitment, Modulator Fitment, Euro Tubes Fitment, Headlamp Fitment, Side Indicator Fitment, etc

CHASSIS LINE: Vehicle’s Chassis enters the chassis line after inspection and then various operations like Rear & Front Axle Fitment, Front & Rear Shock Absorber Fitment (Coil Spring & Leaf Spring), Steering Gearbox Fitment, Stabilizer Bar Fitment & Fuel Tank Fitment on Chassis are carried out. ENGINE LINE: In Engine Line, Engine wiring Harness is fitted to the Engine along with Speedo Sensor. Bell Housing attached to a Gear Box is also coupled to an Engine & Clutch Plate too is fitted. Then Starter Motor and Power Steering Pump & Reservoir are also fitted.

MAIN LINE: In Main Line, Various Operations like all the Bundy Tubes Fitment, Fuel Line Fitment, Radiator Fitment, Body Drop, Facia Drop, Tyre Fitment, Handbrake Fitment and many other Important Operations are carried out. FAI CAI WRAP RFI

INTRODUCTION TO PROCESS SHEET Process sheet is used when there is some problem at the line & helps the engineer & operator for doing the specific operation.

It is made with the help of the following 2 things: (1) Dynamic Control Planning (DCP) (a) Process Flow Chart (PFC) (b) Control Plan (CP) (2) Bill of Materials (BOM)

BILL OF MATERIALS (BOM) BOM is a term which is used for Bill of materials. Bill of Material is a document which contains the information regarding: Part No. Part Description Quantity required of that part for a particular product

As in Mahindra & Mahindra there are 4 different BOM’s for 4 different models of Bolero namely: Di Plus/Longer SLE SLX

BOM is a very sensitive document and must be updated as soon as possible and with precision, because it is directly related with the Product Quality Costing of the Product Safety of the Customer

I made total 407 process sheets of bolero(for all models). I worked at shop floor on five lines, names are given below:- Trim line Facia line Engine line Chassis line Main line

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