1. PROJECT REPORT ON
PRODUCTION ENGINEERING DEPARTMENT-CS
B.Tech (ME) 2012-2016
UNDER THE GUIDENCE OF:-
Mr. MAYUR GANDHI
(-TCF Logistics Centre)
TATA MOTORS LTD. LUCKNOW
Raj Kumar Goel Institute of Technology (UPTU), Ghaziabad
TATA MOTORS LTD, LUCKNOW
3. Industry Profile - TATA Motors
4. TATA Motors - Lucknow Plant
5. Productivity Service Department (PSD) department
6. What Is Production Engineering?
7. Production Engineering department- TATA
8. Vision, Mission & Core Values
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 assembly
all for the seamless working require the PE Department which creates all the fixtures
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-
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.
4. Industry Profile – TATA Motors
TATA MOTORS LTD.
Founded 1945 by J. R. D. Tata
Headquarters Mumbai, Maharashtra, India
Area served Worldwide
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
5. TATA Motors Vehicle range
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.
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.
7. TATA Motors - Lucknow Plant
Currently, the following manufacturing and assembly units exist within the
Assembly Line 1
ERC Proto Shop
PE and Transmission shop
Integral Bus Factory (IBF)
Assembly Line 2
Assembly Line 3
Body-In-White (Welding Shop)
8. 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 mold 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.
9. Production Engineering Division (PE)
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.
10. Z&B 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. 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.
CNC 84 Horizontal Surface Grinder
Maximum grinding length 800 mm
Maximum grinding width 400 mm
Electromagnetic table 600 x 400 mm
Control CNC Siemens Sematic Op 26
11. BFW CONVENTIONAL MILLING-
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.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
Knee Type Milling Machine
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.
12. CHEVALIER SURFACE 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.
FSG-1228ADIII Automatic Precision Grinder
13. CONVENTIONAL LATHE-
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.
Four Jaw Chuck Conventional Lathe Machine
14. GOODWAY CNC TURNING-
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.
POWER LATHE CNC FOR BETTER PRECISION
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.
15. ITL POWER SAW-
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 BAND TYPE SAW FOR LARGE LATERAL SECTIONS
Cutting arm of high tension bearing capacity with preloaded adjustable antifriction
• 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.
16. RADIAL DRILLING 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 maneuver 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 swiveled out of the way.
Self-Feeding Radial Drilling Heavy Duty Machine
• Counter Sinking
• Counter Boring
• Spot Facing
17. STUDER S242-
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.
CNC CYLINDERICAL GRINDER
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.
18. DECKEL MAHO-
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.
GILDEMEISTER DMU 80 T MACHINING CENTER-UNIVERSAL
G00 - Rapid Traverse
G01 - linear interpolation of tool.
G21 - Dimensions in metric units.
M03/M04 - spindle start (clockwise/counter
T01 M06 - Automatic tool change to tool 1
M30 - program end.
19. BFW MACHINE-
Milling is the machining process of using rotary cutters to remove
material from a workpiece advancing (or feeding) in a
direction at an angle with the axis of the tool. 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 default machining
strategy of using any combination of milling and turning within
the same work envelope.
CNC MILLING MACHINE VERTICAL
20. TOOL HEIGHT MACGINE-
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.
TOOL HEIGHT MEASURING MACHINE
21. MUFFLE FURNACE-
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).
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.
HEAT TREATMENT PROCESS OF THE METAL
22. TANAKA GAS CUTTER-
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 favored, for fabricating some types of
GAS CUTTER AND PHOTO TRACER TYPE
23. 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
24. 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.
25. 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.
26. 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.
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
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.