elimination of mount engine noise

ENGINE MOUNT NOISE 2012

GLOBAL INSTITUTE OF TECHNOLOGY

Page 1

INTRODUCTION

A promise is promise and I kept my promise- this is the

historical statement which Mr. RATAN TATA said when he

launched his ambitious TATA NANO; the peoples car in India

on 23 rd march 2009. Tata has always given value products in

the Indian Car Market whether it is path breaking recently

launched TATA NANO or TATA INDICA (which created great

brand into the car industry in the diesel segment).

TATA GROUP OF COMPANIES The Tata group comprises over 100 operating companies in seven business

sectors: communications and information technology, engineering, materials,

services, energy, consumer products and chemicals. The group has operations in

more than 80 countries across six continents, and its companies export products

and services to 85 countries.

Every Tata company or enterprise operates independently. Each of these

companies has its own board of directors and shareholders, to whom it is

answerable. There are 31 publicly listed Tata enterprises and they have a combined

market capitalization of about $80.61 billion (as on July 12, 2012), and a shareholder

base of 3.6 million. The major Tata companies are Tata Steel, Tata Motors, Tata

Consultancy Services (TCS), Tata Power, Tata Chemicals, Tata Global Beverages, Tata

Teleservices, Titan, Tata Communications and Indian Hotels.

Founded by Jamsetji Tata in 1868, Tatas early years were

inspired by the spirit of nationalism. Tata Industries was set up by

Tata Sons in 1945 as a managing agency for the businesses it

promoted. Following the abolition of the managing agency system,

Tata Industries' mandate was recast, in the early 1980s, to promote

Tata's entry into new and high-tech businesses.



Page 2

Tata Industries has initiated and promoted Tata ventures in several sectors,

including control systems, information technology, financial services, auto

components, advanced materials, telecom hardware, airlines and

telecommunication services. In more recent times, its pioneering spirit has been

showcased by companies such as TCS, Indias first software company, and Tata

Motors, which made Indias first indigenously developed car, the Indica, in 1998 and

recently unveiled the worlds lowest-cost car, the Tata Nano.

Areas of business Tata Industries has two operating divisions which function as independent

profit centers:

Tata Strategic Management Group: An independent management

consulting division that assists Tata as well as non-Tata companies in

enhancing their competitive edge.

Tata Interactive Systems: Among the world's leading e-learning

organizations, it offers services such as project management, instructional

design and graphics, and technical know-how.

Tata Motors makes passenger cars, multi-utility vehicles and light, medium and heavy commercial vehicles.

Passenger cars: compact Tata Indica in 1998, the sedan Indigo in 2002 and

the station wagon Indigo Marina in 2004. Tata Motors also distributes Fiats

cars in India.

Utility vehicles: The Tata Sumo was launched in 1994 and the Tata Safari in

1998.

Commercial vehicles: The commercial vehicle range extends from the light

two-tonne truck to heavy dumpers and multi-axled vehicles in the above 40-

tonne segment.

Passenger buses: The Company also manufactures and sells passenger buses,

12-seaters to 60-seaters, in the light, medium and heavy segments.

Tata Industries' main activities are:



Page 3

To promote Tatas entry into new businesses

To maintain shareholding in promoted companies

To invest in operating companies to facilitate growth

Board of directors

Ratan N Tata, Chairman Farrokh K Kavarana RK Krishna Kumar Ishaat Hussain S Ramadorai B Muthuraman Prasad R Menon

Ravi Kant Cyrus P Mistry Kishor A Chaukar, managing

director KRS Jamwal, executive director RR Bhinge, executive director

Tata Group of Companies

Chemicals

Tata Chemicals

Rallis India

Tata Pigments Limited

General Chemical Industrial

Products

Brunner Mond

Advinus Therapeutics

Magadi Soda Company

Consumer Products

Tata Salt

I-shakti

Casa Dcor

Tata Swach

Tata Global Beverages

Eight Oclock Coffee

Tata Ceramics

Infiniti Retail

Tata Tea Limited is the world's

second largest manufacturer of

packaged tea and tea products.

Tetley

Tata Coffee

Tata Industries

Titan Industries

Trent (Westside)

Crom

Tata Sky

TajAir

Tata International Ltd.

Tanishq

Tata Refractories

Westland



Page 4

Energy

Tata Power is one of the largest

private sector power

companies.

Tata BP Solar, a joint venture

between Tata Power and BP

Solar

Hooghly Met Coke and Power

Company

Jamshedpur Utilities and

Services Company

North Delhi Power

Powerlinks Transmission

Tata Power TradingTata Auto

Comp Systems Limited

Tata Projects

Engineering

TAL Manufacturing Solutions

Tata Auto Comp Systems

Limited (TACO)

Hispano CarroceraTata Auto

Comp Systems Limited

Tata Motors, manufacturer of

commercial vehicles (largest in

India) and passenger cars

Jaguar and Land Rover

Tata Daewoo Commercial

Vehicle

Tata Projects

Tata Consulting Engineers

Limited

Tata Cummins

Telco Construction Equipment

TRF

Voltas, consumer electronics

company

Voltas Global Engineering

Centre

Tata Advanced Materials

Tata Advanced Systems

Tata Motors European Technical

Centre

Tata Petrodyne

Tata Precision Industries

Information systems and

Communications

Computational Research

Laboratories

INCAT

Nelco

Nelito Systems

Tata Business Support Services

Tata Consultancy Services Ltd.

(TCS) is Asia's largest software

company.

Tata Elxsi

Tata Interactive Systems

Tata Technologies Limited

Tata Teleservices

Virgin Mobile India



Page 5

Tata Communications

CMC Limited

VSNL International Canada

Tatanet, Managed connectivity

and VSAT service provider

Tata Teleservices

Tata Teleservices (Maharashtra)

Tatanet

Services

Tata Sons

The Indian Hotels Company

Ginger Hotels

Roots Corporation

Landmark

Tata Housing Development

Company Ltd. (THDC)

Tata Limited

TATA AIG General Insurance

TATA AIG Life Insurance

Tata AG

Tata Asset Management

Tata Financial Services

Tata Capital

Tata International AG

Tata Investment Corporation

Tata Advanced Systems Limited

Drive India Enterprise Solutions

Mjunction services

Tata Quality Management

Services

Tata Realty and Infrastructure

Limited

Tata Interactive Systems

Tata Africa Holdings

Tata Auto Comp Systems

Tata Industrial Services

Tata NYK

Tata Services

Tata Strategic Management

Group

Telco Construction Equipment

Steel

Tata Steel

Tata Steel Europe

Tata Steel KZN

Tata Steel Processing and

Distribution

JAMIPOL

NatSteel Holdings

Tata BlueScope Steel

Tata Metaliks

Tata Sponge Iron

Tayo Rolls

The Tinplate Company of India

TM International Logistics



Page 6

TATA MOTORS

Tata Motors Limited is India's largest automobile company, with consolidated

revenues of INR 1, 65,654 crores (USD 32.5 billion) in 2011-12. 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. It is the world's fourth largest truck and bus manufacturer.

The Tata Motors Groups over 55,000 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 6.5 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), Sanand (Gujarat) 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's dealership, sales, services and spare parts network

comprises over 3,500 touch points.

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



Page 7

automobile company. Through subsidiaries and associate companies, Tata Motors

has operations in the UK, South Korea, Thailand, Spain and South Africa. Among

them is Jaguar Land Rover, a business comprising the two iconic British brands that

was acquired in 2008. JLR supports two state of the art engineering and design

facilities and three manufacturing plants (Solihull, Castle Bromwich & Halewood) in

the UK.

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, CIS, Russia and South America. It has franchisee/joint venture

assembly operations in Bangladesh, Ukraine, and Senegal.

The foundation of the company's growth over the last 66 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 4,500

engineers and scientists, the company's Engineering Research Centre, established in

1966, has enabled pioneering technologies and products. The company today has

R&D centers in Pune, Jamshedpur, Lucknow, Dharwad 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 mini-truck.

Tata Motors is equally focused on environment-friendly technologies in emissions

and alternative fuels. It has developed electric and hybrid vehicles both for personal

and public transportation. It has also been implementing several environment-

friendly technologies in manufacturing processes, significantly enhancing resource

conservation.

With the foundation of its rich heritage, Tata Motors today is etching a refulgent

future.



Page 8

PLANT LAYOUT

BODY IN WHITE (Welding) 1A,1B,1C & 1D

Overhead conveyer PAINT-SHOP

ENGINE & GEAR-BOX

ASSEMBLY

Overhead conveyer

TRIM CHASIS FITMENT (ASSEMBLY)

1A, 1B, 1C & 1D

DISPATCH YARD



Page 9

Location

Tata Motors' plants are located at

Jamshedpur (eastern India),

Pune and Sanand (western India),

Lucknow and Pantnagar (northern India).

Tata Motors and Fiat have a common manufacturing facility at Ranjangaon,

near Pune.

TATA MOTORS (Small Car Division) Pantnagar

The Company has set up a plant for its mini-truck Ace and the passenger carrier

Magic (based on the Ace platform) & Venture at Pantnagar in Uttarakhand. The

plant began commercial production in August 2007. This is the company's fourth

plant, after Jamshedpur (commercial vehicles), Pune (commercial vehicles and

passenger vehicles) and Lucknow (commercial vehicles). The plant is spread over

953 acres, of which 337 acres is occupied by the vendor park.

State-of-the-art facilities include weld shops, paint shops, engine and gear box

shops and assembly lines. The Company has invested over Rs.1000 crores in the

plant. Vendors for the vehicle have made additional investments to set up their

plants in the vendor park adjoining the plant. The operation has generated about

7500 direct and indirect jobs in the plant, among vendors and service providers in

the area.

DESCRIPTION OF SHOPS

ASSEMBLY SHOP

o Also known as TCF Shop (TRIM CHASSIS FITTING). In this shop all the

assembly works like Engine,

o Suspension, Tyres, Lights, Dashboard etc. fitment is carried out.



Page 10

WELD SHOP

o Also known as BIW Shop (BODY IN WHITE).

o Here the different parts are welded together and the whole structure of

the car is built.

o This shop plays very important role in framing the body shell. The press

panels are transported from Bhuj and Pune plant.

o It has three main assemblies, which includes-UB(under body), ML(Main

line or main frame) and MF(metal finish) where different welding

processes of

Projection welding

Stud welding

Spot welding

CO2 welding

MIG welding

Are done and after that the parts are attached to the main assemblies.

MANUFACTURING

PRODUCTION SYSTEM

BIW(Body in white)

PAINT

TCF(Trim chassis fitment)

PDI (Pre-Delivery Inspection)

POWERTRAIN

MATERIAL SUPPLY

(JIT,KAIZEN,JIS)

QUALITY MANAGEMENT

MES(Manufacturing execution system)

SAP

PRODUCTION PLANNING



Page 11

POWER TRAIN SHOP

o This shop is divided into Power Train and Engine shop. Here various

operations related to Engine, Gear Trains etc. are performed.

o It consists of Engine Assembly Shop Transaxle Assembly Shop Engine Dressing Line

In Engine assembly the various components of the Engine are assembled into a single unit and sent for the various tests.

PAINT SHOP

o The TAIKISHA paint shop is the beauty parlors of the car plant. This

shop paints the car in various shades. It takes 18 steps spread over less

than 10 hours to accomplish the task.

o Here in Paint shop:

Colour and appearance

Covering of gaps between the weld joints

Corrosion resistance

Smothering of sharp corners

UNDER BODY

LINE

SUB ASSEMBLIES

MAIN FRAME

LINE

SUB ASSEMBLIES

METAL FINISH LINE PAINT SHOP



Page 12

Shop layout

ED OVEN

SOL SEALING (UB) SEALANT

WELD BODY ELECTRODEPOSITION PRETREATMENT

INTERMEDIATE COAT (I/C)

TOUCH UP AND

INSPECTION

UNDERCOAT OVEN

DRY SANDING I/C OVEN COOLING

DRY SANDING TOP COAT

(T/C)

T/C

OVEN TCF

COOLING

UNDER COAT



Page 13

TCF SHOP

Here the painted chassis delivered from the Paint shop is accessorized from scratch to a finish car ready for dispatch and also tested. The car delivered by the TCF shop is completely checked with reference to products utility quality and manufacturing quality. After several inspections made by line operators for operational conformance and ethical looks the Car is permitted to be dispatch from TCF shop by the assurance of Line supervisors and operators. The cart dispatched from the TCF shop is delivered, through drive test to the PDI (Pre-Delivery Inspection) shop where final touching to looks is given and the conformance of working of all the accessories is done.

SHOP LAYOUT

PDI SHOP

o PDI is the final quality check, in this the overall checking of the vehicle takes

place, in this the fitment is not done, only the outward checking is completed.

The final QA OK of the vehicle is done here and after this the vehicle is sent for

dispatch.

NOK

ROLL AND BRAKE TEST CANOPY TEST

REWORK PRE DISPATCH INSPECTION (PDI)

OK

PAD

To costumer

TRIM LINE (TR1, TR2)

UNDER BODY LINE (UB1, UB2, UB3, UB4)

MECHANICAL LINE

WHEEL ALIGNMENT



Page 14

o Parts which are checked are mentioned below:

1. Brake, Brake oil. 21. Inner handle.

2. Carpet fitment. 22. Instrument cluster.

3. Central lock 23. Keys.

4. Coolant filling 24. RH front door.

5. Dents 25. Roof lamp.

6. Door pad 26. Roof lining.

7. Drive shaft 27. Rear bumper.

8. Engine oil. 28. Rear door LH, RH.

9. Engine wiring harness. 29. Rear door lock LH

10. Front bumper. 30. Rear door lock RH.

11. Front door LH 31. Rear seat

12. Front door lock LH 32. Seat. Belt

13. Front door lock RH 33. Spare wheels

14. Front seat 34. Scratches on whole body

15. Fuel. 35. Steering wheels.

16. Gear shifter. 36. Tail lamp.

17. Head lamp. 37. Washer jet.

18. Hood LH. 38. Window glass.

19. Hood RH 39. Wind shield washer.

20. Horn 40. Wiper.



Page 15

TATA MOTORS SUMMER INTERNSHIP PROJECT

ELIMINATION OF ENGINE MOUNT NOISE IN

ACE ZIP & MAGIC IRIS

What is Engine Mount?

Engine mounts hold a vehicles engine in place on the frame. An engine mount is just

that it mounts the engine to a vehicle. It keeps the engine from moving or shifting

out of place while the vehicle is operating. If a mount becomes worn out or broken it

can allow the engine to move excessively providing a rougher ride. If allowed to

persist extra strain will be put on the other mounts increasing their chance of failure,

allowing the engine to come free in the vehicle causing very costly repairs.

Structure

An engine mount consists of two attached metal parts with rubber in

between. One side of the mount is bolted to the engine while the other



Page 16

is attached to the frame. The rubber in the center absorbs vibrations

while allowing a small amount of movement.

Function

The engine mount keeps the engine secured, prevents it from vibrating

excessively and ensures that it stays properly connected. It also keeps

vibrations from traveling through the frame and other parts of the

vehicle.

Malfunction

Engine mounts may malfunction due to the bolts or rubber on the

mount being cracked and worn. The symptoms of a faulty mount

include excessive shaking or vibration from the engine and thumping

noises from under the hood. If symptoms indicate the engine mount is

not secure, it should be replaced right away to avoid damage to the

engine.

The Engine Mount acts as a transition between the motor and the surrounding

components, and allows installers to secure the motor within the device. The right

motor mount can extend the life of the device while the wrong mount may result in

excess vibration and a shortened lifespan for the engine. When choosing motor

mounts, take the time to match the type of mount with the application in order to

maximize its performance.

Types of Engine Mounts:-

Rigid Mounts

In a rigid mount, the motor mount is attached to the frame of the

device with fasteners or bolts. Some rigid mounts may even be built

into the vehicle or equipment or permanently welded in place.

According to "Electrical Construction and Maintenance" magazine, rigid

mounts are most often used with small motors rather than large ones.



Page 17

Rigid mounts provide the most accurate alignment between the motor

and the surrounding mechanisms, but may be damaged by vibration

under heavy-duty operation.

Resilient Mounts

Resilient motor mounts feature a layer of rubber or insulation between

the mount and the motor. This material helps to reduce noise and

vibration, which may extend the life of the motor and related parts.

Resilient motor mounts also allow for some flexibility and movement

without compromising the performance of the motor. According to

"Electrical Construction and Maintenance" magazine, these mounts are

often found in larger motors or in applications where excess noise or

vibration could be problematic. These mounts also help to reduce the

impact as the motor starts and stops, which minimize shock to the

surrounding system.

Hydraulic Mounts

Hydraulic, or hydro motor, mounts contain some form of gel or liquid

to help absorb impact and vibration during operation. This may include

glycol or hydraulic fluid, or any other types of fluid substance. This type

of mount is often used in four-cylinder motors, which produce large

amounts of vibration or noise. They may also be used with other types

of motors when noise levels must be kept to a minimum.

Face Mounts

In a motor designed for face mounting, or NEMA "C" mounting, the

motor attaches directly to the surrounding components without the

use of a standard mount. Often, installers will use a NEMA "C" face

mount adapter in order to adapt a face-mounted motor to a vehicle

designed for another type of motor mount. In this type of mount, the

bolts on the motor pass right through pre-drilled holes in the motor

casing and into the surrounding components or devices.



Page 18

Mechanical problems caused by bad Engine Mount:

Excessive Engine Vibration

Motor mounts help to keep a vehicle's engine anchored securely inside the

engine compartment. Bad motor mounts, especially broken motor mounts,

frequently allow a vehicle's engine to move or shake excessively; causing

excessive engine vibration, which often gets transmitted into the passenger

compartment of the vehicle.

Abnormal Engine Position

An engine that appears lopsided or out of alignment relative to its normal

position is normally an engine, with broken or severely damaged motor

mounts. In addition to securing an engine within the vehicle hood

compartment and stabilizing its movements, motor mounts serve to keep an

engine aligned and positioned properly to allow for adequate engine

operation, and adequate operation of all of the supporting mechanical

devices underneath a car's hood. Bad motor mounts can allow an engine to

sag or tilt, a situation that is easily spotted by a diligent individual.

Engine Damage

In extreme cases, bad motor mounts can totally lose their structural integrity

and allow a vehicle's engine to shift excessively to one side, especially during

rapid engine acceleration or at high rates of speed, which can allow various

mechanical engine parts, including pumps, pulleys, and diaphragms to

contact the vehicle frame and break.

Broken Belts/Hoses

In addition to broken engine parts, bad motor mounts can cause damage to

an engine's belts and hoses. If bad motor mounts allow excessive engine

movement or tilting, various engine fan belts and/or radiator hoses can be



Page 19

damaged or broken, especially under heavy engine acceleration when engine

movement is most pronounced.

So, what is Engine Mount Noise?

Many times bad or broken engine motor mounts will cause loud or excessive

engine noise, usually knocking or clanking types of noises. These types of engine

noises are usually the result of the engine block pounding or bumping against the

broken or damaged motor mounts that have lost their snug fit against the engine.

The engine of Magic Iris and Ace Zip is rear drive type. The engine is

mounted/ supported on four mounts, namely A, B, C and D.

Fig: A mount Fig: B mount

Fig: C mount Fig: D mount



Page 20

When the engine is started, it produces torque. Due to the torque produced

by the engine, it vibrates. If the mounts on which the engine is mounted are loose,

broken or not fixed in correct position, it produces unwanted noise. This outcome

comes in the form of metal-metal clanking noise. Usually, this mount noise are

found and solved in the UNDER PIT section of the TCF shop. Then the vehicle goes

for road test. After road test, any further mount noise which was not found in the

U/P section is found and repaired.

Specification of mounts

A mount B mount C mount D mount

Bracket

bolt

Centre

bolt

Bracket

bolt

Centre

bolt

Bracket

bolt

Centre

bolt

Bracket

bolt

Centre

bolt

No. of

bolts

2 1 4 1 3 1 4 1

Torque

used

(KgM)

4.5 8 2.3 7.7 2.3 4.5 2.3 4.5

Potential causes at each mount which leads to mount noise are as

follows:

1) A mount

a) Gap between engine mount and engine bracket is less.

b) Bracket bolt is loose or free.

c) Centre bolt is loose or broken.

d) A-mount arm bolt is free or loose. (will cause mount noise if 2 or more bolts

are loose).



Page 21

2) B mount

a) Centre bolt loose or free.

b) Bracket of B-mount bend due to

over-tightening.

c) Bracket bolt missing or free.

3) C mount

a) Bracket bolt loose or free.

b) Bracket of C-mount bend due to over-tightening.

c) Centre bolt loose or free.

4) D mount

a) Bracket bolt loose or free.

b) Bracket of D-mount bend due to over-tightening.

c) Gap between engine bracket and engine mount more than required limit.

Due to over tightening the B mount and engine bracket clash with each other

Due to loose fitment of bracket bolt of C mount the engine bracket and BIW part

clash with each other.



Page 22

Engine Mount Noise Monitoring Sheet Under Pit Section

SL. No.

Fouling Location

`No. of Vehicles Cause

5th July 6th July 7th July 9th July

1. A- mount ||||

= 4

|||| |

=6

|||| |||

=8

|||| ||||

=9

Bracket bolt is loose

Amount arm bolt is free Arm bracket is not proper

2. B- mount |

=1

||||

=5

||

=2

|

=1

Bracket bolt loose or free

Centre bolt is loose

Bracket bend

3. C- mount |

=1

|||

=3

|||

=3

||

=2


Centre bolt loose or free

4. D- mount |

=1

|

=1

NIL

|

=1

Bracket bolt is loose or free Centre bolt is loose or free



Page 23

Engine Mount Noise Monitoring Sheet Road Test Section

SL. No.

Fouling Location

`No. of Vehicles Cause

5th July 6th July 7th July 9th July

1. A- mount NIL NIL NIL NIL NIL

2. B- mount |

=1

||||

=5

|||| ||

=7

|||| ||

=7

B MOUNT over-tight or loose

3. C- mount |

=1

|||

=3

||||

=5

||||

=5


Centre bolt loose or free

4. D- mount NIL NIL NIL |||

=3

Bracket bolt is loose or free

Centre bolt is loose or free



Page 24

Figure: Pareto Chart for Mount Noise Monitored

Analysis:

After taking readings from the monitoring sheet, it is found that maximum mount

noise is coming from B and C mount.

0

20

40

60

80

100

120

0

5

10

15

20

25

B mount C mount D mount A mount

Volume

Cum.

Potential Mount Noise Area

A mount

B mount

C mount

D mount

80-20 point

No

. of

Veh

icle

s w

ith

mo

un

t n

ois

e



Page 25

Proposed Solution:

Here at TCF-1D, I was trained by the Line-supervisor to identify the root cause of

mount which can be reduced by proper functioning during fitment process.

During fitment due to human error or by some other way in Under Body section,

mount noise can occur. So proper care need to be to eliminate it.

For resolving the problem mentioned above a standard procedure is followed

during the fitment of mount at trim line.

The procedure is in the form of Work Sheet. It is as follows:

WORK SHEET

Subject: Fitment of B-mount

Model: All ACE ZIP & MAGIC IRIS

Sl. No. OPERATION SEQUENCE

Step1. Pick B mount and hand tighten it in the BIW (Body in White) with 4 Nos.

of MBX22 Hex. Flange screws.

Step2. Tack these bolts and torque tighten these bolts with torque ranch at 2.3

KgM.

Step3. Pick up the central bolt and fit it into the hole of B mount and engine

bracket and hand tighten it.

Step4. At the quality gate check whether the screws are there & are tight or not.

Step5. Torque tighten the central bolt of B mount with torque ranch at 7.7 KgM.

Avoid over tightening or applying torque more than required.



Page 26

WORK SHEET

Subject: Fitment of C-mount Model: All ACE ZIP & MAGIC IRIS

Sl. No. OPERATION SEQUENCE

Step1. Pick C mount and hand tighten it in the BIW (Body in White) with 3 Nos.

of MBX22 Hex. Flange screws.

Step2. Tack these bolts and torque tighten these bolts with torque ranch at 2.3

KgM.

Step3. Pick up the central bolt and fit it into the hole of B mount and engine

bracket and hand tighten it.

Step4. At the quality gate check whether the screws are there & are tight or not.

Step5. Torque tighten the central bolt of B mount with torque ranch at 4.5 KgM.

Avoid over tightening or applying torque more than required.



Page 27

After following the above mentioned procedure 20 vehicles were monitored, which

are as follows:

We see that after following

the procedure, the no. of

vehicles with mount noise

has reduced.

Major reasons which caused are:

The body parts which are sent from BIW are not properly fabricated.

The line man of TCF-1D are not using proper means like torque wrench for

the fitment of Under Body. So, over tightening case become prominent.

SL. No. Vehicle No. U/P(Under Pit) R/T(Road Test)

1) MAT491005CJG26351

2) MAT491005CJG26352

3) MAT491005CJG26353

4) MAT491005CJG26354

5) MAT491005CJG26355

6) MAT491005CJG26356

7) MAT491005CJG26357

8) MAT491005CJG26358

9) MAT491005CJG26359

10) MAT491005CJG26360

11) MAT491005CJG26361

12) MAT491005CJG26362

13) MAT491005CJG26363

14) MAT491005CJG26364

15) MAT491005CJG26365

16) MAT491005CJG26366

17) MAT491005CJG26367

18) MAT491005CJG26368

19) MAT491005CJG26369

20) MAT491005CJG26370



Page 28

Hence I observed that:

Testing and inspection should be carried out at every quality gate.

Tightening of nut and bolt should be proper.

By using automation and precise machinery.

The assembly parts should be manufactured by advanced manufacturing processes in Vendor Company.

The training and motivating policy should be applied to workers.

Kaizen should be applied.

Job rotation policy should be applied.

Possible further aspects in the project: WHAT CAN GO WRONG ANALYSIS: By doing this one can also find the root cause

of the untraceable line problems and take suitable steps towards its elimination and

thus TML TCF-1D shop can assure nearly perfect fitment for the car .

CONCLUSIONS

After analyzing the problem, in the Under Body section (Magic iris and Ace Zip) the

mount noise was eliminated with positive results.

elimination of mount engine noise

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