“Logistics/Inventory Planning For

Upcoming Vehicle”

Review 1

Industry Guide Institute Guide Prepared By

MR. RAJIV JAKHMOLA Dr. K M Patel PRATIK LAKKAD (18BME058)

Deputy General Manager, Professor & Head
TCF Planning - TATA Motors Mechanical Engineering Department
Activities of TCF Planning Department

● TCF - Trim Chassis Fitment(Assembly Shop)

● F & D - Flashing and Diagnostic
BACKGROUND

● TATA Motors Sanand plant was started as a single

model plant in 2010 for manufacturing only the Tata
Nano
● Nano had only 4 variants with limited varieties
● So the inventory areas adjacent to assembly lines
were designed according to the variants and planned
capacity only
PROBLEM
● Now it manufactures other hatchbacks like Tata Tiago and Tata Tigor with over 20 variants
combined

● These cars are assembled on the same assembly line and has same inventory area which was
designed for the Nano

● Over and above this, by the end of this year few more variants are planned

● But the existing storage area is not capable to store more inventory
SOLUTIONS IMPLEMENTED

Solutions

Optimize existing
Extension of Assembly
inventory to the daily
Shop(TCF)
production targets
OPTIMIZATION OF INVENTORY

Preparation of
Mapping of TCF
Layout in Optimization
Storage Areas
AutoCAD
MAPPING OF TCF STORAGE AREAS
# TYPE OF LINES NO. OF TOTAL
STATIONS

1 UNDERBODY 1 8
1. Taking measurement of storage and kitting
zone 2 UNDERBODY 2 15

2. Rough layout of area on paper 3 UNDERBODY 3 8 58

4 UNDERBODY 3A 20
3. Details of parts stored in that area
5 UNDERBODY 4 7
○ Type of storage(Bin/Box, Pallet, Trolley,
Rack…) 6 TRIM 1 23
46

○ Quantities per bin/box 7 TRIM 2 23

8 DOOR 12 12
○ Maximum Storage capacity per
Pallet/Trolley/Rack 9 CRADLE 20 20

4. Prepare detailed Excel sheet 10 COCKPIT 12 12

11 MECHANICAL 16 16

TOTAL NUMBER OF STATIONS 164

Sample Data

Part Description DOOR Line

FUTURE WORK

● To prepare detailed layouts in AutoCAD

● Study past few months data of the daily production
● Study frequencies of Supply
● Optimize inventory based on Production and Supply
Flashing & Diagnostic
● Connect Toughbook to the ECU
● Reset and Connect all the control units with the head unit
○ EMS - Engine Management System
○ FATC - Fully Automated Temperature Control
○ IPC - Instrument Panel Control
○ EPAS - Electrical Power Assisted Steering
○ BCM - Body Control Module
○ ABS - Antilock Braking System
○ PEPS - Passive Entry Passive Start
○ Airbag Actuator

● F & D is carried out at two stages

○ Before Door Fitment(BDF)

○ After Door Fitment (ADF)

F & D at BDF
● Parameters Checked
○ Working of Instrument Panel Control
○ Head and Tail Light
○ Hazard Light
○ Front and Rear Wiper
○ Gearing Mechanism
○ Accelerator, Brake and Clutch Pedal
○ Central Locking
○ Key Pairing

● Common Errors
○ Loose Connections of wire harnesses
○ Wrong Part Fitting
○ Battery short or not grounded
F & D at ADF
● Parameters Checked
○ Key Remote Pairing
○ Opening and Closing of Doors and Tailgate
○ Working of Power Window
○ Control of ORVM (Outside Rear View Mirror)

● Common Errors
○ Loose Connections of Latches
○ Defective Hardwares
F & D at Level 2

Once passing from BDF and ADF Cars go through following tests at Level 1:
❏ Vibration Test
❏ Wheel and Headlight Alignment
❏ RBT (Roll and Brake Test )
❏ Shower Test
❏ CANOPY (Paint Test)
❏ Drive Test (DT)

● After DT (at level 2) F&D is again performed as fitments may get loose
because of all the tests at Level 1
TIMELINE