ABHAY VERMA PROJECT

TATA MOTORS LTD.
SUMMER TRAINING PROJECT REPORT ON
 Installation of ABS (Anti-Lock Braking
system) in two Vehicles (Bus)
24
th
May 2016 – 5
th
July 2016
Department: PLANNING
Under The Guidance of: Mr. Ritesh Srivastava
(Asst. General Manager)
Mr. Vipin C Jaiswal
(Manager)
Mr. Vishal Ranjan
(Asst. Manager)
Submitted by: ABHAY KUMAR VERMA
MOTILAL NEHRU NATIONAL INSTITUTE OF
TECHNOLOGY, ALLAHABAD

ACKNOWLEDGEMENT
Words fail to express my sincerest gratitude to this esteemed organization,
which has conferred on us the privilege to pragmatically convert our theoretical
knowledge into practical viable experience. During the course of my training at
TATA MOTORS, LUCKNOW, many people have guided me and I will remain
indebted to them throughout my life for making my training here a wonderful
learning experience.
I wish to express my indebted gratitude and special thanks to my project
guide, Mr. Ritesh Srivastava, Tata Motors Limited, Lucknow’ who inspite
of being extraordinarily busy with his duties, took time out to hear, guide and
keep me on the correct path and allowing me to carry out my industrial project
work in his department of PLANNING.
I express my deepest thanks to project mentor, Mr. Vipin C Jaiswal, and
Mr. Vishal Ranjan, Tata motors Limited, Lucknow for taking part in useful
decision & giving necessary advices and guidance and took keen interest in my
project work. All that, I have acquired would not have been possible without the
kind guidance of him.
I would also like to thank all my colleagues and the employees for
supporting to complete my work and also help me to get a better knowledge.
The exposure to the working of the industry that I have got here would
not have been possible without their support. My mentors took keen interest in
my project and ensured that my tenure at TATA MOTORS is a fruitful
experience for me. Without their help, it would have been an uphill task for me
to complete the project successfully.
I perceive this opportunity as a big milestone in my career. I will strive to
use gained skills and knowledge in the best possible way, and I will continue to
work on their improvement, in order to attain desired career object.
Dated: 5
th
July, 2016
ABHAY KUMAR VERMA
MNNIT, ALLAHABAD

Contents
INTRODUCTION...................................................................................................................................................4
TATA GROUP OF COMPANIES......................................................................................................................4
TATA MOTORS.................................................................................................................................................5
LUCKNOW PLANT...........................................................................................................................................6
PROJECT 1..............................................................................................................................................................8
NEW PRODUCT INTRODUCTION.................................................................................................................9
NEED FOR NPI IN TATA MOTORS..............................................................................................................10
ABS IMPLEMENTATION DATE...................................................................................................................10
ANTILOCK BRAKE SYSTEM (ABS)............................................................................................................11
GLOSSARY......................................................................................................................................................13
BOM..............................................................................................................................................................13
ERC...............................................................................................................................................................14
PLM..............................................................................................................................................................14
PPAP.............................................................................................................................................................14
SAP...............................................................................................................................................................15
UPL...............................................................................................................................................................16
VLO................................................................................................................................................................16
IFD................................................................................................................................................................17
ICA.................................................................................................................................................................17
PCA...............................................................................................................................................................18
RISK MITIGATION SHEET...............................................................................................................................18
FLOW DIAGRAM............................................................................................................................................19
INTRODUCTION ABOUT PROJECT.........................................................................................................................20
PARTS OF ABS ................................................................................................................................................21
PULSE WHEEL....................................................................................................................................................22
WHEEL SENSOR..................................................................................................................................................24
FITMENT OF PULSE WHEEL AND SENSOR.........................................................................................................26
ECU....................................................................................................................................................................27
ABS INDICATOR LAMP.......................................................................................................................................30
TRACTION CONTROL SYSTEM.............................................................................................................................31
PROCEDURE FOLLOWED DURING PROJECT......................................................................................................33
CONCLUSION.....................................................................................................................................................34
SUMMARY.........................................................................................................................................................35

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 people’s car in India on 13th March
Fig.1 Mr Ratan Tata 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’s core purpose is to improve the quality of life
of the communities it serves globally, through long-term stakeholder
value creation based on leadership with trust.
Founded by Jamsetji Tata in 1868, the Tata group is a global
enterprise headquartered in India, and comprises over 100 operating
companies, with operations in more than 100 countries across six
continents, exporting products and services to over 150 countries. The
revenue of Tata companies, taken together, was $103.27 billion
around Rs624,757 crore) in 2013-14, with 67.2 percent of this coming
from businesses outside India. Tata company’s employee over
581,000 people worldwide.
Fig.2 Mr Jamsetji Tata

Good corporate citizenship is part of the Tata group’s. Sixty-six
percent of the equity of Tata Sons, the promoter holding company, is
held by philanthropic trusts, thereby returning wealth to society. As a
result of this unique ownership structure and ethos of serving the
community, the Tata name has been respected for more than 140
years and is trusted for its adherence to strong values and business
ethics.
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, India’s first software company, and Tata Motors, which made
India’s first indigenously developed car, the Indica, in 1998 and
recently unveiled the world’s lowest-cost car, the Tata Nano.
Areas of business:
Tata Industries has two operating divisions which function as
independent profit centres: 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 Fiat’s 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-axle 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 segment.
TATA MOTORS
Tata Motors Limited (formerly TELCO, short form for Tata
Engineering and Locomotive Company) is an Indian multinational
automotive manufacturing company headquartered in Mumbai,
Maharashtra, India and a subsidiary of the Tata Group. Its products
include passenger cars, trucks, vans, coaches, buses, construction
equipment and military vehicles. It is the world's seventeenth-largest
motor vehicle manufacturing company, fourth-
largest truck manufacturer and second-
largest bus manufacturer by volume.
Founded in 1945 as a manufacturer of
locomotives, the company manufactured
its first commercial vehicle in 1954 in
collaboration with Daimler-Benz AG,
which ended in 1969. Tata Motors
entered the passenger vehicle market in
1991 with the launch of the Tata Sierra,
becoming the first Indian manufacturer
to achieve the capability of
developing a competitive indigenous automobile.
In 1998, Tata launched the first fully indigenous car, the Indica,

and in 2008 launched the Tata Nano, the world’s most affordable car.
Tata Motors acquired the South Korean truck manufacture Daewoo
Commercial Vehicles Company purchased Land Rover from Ford in
2008.
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 power
trains. The company's dealership, sales, services and spare parts
network comprises over 3,500 touch points. 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 centres in Pune, Jamshedpur,
Lucknow, Dharwad in India, and in South Korea, Spain, and the UK.

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
LUCKNOW PLANT
Tata Motors, Lucknow is one of the youngest production
facilities among all the Tata Motors locations and was established in
1992 to meet the demand for Commercial Vehicles in the Indian
market. The state of art plant is strongly backed by an Engineering
Research Centre and Service set-up to support with latest technology
and cater to the complexities of automobile manufacturing. Fully
Built Vehicle business, which is one of the fast growing areas of our
business, is also established in Lucknow.
The plant, rolls out commercial vehicles and is specialized in
the designing and manufacturing of a range of modern buses which
includes Low-floor, Ultra Low-floor, CNG & RE Buses. The
Lucknow facility also specializes in manufacturing HCBS (High
capacity Bus System) buses.
Fig.4 Tata Motors Ltd, main entry, Lucknow Plant

The HCV/MCV/LCV assembly line is semi-automated and is
divided into 19 stations. Over these stations frame transforms to a
full CV chassis.
The major facilities at the plant are:
 Vehicle Factory - Assembly Plant for Trucks and Bus
Chassis. There are total 3 assembly lines with two of them in
Eastern Complex and one in Western Complex.
 Integral Bus Factory - Assembly Plant for Module Buses
catering to the needs of Tata Marcopolo Motors Limited and
FBV operations.
 Transmission Factory - Gear Parts, Crown wheel &
Pinion and Heat Treatment facility.
 Production Engineering Shop catering to the tool design and
manufacturing needs.
 A well established Training Centre through which around 500
apprentices are trained in various trades.
 Engineering Research Centre with specific focus on buses,
including a Digital prototyping lab, use of PLM software
etc.
 Service Training Centre providing training to drivers and
technicians of the STU's
 RECON Factory (for Reconditioning Business).
 The satellite plant of TMML which caters to the Hi-end
buses for the Northern Market.
State of the art facilities like the Paint Shop, BIW Shop and the TCF
factory with automated lines have been benchmarked with the best
in the world.
MODELS MANUFACTURED AT TATA MOTORS
LUCKNOW: -
 LCV (Light Commercial Vehicles) - GVW less than 10 tons.
1. Truck Models- SFC 407 CNG, LPT 407, LPT 909 CNG.
2. Bus Models- LP 407 CNG, LP 909 CNG, LP 709.
 MCV (Medium Commercial Vehicles) - GVW 11 ton to 24

tons.
1. Truck Models- LPT 1613, LPT 1615 2.
2. Bus Models - LPO 1316 RHD, LPO 1316 LHD, LP
1512, LPO 1512, LPO 1612, LPO 1613, LPO 1613
CNG, LPK 1616, LPK 1618, LPO 1618 RHD,
LPO 1618 LHD, LPO 1623 DTC CNG, LPO 1624, LPO
1628, LPO 1924.
• HCV (Heavy Commercial Vehicles) - GVW 25 ton and
above.
1. Truck Models- LPT 2518, LPK 2518, LPT 3118, LPS
3518, LPT 3723, LPS 4018

HR
Lucknow Works
Finance
Manufacturing
Materials &
Planning
Central Plant Commercial
NPI & TS
Supply Chain Quality Services Services
Assy Assy Assy Weld Cab Cowl
Line 1 Line 2 Line 3 Shop Trim Trim
Assy Assy
Cowl Integral
Transmissi Paint AutoTrim Bus
MaintenancAssy EC Factory on Factory Shop
e
CX CX
CX Heat CX
CV Module Module
Treatment Machining
Fabrication Assembly
Fig.5 Various departments at CVBU, Lucknow
Role of Planning Department
 Planning, installation and commissioning of facility for
improving line productivity, safety and quality.
 Capital budgeting, facility, process planning and validation
for NPI (New Product Introduction) in commercial vehicle
segment.

PROJECT
INSTALLATION OF ABS IN TWO VEHICLES
NEW PRODUCT INRODUCTION (NPI):
The new product introduction (NPI) is the process by which a new
product idea is conceived, investigated, taken through the design
process, manufactured, marketed and serviced. In the automotive
industry, within the context of ISO/TS16949:2002 (the automotive
quality management system international standard), these related to
the product realization process (PRP) which consists of five phases:
“Plan and Define Program”, “Product Design and Development”,
“Process Design and Development”, “Product and Process
Validation”, and “Production Launch, Feedback Assessment and
Corrective Action”. These phases may be done concurrently and have
correlated activities.
INTRODUCTION:
The product quality planning, which is sometimes used
interchangeably with new product introduction (NPI), however, the
second one seemed to represent the broader term, is the process by
which a new product idea is conceived, investigated, taken through
the design process, manufactured, marketed and serviced through
obsolescence. The competitive advantage of a company can be linked
to two key factors: (i) the ability to generate new intellectual property
that offers superior value to customers and (ii) the ability to capitalize
on it quickly. Superior quality and project management optimize the
performance excellence of organizations, unfortunately, the combined
leverage of quality and project management is often underutilized due
to inadequate related knowledge and experience, time pressures or
budgetary cutbacks. The quality planning road map is described as the
activity determining customer needs and developing the products and

processes required meeting those needs. The Automotive Quality
Management System (QMS) International Standard,
ISOTS16949:2002, the particular requirements for the application of
ISO 9001:2000 for automotive production and relevant service part
organizations, defined “Product Realization Process (PRP)” as one of
major parts of the standard, a useful framework for understanding the
product quality planning in general. The methodology for managing
new product introduction is defined as Advance Product Quality
Planning (APQP), in the automotive supply chains.
ISO/TS16949:2002 determines this as one of the means to achieve the
PRP (NPI)’s objectives. Since it is published, the APQP play an
important role in the automotive industry worldwide, especially in
TATA Motors, as it appeared to be significantly practical to the NPI
team. In other words, implementing the PRP without more specific
methodology like APQP, especially for the local companies in India,
result in less competitiveness to the market. The APQP embodies the
concepts of error prevention and continual improvement in contrasted
to error detection, and is based on a multidisciplinary approach. The
APQP consists of five phases as follows:
Phase 1 - Plan & Define Program.
Phase 2 - Product Design and Development.
Phase 3 - Process Design and Development.

Phase 4 - Product and Process Validation.
Phase 5 - Production Launch, Feedback Assessment and Corrective
Action.
In real practice, these phases may overlap and many tasks are
done in parallel (concurrent engineering) to streamline and maximize
resource utilization.
Fig.6 Advance Product Quality Planning (APQP)
Need for NPI in Tata Motors:
As per new CENTRAL MOTOTRS VEHICLE REGULATIONS
(CMVR) Rule-96 ABS fitment has been made mandatory for all M3
(Buses) & N3 (Goods) category of vehicles manufactured on & after,
as per final notification GSR 389(E) dated 9th June 2014.
 M3 category: A vehicle used for the carriage of passengers,
comprising nine or more seats in addition to the driver’s
seat and having a GVW exceeding 5 ton
 N3 category: A vehicle used for the carriage of goods
and having a GVW exceeding 12 tons.
ABS Implementation date:

 New models of M3 and N3 categories of vehicles
manufactured on and after the :1st April 2015
 Existing models of M3 and N3 categories of vehicles
manufactured on and after the :1st Oct 2015
Due to new CMVR Rules, following is the distribution of the
Vehicles affected produced in the Lucknow Plant.
10 | P a g e
ANTI-LOCK BRAKING SYSTEM (ABS):
The braking system of any vehicle must be capable of slowing
and stopping the vehicle safely within reasonable limits. Our present
Air brake system for heavy commercial vehicles fulfils this by
generating adequate brake torque to arrest the wheel rotation while
braking. Safe braking of heavy vehicles not only depends on brake
system but also on control of acceleration, road condition and steering
inputs given by driver. A good driver keeps a sharp eye on traffic and
road conditions anticipating any changes well before they occur and
tries to make appropriate control to avoid any unsafe condition while
riding or braking. However, during a panic braking situation even an
experienced driver can over-brake the vehicle causing wheel lock up
especially on slippery roads. This causes skidding and even makes the
vehicle to go out of driver's control often causing accidents. Many of
us would have experienced this skidding in a two-wheeler or car
while applying sudden brake. In order to stop the vehicle during hard-
braking without losing stability, the brakes must apply quickly, at the
same time they must release quickly so that a driver can quickly
regain control in the event of a wheel getting locked and starts to skid.
Incorporation of Antilock brake system over the conventional
brake system prevents this wheel locking thereby avoids skidding thus
ensuring stability of vehicle. A brake is one of the most important
parts of any type of vehicle. Brake is used to retard or stop a vehicle.

Here Kinetic energy is transferred into Heat energy. The kinetic
energy increases with the square of the velocity. So, K.E.=1/2mv².An
anti-lock braking system is a safety system that allows the wheels on
a motor vehicle to continue interacting tractively with the road surface
as directed by driver steering inputs while braking, preventing the
wheels from locking up (that is, ceasing rotation) and therefore
avoiding skidding.
Stopping a car in a hurry on a slippery road can be very
challenging. Anti-lock braking systems (ABS) take a lot of the
challenge out of this sometimes nerve-wrecking event. In fact, on
slippery surfaces, even professional drivers can't stop as quickly
without ABS as an average driver can with ABS.
An ABS generally offers improved vehicle control and
decreases stopping distances on dry and slippery surfaces for many
drivers; however, on loose surfaces like gravel or snow-covered
pavement, an ABS can significantly increase braking distance,
although still improving vehicle control. Since initial widespread use
in production cars, anti-lock braking systems have evolved
considerably. Recent versions not only prevent wheel lock under
braking, but also electronically control the front-to-rear brake bias.
ABS Operation:
ABS operation can be broken down into three stages or
functions.
 Data Inputs
 Data Processing
 Output or Control Actions

Inputs Processing Output
Fig.7 Stages for ABS operation
Fig.8 ABS implementation flow chart
Data inputs are the wheel speed signals generated by sensors
fitted in each wheel, switches and diagnostic equipment’s. The data
inputs are sent to the Electronic Control Unit (ECU) where the signals
are interpreted and operating strategy is determined. The final output
commands are sent from ECU to the system components such as
valves, lamps etc.
ABS takes over control of the air pressure whenever a wheel
starts to lock up. Sensors continuously monitor wheel speed and send
this information to an Electronic Control Unit (ECU). When a wheel
starts to lock, the ECU, using the wheel-speed information and
programmed data, sends output signals to control the operation of the
ABS valves. The ECU causes the ABS valves to adjust air pressure
supplied to the brake chambers to control braking and prevent wheel
lockup.
A typical ABS includes a central electronic control unit (ECU),
four-wheel speed sensors, and at least two hydraulic valves within the
brake hydraulics. The ECU constantly monitors the rotational speed
of each wheel; if it detects a wheel rotating significantly slower than
the others, a condition indicative of impending wheel lock, it actuates
the valves to reduce hydraulic pressure to the brake at the affected

wheel, thus reducing the braking force on that wheel.
The wheel then turns faster. Conversely, if the ECU detects a
wheel turning significantly faster than the others, brake hydraulic
pressure to the wheel is increased so the braking force is reapplied,
slowing down the wheel. This process is repeated continuously and
can be detected by the driver via brake pedal pulsation. Some antilock
system can apply or release braking pressure 16 times per second.
The ECU is programmed to disregard differences in wheel
rotation speed below a critical threshold, because when the car is
turning, the two wheels towards the center of the curve turn
Slower than the outer two. For this same reason a differential is used
in virtually all raod going vehicles. If a fault develops in any part of
the ABS, a warning light will usually be illuminated on the vehicle
instrument panel, and the ABS will be disabled until the fault is
rectified.
The modern ABS applies individual brake pressure to all four
wheels through a control system of hub-mounted sensors and a
dedicated micro-controller. ABS is offered or comes standard on most
road vehicles produced today and is the foundation for ESC systems,
which are rapidly increasing in popularity due to the vast reduction in
price of vehicle electronics over the years. Modern electronic stability
control (ESC or ESP) systems are an evolution of the ABS concept.
Here, a minimum of two additional sensors are added to help the
system work: these are a steering wheel angle sensor, and a
gyroscopic sensor. The theory of operation is simple: when the
gyroscopic sensor detects that the direction taken by the car does not
coincide with what the steering wheel sensor reports, the ESC
software will brake the necessary individual wheel(s) (up to three
with the most sophisticated systems), so that the vehicle goes the way
the driver intends. The steering wheel sensor also helps in the
operation of Cornering Brake Control (CBC), since this will tell the
ABS that wheels on the inside of the curve should brake more than
wheels on the outside, and by how much.

The ABS equipment may also be used to implement a traction
control system (TCS) on acceleration of the vehicle. If, when
accelerating, the tire loses traction, the ABS controller can detect the
situation and take suitable action so that traction is regained. More
sophisticated versions of this can also control throttle levels and
brakes simultaneously.
GLOSSARY
BOM:
BOM or bill of material is a list of raw materials , sub assembemblies
Intermediate assemblies , sub component parts and quantttities of each
Needed to manufacturing partners, or confined to a single
manufacturing plant. It can define products as they are designed, as
they are ordered, as they are built, or as they are maintained (service
bill of materials or pseudo bill of material). The different types of
BOMs depend on the business need and use for which they are
intended.

• ERC:
The Engineering Research Centre (ERC) is the R&D
Department of Tata Motors and is behaviour of activity where
engineers and designers work on 20 different engine platforms with
250 variants of vehicles. It is one of the most modern in the Indian
automobile industry, featuring state-of the-art equipment and facilities
such as a noise, vibration and harshness (NVH) lab and a crash test
lab. The ERC has come a long way from the time it was set up in
1966, just three years before the collaboration between Telco (as Tata
Motors was known then) and Daimler-Benz AG was to end. It is
responsible for the Design and Development of new parts and
products and carrying out Research on existing facilities and models
for further improvement. They are also required to release detailed
technical drawings of their projects and models for better
understanding of the technical staff.
• PLM:
Product lifecycle management (PLM) is an information
management system that can integrate data, processes, business
systems and, ultimately, people in an extended enterprise. PLM
software allows you to manage this information throughout the entire
lifecycle of a product efficiently and cost effectively, from ideation,
design and manufacture, through service and disposal. Diverse
functions and technologies converge through PLM, including:
 Product data management (PDM)
 Computer-aided design (CAD)
 Computer-aided manufacturing (CAM)
 3D computer-aided engineering (CAE) and simulation
 Finite element analysis (FEA)
 Modal testing and analysis
 Digital manufacturing
 Manufacturing operations management (MOM)

Fig.10 PLM ScreenShot
• PPAP:
Production Part Approval Process (PPAP) is used in the
automotive supply chain for establishing confidence in component
suppliers and their production processes, by means of demonstrating
that “all customer engineering design record and specification
requirements are properly understood by the supplier and that the
process has the potential to produce product consistently meeting
these requirements during an actual production run at the quoted
production rate.”
The PPAP process is designed to demonstrate that the
component supplier has developed their design and production
process to meet the client's requirements, minimizing the risk of
failure by effective use of APQP. Requests for part approval must
therefore be supported in official PPAP format and with documented
results when needed.
The result of this process is a series of documents gathered in
one specific location (a binder or electronically) called the "PPAP
Package". The PPAP package is a series of documents which need a
formal approval by the supplier and customer. The form that
summarizes this package is called PSW (part submission warrant).
The approval of the PSW indicates that the supplier responsible
person (usually the Quality Engineer) has reviewed this package and
that the customer has not identified any issues that would prevent its a
SAP.

• SAP:
SAP stands for Systems Applications and Products and is a
German multinational software company known for making
enterprise resource planning (ERP) software. ERP software allows
organizations to manage business operations, and usually refers to
suite of modular applications that collect and integrate data from
different aspects of the business.
SAP is an ERP system provided by the SAP Company that
handles almost all departments of organizations. SAP handles an
organization's Finance, Controlling Human Resource, Sales,
Distribution, Material management, Warehouse, Production,
Security, Research and many other departments.
Fig.11 Systems Applications and Products

•UPL:
Unique Parts List (or UPL) is a subset of BOM. It is the list of
the raw materials, sub-assemblies, intermediate assemblies, sub- components
and parts which are unique with respect to a vehicle model. These parts are
either a part of any other model or may be a new fresh part that needs to be
ordered from a new supplier or an existing one. UPL is created to classify
the parts for if their Development is required (i.e. when they are new to the
vehicle and not been manufactured in the plant earlier or procured from a
supplier which means their Purchase Order was not available) and if their
Purchase order is available, then to distribute its Share of Business (SOB
among the different suppliers.
e
Fig.12 UPL Screenshot

INFO FITMENT DRAWING (IFD):
These drawings are released by the ERC
(Engineering research centre) and can be download by PLM software.
IFD’s are used for knowing the parts fitment position and how that
part will be fitted on vehicle. What is the routing of wire harness? And
how many clamps should be used for holding that component? these
all information is taken by the IFD’s.
Fig. 13 screenshot of info fitment drawing (tail wiring and abs connection)

VLO:
VLO stands for vehicle lay out. After roll out the vehicle
Quality Engineering Department conform the vehicle with the
drawings and make a report of defects in that vehicle according to the
drawing like – some parts are missing which is in drawing but not
fitted in vehicle, some parts are not fitted as per the drawing. This
report is called VLO report. Quality engineering department gives
some pointers to every defect according to their critical parameters.
Pointers ranges between 10 to 100. Every 40 and 100 pointer defects
are said to be very critical issues. All 40 and 100 pointer issues should
be closed before VLO closure.
Fig. screenshot of VLO report

TMPS:
TMPS means TATA Motors Production System.
According to this there may many critical issues beyond the drawings
i.e. pipe fouling, AC pipe and fuel pipe is tied together. These are
many critical issues which are not shown in drawings. So these issues
are listed under the TMPS. These also should be closed before VLO
closure.
ICA:
ICA stands for Immediate Corrective Action. After getting
the VLO report from the CQ department, Planning department has to
work on that issues which are described in report.
Vehicle goes in R1 area and rework has been performed there under
the guidance of planning staff. All the issues are corrected there and
again CQ conform this vehicle and gave the pointers. This process
will not be completed until the total score of TMPS and VLO does not
become under 400 and all the 40 and 100 pointer issues must be
closed.
PCA:
Permanent Corrective Action that means which issues had
corrected from the VLO and TMPS report, now are going to be as
PCA. All the issues are informed to the respective departments that
these issues should not be repeated in the future vehicle of same
model, and get the signature of respective officers.

RISK MITIGATION SHEET:
This sheet is prepared by Launch Quality
Department, because there are many technical risk after the rework.
That may be Wheel Base or Locking angle, Max. torque. This
department conform the data provided by ERC in the form of VPN
(Vehicle Pass of Norms) to the roll out vehicle and prepared a risk
mitigation sheet. After that planning department again make
correction in that vehicle and send the report to all the department.
After taking the signature from all the departments and being
confirmed that vehicle can be dispatched with theses left little risk,
vehicle is dispatched.
Fig. screenshot of risk mitigation sheet

FLOW DIAG. OF ALL THE WORKS DURING NEW
PRODUCT INTRODUCTION
fig. 13 flow diagram

INTRODUCTION ABOUT PROJECT:
• To Study about the ABS and work with the team in installation of
ABS in vehicle: LP 1512/42 WB MSRTC
LPO 1512/53 WB SBSTC
Parts of ABS:
PULSE WHEEL:
Each speed sensor usually has a pulse wheel
(toothed wheel), like a gear, that rotates at the same speed as
the vehicle wheel or axle.
fig.14 pulse wheel or toothed wheel

Wheel Speed Sensor:
A wheel speed sensor or vehicle speed
sensor (VSS) is a type of tachometer. It is a sender
device used for reading the speed of a
vehicle's wheel rotation. It usually consists of a
toothed ring and pickup. Wheel speed sensors are
installed directly above the pulse wheel, which is
connected to the wheel hub or the drive shaft. The pole
pin inside a coil is connected to a permanent magnet and
the magnetic field extends to the pulse wheel. The
rotational movement of the pulse wheel and the
associated alternation of teeth and gaps effects a change
in the magnetic flux through the pulse wheel and the coil.
The changing magnetic field induces an alternating
voltage in the coil that can be measured. The frequencies
and amplitudes of the alternating voltage are related to
the wheel speed. Passive inductive sensors do not need a
separate power supply from the control unit.
fig. 15-wheel speed sensor

fig. 16 setup of sensor with pulse wheel
ELECTRONIC CONTROL UNIT (ECU):
The ECU connects to the following ABS components:
wheel speed sensors, ABS modulator valves, power source,
ground, warning lamps, blink code switch, diagnostic connector,
and retarder control device. During braking, the ECU uses voltage
pulses from each wheel speed sensor to determine wheel speed
changes. If the ECU determines that the pulse rate of the sensed
wheels indicates imminent lock-up, it cycles the ABS modulator
valves to modify brake air pressure as needed to provide the best
braking possible. The ECU sends signals to the ABS malfunction
indicator lamp or blink code lamp to communicate ABS faults. It
also sends signals to the retarder control to disengage the retarder
when the ABS is working. When the ABS stops modulating the
brake pressure, the ECU permits retarder use once again.
fig. 17 flow dig. ECU

MODULATOR VALVE:
ABS modulator valves regulate the air
pressure to the brakes during ABS action. When not receiving
commands from the ECU, the modulator valve allows air to flow
freely and has no effect on the brake pressure. The ECU
commands the modulator valve to either:
• Change the air pressure to the brake chamber, or
• Hold the existing pressure.
However, it cannot automatically apply the brakes, or
increase the brake application pressure above the level
applied by the driver. The modulator valve typically contains
two solenoids. The modulator valve and relay valve may be
incorporated into a single unit. The modulator valve may
also be separate, inserted into the service line to the brake
chamber(s) after any relay valve, located as close as
practicable to the chamber(s) itself. When the modulator
valve is separate, it has to control more air flow and,
therefore, includes two larger diaphragm valves which are
controlled by the solenoids. It usually has three ports: the
supply port, the delivery port and the exhaust port
• The supply port receives air from a quick release or relay
valve.
• The delivery port sends air to the brake chambers.
• The exhaust port vents air from the brake chamber(s).
Typically, when an ECU controlling a separate modulator valve
detects impending wheel lockup, it activates the solenoids to close
the supply port and open the exhaust port. When enough air is
vented to prevent wheel lockup, the exhaust valve will close and
the ECU will - depending on the situation - either:
• Keep the supply port closed to maintain existing pressure,
• Open the supply port to allow brake application pressure to
increase and repeat the cycle.

fig.18 modulator valve fitted at the cross member
ABS Malfunction Indicator Lamp:
Indicator lamp are required
to light up for short periods of time for a bulb check whenever
the ABS starts to receive electrical power. In-cab ABS indicator
lamps are typically located on the instrument panel.
fig.19 ABS indicator lamp on

TRACTION CONTROL SYSTEM:
Traction control systems are
designed to prevent wheel spin in the power mode. Traction
control attempts to regain traction by braking the spinning wheels,
and sometimes throttling back engine power. Unlike an ABS,
traction control can automatically apply the brakes. The driver
does not need to depress the brake pedal for traction control to
engage. Traction control electronics are integrated into the ABS
ECU. The system applies the brakes on the spinning wheel’s when
the wheel speed sensors tell the ECU that a wheel is accelerating at
a much faster speed than the wheel on the other end of the axle. It
does this by energizing a solenoid valve, which directs reservoir
pressure to the relay valve and simultaneously activates the
modulator valves to keep air pressure from the brake chambers.
The ECU then directs the modulator valve to open, and pulse air
into the brake chamber on the spinning wheel until wheel speed
balance is regained. On some systems, the ECU will throttle back
engine power if both wheels are spinning too fast. If all the drive
wheels on a tractor are spinning too fast, the tractor can become
unstable, spin or jack knife. Traction control is especially valuable
when a light drive wheel load might allow the wheels to spin under
power, or when a tractor is pulling multiple trailers.
• Traction control systems are designed to prevent wheel spin
in the power mode.
• Unlike an ABS, traction control can apply the brakes
automatically. The driver does not need to depress the brake
pedal for traction control to engage.
• Traction control is not required by law, but it is a common
ABS option.

PROCEDURE FOLLOWED DURING PROJECT:
• study and analyze the working of ABS.
• understand the process of new product introduction.
• Work in the team for installation of ABS in two vehicles
LP 1512/42 WB MSRTC, LPO 1512/53 WB SBSTC
• We have to close all the all the severe point from the VLO
report which was provided by the CQ department.
• After the closure of VLO we have to work on risk
mitigation list.
• Finally, the closure of VLO report and risk mitigation report
has been done, and now the vehicle is ready to dispatch.
CONCLUSION:
Concluding the project, I had worked on
understanding the challenges faced by staffs in installation of
ABS and came up with suggestions which I hope would be
helpful improving the further operations.
SUMMARY
The entire training period at TATA Motors, Lucknow was a
memorable experience for me. This experience gave me a
deeper insight into the work culture of the company. I greatly
value the project undertaken by me during this period since this
proved to be extremely enlightening. The project gave me an
opportunity to work in the industrial environment. My project
head was extremely helpful and guided me throughout the
period. I cherish the experience gained by me during this
endeavour and hope this would be of great help in future. I also
owe a lot to our fellow trainees and other employees in this
facility that were extremely supportive and made my training
experience here very enlightening as well as enjoyable.
Finally, I would like to thank Mr. Prashant Pandey for having
given us this wonderful opportunity.

ABHAY VERMA PROJECT

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