Maharashtra State Board of Technical Educationpage 1

AN INDUSTRIAL TRAINING
REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENTS
IN
MECHANICAL ENGINEERING
BY
NITIN CHANDRAKANT DUDHAVADE
AT
GENERAL MOTORS COMPANY LLC
DEPARTMENT OF MECHANICAL ENGINEERING

DR. D.Y. PATIL POLYTECHNIC AKURDI, PUNE – 44
(Affiliated To MSBTE, DTE Mumbai) 2019 – 2020
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 1

Maharashtra State
Board of Technical education

Certificate of Completion
Of Industrial Training
This is to certify that Mr/Ms. Nitin Chandrakant Dudhavade With
Enrollment No. 1801340177 has successfully completed Industrial
Training (22049) in General Motors & Process Quality Control from
23/06/2020 to 20/07/2020 for partial fulfillment towards completion of
Diploma in Mechanical Engineering from Y.B Patil Polytechnic, Akurdi
Institute Code - 0134
Seal of the
Head of the Department Institute Head of the Institute

ABSTARCT

ACKNOWLEDGEMENT
I am highly grateful to our honorable Principal Mr. A.S. Kondekar for allowing me to do this
project work. I am also thankful to our Head of Department Mr. D.V. Moghekar. It is truly a
matter of great pleasure me to express my sincere thanks and gratitude to Mr. Chandru
Pattanshetty for his supervision and encouragement throughout this project. I am immensely
indebted to Mr. Chandru Pattanshetty for the invaluable help that he rendered at every step of
this project. It is a wonderful experience to be a part of. “General Motors Company” Where we
work under brilliant minds. We owe our deep regards for the supporting and kind staff
authorities who are helping me In my lean patches during these two months. The knowledge we
are gaining throughout our studies have the practical implementation during this period. We are
grateful to all the staff of “Y.B PATIL POLYTECHNIC AKURDI”

INDEX
SR
TITLE PAGE NO.
NO.
Certificate Of Completion 2
1.
Abstract 3
2.
3. Acknowledgement 4
Chapter 1 :- Introduction Of Organization 6-7

4.
Chapter 2 :- Organizational Structure
5.
Chapter 3 :- Types Of Machines &
6.
Instruments
Chapter 4 :- Manufacturing Processes Of
7.
Production
Chapter 5 :- Testing Of Raw Materials
8.
Chapter 6 :- Quality Policies Of Company
9.
Chapter 7 :- Range Of Products
10.
Chapter 8 :- Vision & Mission Of Company
11.
Chapter 9 :- Expansion Of Company
12.
Chapter 10 :- Turnover Of Comapany
13.
Chapter 11 :- Furure Plans
14.
Chapter 12 :- Milestones Of Company
15.
Process:- Quality Control In Detail
16.
CHAPTER I

 Introduction:-
General Motors (GM), one of the world's largest auto manufacturers, makes and sells cars and
trucks worldwide under well-known brands such as Buick, Cadillac, Chevrolet, GMC, and
Holden. Business divisions GM North America and GM International handle the automotive end
of the business while General Motors Financial Co. provides financing services. Looking toward
the future of transportation, the company is investing in developing electric vehicles and
autonomous vehicles, and it has established a ride-sharing service dubbed Maven. GM's biggest
single market is the US, which accounts for about 80% of sales. General Motors Co designs,
builds and sells trucks, crossovers, cars and automobile parts worldwide. The Company also
provides automotive financing services through General Motors Financial Company, Inc. (GM
Financial). GM North America (GMNA) and GM International (GMI) are its automotive
segments. GMNA and GMI are meeting the demands of customers with vehicles developed,
manufactured and/or marketed under the Buick, Cadillac, Chevrolet and GMC and Holden
brands. Its brands offer luxury cars, crossovers, sport utility vehicles (SUVs) and sedans. The
Company’s Car-and Ride-Sharing Maven is a shared vehicle marketplace. Through its subsidiary,
OnStar, LLC (OnStar), it provides connected safety, security and mobility solutions for retail and
fleet customers. GM Cruise is its global segment engaged in the development and
commercialization of autonomous vehicle technology.
 History:-

General Motors was founded in Flint, Michigan in 1908. In the early years of the auto industry,
hundreds of carmakers each produced a few models. William Durant, who bought a failing
Buick Motors in 1904, reasoned that manufacturers could benefit from banding together and
formed the General Motors Company in Flint, MI in 1908. In 1909, GM purchases Cadillac, AC
Spark Plug, and Rapid Motor Vehicle Company. It later developed the General Motors Truck
Company (which later became GMC), Chevrolet Motor Company of Michigan, General Motors
Export Company, and general Motors of Canada. After the stock market crash of 1929, GM
bought out the Fokker Aircraft Company and the General Motors Aviation Company was
launched. During WWII, the company began making military vehicles including trucks, guns,
airplane engines, airplanes and parts, tanks, and shells among other products. It also provided
the mobility system for the Lunar Roving Vehicle during the 1971 Apollo 15 space mission to the
moon. General Motors has manufactured some of the most popular vehicles ever made
including the Cadillac, Corvette, El Camino, Malibu, and Camaro. The auto giant went through a
six-week period of bankruptcy protection in 2009. GM was split into two companies — General
Motors and Motors Liquidation (the name for leftover assets). In 2011 Motors Liquidation sold
the majority of its assets, which encompassed almost 90 industrial sites in 14 states, which
cleared the way for GM bondholders to receive stock in the new company

CHAPTER II
 Organizational Structure Of General Motors Company:-

 Board Members & Advisors Of GM:-

CHAPTER III
 Types Of Machines & Instruments In GM:-
 Welding Robot:-
There are two basic categories of robotic welders: fully automatic, and semiautomatic:-
Semiautomatic welding, often good for limited quantities of products, requires an operator to
manually load the parts into the fixture. In fully automatic welding – ideal for critical welds,
repetitive work on identical parts, or if the parts are already hold significant value – there are
custom machines, or sometimes even a series of custom machines, set up to load parts, move
the torch, weld, monitor the quality of said weld, and then unload the completed part.
 Painting Robot:-
 CNC Machines:-

 Overhead Conveyor:-

 Stamping Dies:-
CHAPTER IV

 Manufacturing Processes Of Production:-
GM has adopted a number of innovations to reshape its manufacturing operations. An
innovation called the GM agile machining fixture introduced a process known as flexible
manufacturing that enables power train facilities to run different engine or transmission
families across common machining lines. This manufacturing technology allows for a significant
reduction to the setup and tooling costs that are typically incurred during product changeover.
Other innovations include a computer-based vision system, known as the Video Variance
Monitor, and web-based software called the Variation Reduction Adviser. The introduction of
these applications enables GM body assembly plants to quickly zqdiagnose and resolve quality
issues. Employees at the plant view and analyze body shop operations in real-time and share
problem-solving data on a variety of issues within the plant and across all GM’s assembly
centers. In addition to the efficiencies gained through the manufacturing innovations above,
GM operations have also benefited from a company-wide energy saving initiative. GM’s
product mix varies by country. In the U.S the company currently offers a lineup of 63 different
vehicle models, spread among nine different product areas. These product areas include coupe,
sedan, hatchback/wagon and sport/convertible cars, as well as, sports utility, crossover vehicles
and pick-up trucks. In addition, GM also offers vans and hybrid/electric vehicles. Today, our
vehicle manufacturing process has the lowest environmental footprint in our history, thanks to
steady progress toward achieving our 2020 operational commitments to reduce energy,
carbon, water and waste intensity.
MANUFACTURING:-

It is responsible for assembling various components of the car to make the final product.
Manufacturing department consists of the body shop, where the sheet metal parts are all
assembled and the basic BIW (Body In White) structure of the body is made; paint shop, where
the body and its assembly parts are chemically treated and painted; and finally Trim Line where
the vehicle is equipped with its various components, including chassis, engine, wheels, seats,
suspensions, etc.
The GMI manufacturing has in it three major shops as follows:
 BODY SHOP:-
Major activity carried out in body shop is the welding of all the press components and
assembling it to form the car body as per specified model. The maintenance team 1 is
responsible for this area. This team is split into two groups which work alternatively in A and
B shifts under leadership of team leader and assistant team leader respectively. Major
equipments in this area are Weld Transformers, Weld Guns, Fixtures, Sealer Pumps, Stud
welders, Projection welders, Mig welders, etc.
 PAINT SHOP:-
The paint shop is further divided into Body Paint shop and Plastic paint shop. The output
from the Body shop comes to the Body paint shop and after the paint job is completed, the
painted car body is transferred to the Assembly shop for final assembly. Major areas or
booths in Paint Shop are Pre Treatment plant, electro dip
plant, electro coat oven, spray booths, prima and topcoat oven, paint shop ventilators,
body-carrying trucks, PT-Elpo conveyors and spray-booth. The Plastic parts like Bumpers

are painted in the Plastic Paint shop and once the paint job is completed it is send to the
Assembly line for final assembly. The Major equipments in the plastic paint shop are
Flaming Zone, Spray Booth and Humidifier; Sludge handling system, Oven and plant
ventilation. Maintenance Team 4 is responsible for this area.
 ASSEMBLY SHOP:-
This is the last activity of the Production where the car is completely assembled. The major
areas in the Assembly shop are Trim Line, Chassis Line, Car Final and Final Process. Currently
two lines are running parallel to each other. One is T&J line producing Optra, Aveo, UVA and
Spark under the brand name of Chevrolet & second one is I-163 line producing Tavera under
the brand name of Chevrolet.
CHAPTER V
 Testing Of Raw Materials:-

Raw Materials, Services and Supplies We purchase a wide variety of raw materials, parts,
supplies, energy, freight, transportation and other services from numerous suppliers to
manufacture our products. The raw materials primarily include steel, aluminum, resins, copper,
lead and platinum group metals. We have not experienced any significant shortages of raw
materials and normally do not carry substantial inventories of such raw materials in excess of
levels reasonably required to meet our production requirements. Costs are expected to remain
elevated due to the price of commodities and the continuing existence of tariffs. In some
instances, we purchase systems, components, parts and supplies from a single source and may
be at an increased risk for supply disruptions. Raw materials analysis requires a wide range of
analytical chemistry expertise. The most common tests performed in a raw materials laboratory
include titrations, loss on drying, Karl Fischer moisture determination, heavy metals limit tests,
and infrared spectrophotometry. Full monograph testing often requires as many as seven
different analytical techniques. For example, to perform full USP monograph testing for
methylparaben, eight different tests using six analytical techniques ranging from infrared
absorption to gas chromatography are required. Therefore, the most efficient organization of a
raw materials laboratories is by function so that analysts can specialize in specific techniques.
To perform even basic monograph testing, laboratories must contain a wide spectrum of
instrumentation.
CHAPTER VI
 Quality Policies Of Company:-

GM International Single Administrator provides this document, in order to define the Policy for
Corporate Quality and the related goals and tasks. GM International S.r.l offers international
shipping services on customer’s specific request and stands out as a cutting-edge company for
speed, efficiency and flexibility, thanks to the commitment and skills of its employees.
Therefore GM International S.r.l aims at offering its customers high quality services, which go
beyond the shipment itself and stretch to full assistance and consultancy in the field of logistics,
transportation, delivery, storage and any services related to custom clearance of foreign goods,
including custom and VAT deposit. Our main goal is to strengthen and develop our position in
the market, through a continuous improvement in our offering, in order to increase customer
satisfaction. Our first task is the creation and maintenance of procedures, which help our
organization in defining clear and efficient operations and communication processes, so that we
are able to check and improve every stage of our service offering, thus facilitating the
achievement of both personal and company goals. GM International Single Administrator is
determined to increase brand awareness, through crystal-clear communication towards
customers, high professionalism and unmistakable and personal style. Being aware of the
importance and responsibility of what above mentioned and having identified the
organizational solutions within the Company, the Single Administrator of GM International S.r.l
decided to implement and maintain a Quality Management System accomplishing the ISO 9001:
2015 prescriptions and the Guidelines on good distribution practice (GDP) of medicinal
products for human use issued on 5th November 2013 (ex art 84, art 85 ter, par 3, EEC Directive
2001/83). The Company Quality System is also fully integrated with all the other systems within
the Company, such as: AEO certified system for custom compliance; IATA Certified system for

safe air shipment. GDP certified system for shipment and delivery of pharma products. Given
the above, GM International S.r.l aims at constantly improve its efficiency, services,
communication, and skills and above all the motivation and engagement of its team. Being
aware of the importance and responsibility of what above stated, the Single Administrator of
GM International S.r.l is committed to implementing, maintaining and improving the current
Company Quality System. Quality department ensures the best quality to be delivered to the
customers. Quality department audits vehicles right from body shop until final buyoff of the
vehicle. This department has Global Customer Audit area (GCA) where the vehicle is being
inspected for quality, manufacturing and engineering related faults in front of their respective
dept. director and vice-president. The faults are noted down in a book and respective actions
are then taken.
CHAPTER VII
 Range Of Products:-
GM (General Motors) is best known as the worlds largest full-line vehicle manufacturer. As a
leader in the transportation business GM has products categoring to about every transportation
need. What cars does GM make? Who does GM own? Among the General Motors brands are

Chevrolet, Buick, Cadillac, and GMC. GM makes all kinds of vehicles, from GM sports cars, SUVs,
and smaller cars as well.
 These Products Include:-
 Cars, Trucks, Vans, Buses And Sport Utilities
 Locomotives, Diesel Engines, And Gas Turbines
 Heavy Duty Automatic Transmissions
 Defense Equipment
 Financial Products
 Information Management And Communication
 Ventilators In Recent Covid19 Crisis
 General Motors features several popular vehicle models, including:-
 Hummer H2:- This pick-up truck offers an extendable box that can reach a length of 6
feet. The cab has room for 6 or 7 passengers.
 Pontiac GTO:- Available from 1964 to 1974, this was widely considered to be the first
muscle car, heralding a trend that resulted in numerous competitors.
 Chevrolet Volt:- The Volt is a plug-in hybrid introduced in the US in December 2010. GM
has sold 73,000 Volts since the model's introduction.
 Cadillac Escalade:- Cadillac's first SUV, this luxury model was first introduced for the
1999 model year in response to similar luxury SUVs.

 Corvette Stingray Racer:- This concept car was produced in 1957 to serve as the basis
for the second-generation Corvette Stingray.
 Chevrolet Camaro:- The iconic Camaro has been classified as both a pony car and a
muscle car. It was designed for the 1967 model year to compete with the Ford Mustang.
 Pontiac Aztek:- This mid-size four-door crossover with four-wheel drive and a four-
speed transmission was manufactured from the 2001 model year through 2005.
 Cadillac CTS:- This mid-size luxury sedan was introduced in 2002. It's currently available
as a four-door sedan, two-door coupe, or five-door sport wagon.
 Hummer H3:- This SUV is the smallest Hummer in the line, and the only one built by
GM.
 Chevrolet Chevette:- Available in both three-door and five-door styles, this subcompact
car was made for model years 1976 through 1987.
CHAPTER VIII
 Mission Of General Motors:-

General Motors Mission Statement:-
"G.M. is a multinational corporation engaged in socially responsible operations, worldwide. It is
dedicated to provide products and services of such quality that our customers will receive
superior value while our employees and business partners will share in our success and our
stock-holders will receive a sustained superior return on their investment." The statement

inclines towards the experience General Motors can have on anyone the company interacts
with. It has the following components:
 Distinguished services
 Improving communities
In the motor vehicle industry, there is no room for laxity. General Motors understands that
competition is stiff and that customers go for nothing but the best brands. To satisfy this need,
General Motors ensures that it is abreast with the latest technological advancements, and
incorporates these to its designs. In this way, it has been offering its customers products and
services they can get nowhere else. Additionally, General Motors do more than design cars and
related products. The company extends its benefits to the society not only by designing
sustainable sensitive cars but also by building healthy communities.
 Vision Of General Motors:-

General Motors Vision Statement:-
General Motors’ vision statement is “to create a future of zero crashes, zero emissions, and
zero congestion, and we have committed ourselves to leading the way toward this future.” The
statement has the following elements:
 Create a future
 Leading the way towards this future

In the first element, General motors take up the responsibility of stimulating innovations that
favor future success in the motor vehicle industry through its diverse and highly creative team
of experts. The second component relates to the first one in that the company also takes up the
mandate of leadership to show the way and how to exploit innovations for the holistic growth
of the sector. GM’s vision statement, unlike its mission statement, alludes to it being a vehicle
manufacturer that takes responsibility for building a safer, better future. “…zero crashes, zero
emissions, and zero congestion” to us, it feels as though the company is alluding to its ongoing
R&D to build better and safer vehicles. However, the company is investing heavily in green
technology, which has next to no emissions.
CHAPTER IX
 Expansion Of General Motors:-
 GMC - Corporate Affairs (Detroit).
 NAO - North America Operations.
 Vehicle Sales, Service, & Marketing Group - Warren Michigan, Midsize and Luxury Car
Group - Los Angeles, California + Mexico & Canada sales offices.
 LAO - Latin America Operations Brazil, Argentina.
 GME - General Motors Europe,

Poland, Germany, Egypt, South Africa, Hungary, Czech Republic.
 APO - Asia Pacific Operations,
Indonesia, Japan, China & Hong Kong, Philippines,
India, Australia,Malaysia, South Korea, Thailand.
CHAPTER X
 Turnover Of General Motors:-
General Motors Annual Revenue (Millions of US $):-
 2019 $137,237
 2018 $147,049
 2017 $145,588
 2016 $149,184
 2015 $135,725

 2014 $155,929
 2013 $155,427
 2012 $152,256
 2011 $150,276
 2010 $135,592
 2009 $104,589
 2008 $148,979
CHAPTER XI
 Future Plans Of GM:-
Now that it has become evident the future for the automotive industry is electric, auto
companies are betting big on electrification. General Motors recently that it will have 20 all-
electric vehicles to offer by 2023. As for near future, the biggest automobile company in the
United States plans to introduce two electric cars in coming 18 months. Known for its
performance and sports utility vehicles, General Motors is also looking at a catalogue of
battery-operated vehicles and hydrogen fuel-cell cars, which also run on electricity, stated a

Bloomberg report. The profits from GM's SUV line-up will be reportedly used to fuel company's
shift towards zero-emission vehicles. Mirroring the global auto scenario, Indian car markets
have also decided to go electric. Even though General Motors has already decided to close shop
here, there is no dearth of players. Market leader Maruti Suzuki has planned to produce electric
cars at its Gujarat plant for supplying both Indian and world markets. Another Indian auto giant,
Tata Motors, bagged Rs 1120 crore bid to supply 10,000 electric cars that will replace the fossil
fuel-driven government vehicles. Mahindra and Mahindra, which has been present in the
electric segment for long now, has disclosed plans to launch electric variants of its flagship SUVs
Scorpio and XUV500. The Indian car maker has even signed an agreement with Ford Motors, of
which electrification is a crucial aspect. General Motors even showcased the upcoming version
of its electrically powered sedan Volt, alongside other concept cars based on its Buick and
Cadillac brands in Detroit yesterday.
The event included a utility vehicle concept that uses fuel cells and two electric motors, named
Silent Utility Rover Universal Superstructure or SURUS. In a market still dominated by engine-
powered vehicles, General Motors is committed to an all-electric future. The Chevrolet Bolt EV
is just a start, as the company prepares to launch a number of all-electric models in the next
several years. The team is repositioning a 110-year-old company from one of massive scale,
industrial might and market coverage into a nimble, technology-driven mobility company intent
on reinventing personal transportation as we know it. All with the vision of creating a world
with Zero Crashes, Zero Emissions and Zero Congestion. The company plans to be present in
every market segment. GM will soon roll out the small car, Chevrolet Spark (the relaunched
version of Daewoo’s Matiz). The company is also conducting a due diligence on Daewoo Motors

India Limited and, as per plans, Chevrolet Spark will be rolled out from the company’s Surajpur
facility near Delhi.
CHAPTER XII
 Milestones Of General Motors :-
GM recently reached a significant milestone: 500 million vehicles built globally under our
brands Chevrolet, Cadillac, Opel, Wuling and others. Within that exclusive 500-million
production milestone are dozens of innovations that have improved our customers’ lives and
changed the face of the automotive industry.
 1964: 100 Million in Worldwide Production

1901: Ransom Olds’ famous Curved Dash Oldsmobile, designed with simplicity, reliability and
value in mind, was the first American car built in a factory designed specifically for automobiles
and in standardized volume production. GM acquired Oldsmobile in 1908.
1908: Cadillac wins the Dewar Trophy, Europe’s most prestigious award for precision and
excellence in manufacturing, by demonstrating the auto industry’s highest standards for
precision and interchangeability of parts by disassembling three Cadillacs and mixing the parts
randomly before reassembling and driving them before a contingent of judges.
1961: The world’s first industrial robot is used at GM’s Ternstedt components plant in Trenton,
N.J. The Unimate’s 4,000-pound arm positions extremely hot diecast metal parts into cooling
pools.
1969: The world’s first programmable logic controller (PLC) application occurs at the Hydra-
Matic Transmission plant in Ypsilanti, Mich. This digital controller was used to automotive
machinery on assembly lines, replacing the labor-intensive use of relays.
1966: Lordstown (Ohio) Assembly opens, and is touted as the most automated automotive
plant in the world.
1980: GM unveils a standardized computer language called Manufacturing Automation Protocol
(MAP) to communicate with PLCs, robots, conveyors and other plant-floor equipment. Within

two years GM Truck and Bus in Pontiac, Mich. truck begins installing MAP. The result is better
control over the manufacturing process because proprietary data systems are eliminated.
2005: GM operates three of the top five vehicle assembly plants in the annual Harbour Report.
The Oshawa, Ontario, plant is ranked the most productive plant in North America.
PROCESS: QUALITY CONTROL
 Definition Of Quality Control:-
Quality is a relative concept. It is related to certain predetermined characteristics such as shape,
dimensions, composition, finish, colour, weight, etc. In simple words, quality is the performance
of the product as per the commitment made by the producer to the consumer. J. M. Juran
(1970) who is considered the father of quality research has defined quality as “the performance
of the product as per the commitment made by the producer to the consumer.”
 There are two main elements in this definition of quality:-
 First, the commitment may be explicit such as a written contract or it may be implied in
terms of the expectations of the average consumer of the product.

 Second, the performance of the product relates to the ultimate functions and services
which the final product must give to the final consumer.
For example, a watch should show accurate time or a ball point pen should write legibly on a
piece of paper. According to ISO 8402: Quality is the “The totality of features and characteristics
of a product or service that on its ability to satisfy stated or implied needs.” In practice, when
we say any product as a quality product, it means the product satisfies certain criteria for its
functioning. For a quality product, it is necessary that it should satisfy the laid down criteria not
only at the time of its manufacture, but also over a reasonable length of time. In India, Bureau
of Indian Standards lays down certain criteria for a number of products both industrial and
domestic.
Quality control is also a strategic decision. It can be defined as the systematic control of those
variables which are encountered in the manufacturing process and which adversely affect the
excellence of the final product in one way or other.
 Alfort and Beaty defined quality control as:-
“Quality control is the mechanism by which products are made to measure up to the
specifications determined from the customer’s demands and transform into sales, engineering
and manufacturing requirements. It is concerned with making things right rather than
discovering and rejecting those made wrong. Quality control is a technique by means of which
products of uniform acceptable quality are manufactured.”

 Quality control (QC) is a process by which entities review the quality of all factors involved
in production. ISO 9000 defines quality control as "A part of quality management focused
on fulfilling quality requirements".
This approach places emphasis on three aspects (enshrined in standards such as ISO 9001):-
 Elements such as controls, job management, defined and well managed processes,
performance and integrity criteria, and identification of records
 Competence, such as knowledge, skills, experience, and qualifications
 Soft elements, such as personnel, integrity, confidence, organizational culture, motivation,
team spirit, and quality relationships.
 The quality of the outputs is at risk if any of these three aspects is deficient in any way.
History And Introduction
 Quality Control In Early Times:-
Early stone tools such as anvils had no holes and were not designed as interchangeable parts.
Mass production established processes for the creation of parts and system with identical
dimensions and design, but these processes are not uniform and hence some customers were
unsatisfied with the result. Quality control separates the act of testing products to uncover
defects from the decision to allow or deny product release, which may be determined by fiscal
constraints. For contract work, particularly work awarded by government agencies, quality
control issues are among the top reasons for not renewing a contract. The simplest form of
quality control was a sketch of the desired item. If the sketch did not match the item, it was
rejected, in a simple Go/no go procedure. However, manufacturers soon found it was difficult

and costly to make parts be exactly like their depiction; hence around 1840 tolerance limits
were introduced, wherein a design would function if its parts were measured to be within the
limits. Quality was thus precisely defined using devices such as plug gauges and ring gauges.
However, this did not address the problem of defective items; recycling or disposing of the
waste adds to the cost of production, as does trying to reduce the defect rate. Various methods
have been proposed to prioritize quality control issues and determine whether to leave them
unaddressed or use quality assurance techniques to improve and stabilize production.
Methods Or Tools Of Quality Control
Any variations in the quality of a product, i.e., standards set are mainly caused by variations in
raw material, men, machines, methods, and procedures of procedures of production and
inspection. In order to produce the quality products, these variations need to be checked and
controlled.
There are mainly two methods of quality control:-
 Inspection:-
Inspection, in fact, is the common method used for quality control purposes not only in
production but also in services.
As regards inspection in production, there are three important aspects involved in it:-
 Product Inspection:-

As the name itself suggests, the product inspection relates to the final product sent into the
market. The main purpose of product inspection is to ensure that the products sent into the
market comply with the set standard for quality. In other words, it is to ensure that the product
ready for sale is perfect and free of defects.
 Process Inspection:-
Process inspection proceeds to product inspection. It is aimed at ensuring that the raw material
and machines and equipment’s used in the production process are of prescribed quality and
mark.
Process inspection benefits the unit in two ways:-
 It ensures the manufacturing of a quality product.
 It saves wastages of material by preventing process bottlenecks.
 Inspection Analysis:-
This is a method based on the analyses of inspections made. The conclusions derived from the
inspection analyses help the entrepreneur locate the exact points in manufacturing process
where faults lie. In other words, it enables the entrepreneur to identify the points at which
deviations from standard set start. Quality control through Inspection Method is shown in the
following Figure.

Quality Control Through Inspection
 Statistical Quality Control:-
It is an advanced method or technique used to control the quality of a product. This method is
based on statistical techniques to determine and control the quality. Sampling, probability, and
other statistical inferences are used in this method for controlling the quality of a product. It is
widely used in process control in continuous process industries and in industries producing
goods on a mass scale.
Under this method, the entire lot is, firstly sampled on the basis of its specific characteristics
and, then, is divided into three parts as mentioned below:-
 Analysis of Samples.
 Use of Control Charts.
 Corrective Measures.
A brief description about each of these follows:
 Analysis of Samples:-
This is based on sampling techniques. First of all, the universe i.e., the population to be
analysed, is identified. After this, following the sampling technique, the sample representing the
whole population is selected and analysed. It is important that we do not need to analyse all
the units of the population, but only a few units called ‘sample units’ are studied and analysed.

The result drawn from these sample units are then generalized as a whole. In other words,
inspection of samples means statistical inspection of the whole manufactured lot.
 Use of Control Chart:-
Realizing that figures/ charts are always welcome to depict the fact of findings, the results
obtained from analysis of samples are presented in a chart.
The method to draw a chart is as follows:-
 Measure the quality characteristics of sample selected.
 Find out the mean of the sample and also measure its range of dispersion.
 Then, data regarding mean and dispersion are gathered.
 Take a graph paper and plot the gathered data on it.
 Thus, you have a control chart ready to guide you about the quality deviation of your
product.
The shape of the control chart so plotted will be like as follows:-
Quality Control Chart

 Corrective Measures:-
Having drawn quality control chart, the entrepreneur can easily and clearly locate the points of
deviations and causes of it. This enables him to evolve corrective measures to control the
quality of the product accordingly. For example, if variation in quality is caused by inferior
quality raw material, the quality of raw material will be increased. Similarly, in case of
traditional machinery, new and modem machinery will be installed.
Quality Control In Manufacturing
In manufacturing, quality control is a process that ensures customers receive products free
from defects and meet their needs. When done the wrong way, it can put consumers at risk.
For example, the recent defect found in Takata airbags resulted in the biggest automotive recall
in history. The recall includes almost 69 million airbag inflators and may cost billions of dollars.
The recall will last until the end of 2019 and take until 2020 to resolve. Major recalls like these
can be prevented through effective quality control in manufacturing.
Some common tools used to support quality control include:-
 Statistical process control (SPC):-
Monitors and controls quality by tracking production metrics. It helps quality managers identify
and solve problems before products leave the facility.
 Six Sigma:-

Uses five key principles to ensure products meet customers’ needs and have zero defects.
When supported by lean tools like Total Productive Maintenance (TPM), 5S, and Kaizen, most
if not all defects can be eliminated.
 Benefits of Using Quality Control in Manufacturing:-

 Customers expect and demand high-quality products. When customers receive quality
products you will:-

 Increase customer loyalty.
 Gain repeat business.
 Gain new customers from referrals.
 Maintain or improve your position in the market.
 Improve safety.
 Reduce liability risks.
 Contribute to overall positive branding of your product.
Manufacturers with quality control procedures in place are far less likely to face product recalls
or place customers at risk from poorly made products. The cost associated with these recalls
can be steep. Testament to this is the Takata recall, which is estimated to cost the company
between $7 and $24 billion. Discover how you can avoid costly recalls and support your quality
control system with TPM. Graphic Products’ Best Practice Guide to Total Productive
Maintenance (TPM) will help you on the road to total quality. Improve quality, eliminate
defects, and increase your profits.
 Incorrect Implementation of Quality Control in Manufacturing:-

Quality control in manufacturing can be a little tricky. Often, it is done at the end of the
production process, only catching defects after the fact.
Effective quality control is more involved and should include two levels:-
 Operators monitor the manufacturing process and ensure that there is little variation.
 Engineers routinely monitor the product design for issues. When a problem is found, it is
immediately fixed.
By monitoring products at the end of production as well as reviewing the products design,
companies can solve problems more efficiently, saving time and money.
 How to Implement Quality Control in Manufacturing:-
To implement an effective quality control program, first create and document your approach to
quality control. This includes:-
 Defining the quality standards for each product
 Selecting the quality control method
 Defining the number of products/batch that will be tested
 Creating and training employees for quality control
 Creating a communication system for reporting defects or potential issues.
Quality Control in Small-Scale Industries

Although quality control is necessary for all units, yet it is more necessary for small-scale units.
This is because of the great use of manpower in small-scale industries during the manufacturing
processes. But, the application of quality control is difficult in them because of several
limitations like financial, technical and managerial. Quality implementation is total
organizational effort. The successful implementation of quality control largely depends upon
the quality of raw materials, selection of machinery and equipment, designing, manufacturing,
processes, etc. Besides, the timely and required assistance from the Government organizations,
associations, and institutes also contribute to successful implementation of quality control. In
India, Bureau of Indian Standards (BIS) has been doing a yeoman job in determining the quality
of a large number of products by laying down various criteria for them.
The quality control in small-scale industries is generally based on:
 Indian Standards specification.
 Quality marketing schemes.
 Company Standards in case of ancillary units.
 Any other standard specification prescribed by the Government or other purchasing
agencies.
The Indian Standards Specifications have been playing an important role in persuading small-
scale industries to adhere to the quality of their products.
For controlling quality of products manufactured by small units, the following Indian
Standards have been published so far:-

 Methods of statistical quality control during the production period.
 Manual on basic principles of lot sampling; and
 Sampling inspection table.
Several State Governments have been operating quality marketing schemes and standards for
various products of small-scale industries. When the small units manufacture their products
according to the standards set, the Quality Marketing Centers of the Government stamp the
“Q” mark on their products. This is an assurance for the customers that the product has been
manufactured adhering to certain quality standards.
 Quality Control of Export Production:-
Implementation of quality control has been very useful in raising exports from an economy. A
product can be sold in foreign markets only when it is not only cheaper but up to a certain
quality also. Standardization of these products convinces the foreign customers better than any
sales campaign. Realising this fact, the Government of India has made the inspection of several
products manufactured by small-scale industries compulsory before they are shipped abroad.
This has proved very beneficial for the Indian exporters to sell their products in highly
competitive foreign markets.
Importance Of Quality Control

Quality is an important factor when it comes to any product or service. With the high market
competition, quality has become the market differentiator for almost all products and services.
Quality control is essential to building a successful business that delivers products that meet or
exceed customers’ expectations. It also forms the basis of an efficient business that minimizes
waste and operates at high levels of productivity. A quality control system based on a
recognized standard, such as ISO 9001 published by the International Organization for
Standardization, provides a strong foundation for achieving a wide range of marketing and
operational benefits. Therefore, all manufacturers and service providers out there constantly
look for enhancing their product or the service quality. In order to maintain or enhance the
quality of the offerings, manufacturers use two techniques, quality control and quality
assurance. These two practices make sure that the end product or the service meets the quality
requirements and standards defined for the product or the service. There are many methods
followed by organizations to achieve and maintain required level of quality. Some organizations
believe in the concepts of Total Quality Management (TQM) and some others believe in internal
and external standards. The standards usually define the processes and procedure for
organizational activities and assist to maintain the quality in every aspect of organizational
functioning. When it comes to standards for quality, there are many. ISO (International
Standards Organization) is one of the prominent bodies for defining quality standards for
different industries. Therefore, many organizations try to adhere to the quality requirements of
ISO.
In addition to that, there are many other standards that are specific to various industries. Since
standards have become a symbol for products and service quality, the customers are now keen

on buying their product or the service from a certified manufacturer or a service provider.
Therefore, complying with standards such as ISO has become a necessity when it comes to
attracting the customers. Every organization that practices QC needs to have a Quality Manual.
The quality manual outlines the quality focus and the objectives in the organization. The quality
manual gives the quality guidance to different departments and functions. Therefore, everyone
in the organization needs to be aware of his or her responsibilities mentioned in the quality
manual.
Some of the important advantages to quality control are as follows:-
 The brand products build up goodwill or image which ultimately increases sales.
 It helps the manufacturers/ entrepreneurs in fixing responsibility of workers in the
production process.
 Quality control also helps in minimizing the costs by increasing efficiency, standardization,
working conditions, etc.
 It also enables the entrepreneur to know the cost of his / her product quite in advance
which helps him in determining competitive prices of his product.
 Last but not the least; the entrepreneur can confirm whether the product manufactured by
him / her is in accordance with the standard set by the Government.
Quality Control, QA and Lean Manufacturing

Lean manufacturing tools can bolster your company’s quality program. Lean revolves around
improving quality and safety while increasing efficiency and profits.
Some powerful lean manufacturing tools that can bolster your quality system include:-
 TPM improves product quality by eliminating downtime, defects, and accidents. TPM
accomplishes this through comprehensive maintenance programs and operator training.
 Kaizen helps eliminate problems at their source by empowering workers to find and solve
problems on a daily basis.
 5S helps organize and standardize the workplace. Take control with the 5S System Best
Practice Guide, by Graphic Products. Improve procedures and eliminate errors in your
facility.
The Techniques Of Quality Control

 There are several methods of measuring the performance of quality control. A quality
control chart is a graphic that depicts whether sampled products or processes are meeting
their intended specifications—and, if not, the degree by which they vary from those
specifications. When each chart analyzes a specific attribute of the product it is called a
univariate chart. When a chart measures variances in several product attributes, it is called
a multivariate chart.
 Randomly selected products are tested for the given attribute or attributes the chart is
tracking. A common form of a quality control chart is the X-Bar Chart, where the y-axis on
the chart tracks the degree to which the variance of the tested attribute is acceptable. The
x-axis tracks the samples tested. Analyzing the pattern of variance depicted by a quality
control chart can help determine if defects are occurring randomly or systematically.
 The Taguchi Method of quality control is another approach that emphasizes the roles of
research and development, product design, and product development in reducing the
occurrence of defects and failures in products. The Taguchi Method considers design to be
more important than the manufacturing process in quality control and tries to eliminate
variances in production before they can occur.
The Role of Quality Control Inspectors

A Quality Control Inspector checks the quality of incoming and outgoing products for a
company by conducting tests, monitoring production processes and identifying malfunctions.
They work in various manufacturing and production settings, such as the quality control
department, assembly lines and laboratories. These professionals examine quality standards in
the manufacturing stage of products like foods, motor vehicles, electronics, textiles and
clothing. Quality Control Inspectors ensures products meet their company’s quality standards
and are safe for consumers to use. Quality control inspectors protect the consumer from
defective products and the company from damage to its reputation due to inferior
manufacturing processes. If the testing process reveals issues with the product, the inspector
has the option of fixing the problem himself, returning the product for repairs or tagging the
product for rejection. When issues arise, the inspector notifies supervisors and works with them
to correct the problem. A Quality Control Inspector performs assessment, documentation and
organization tasks to support the efficiency and effectiveness of their organization’s supply
chain. These workers monitor quality standards for nearly all manufactured products, including
foods, textiles, clothing, glassware, motor vehicles, electronic components, computers, and
structural steel. Specific job duties vary across the wide range of industries in which these
inspectors work.
Cost of Quality Control

Lastly, let us also address to an important aspect of quality control, i.e., cost involved in
ensuring quality products. In fact, it is difficult, if not impossible, to precisely define cost
incurred in quality assurance due to so many imponderables involved. But there is no denying
of the fact that it should be a minor proportion of the total product cost incurred. How much
minimum should be the proportion of quality cost to total cost depends upon various factors?
Some of the important ones are:-
 Type of product, its functional use and hazards involved in its use.
 The degree of quality awareness prevailing in the enterprise by implementation of the
concepts like Total Quality Management (TQM) and Quality Control (QC).
 Lastly, additional costs to be incurred for ensuring higher quality standards. It must be
kept in mind that there is no optimum value between quality and product cost.


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AN INDUSTRIAL TRAINING

SUBMITTED IN PARTIAL FULFILLMENT OF THE

DEPARTMENT OF MECHANICAL ENGINEERING

(Affiliated To MSBTE, DTE Mumbai) 2019 – 2020

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 1

Board of Technical education

This is to certify that Mr/Ms. Nitin Chandrakant Dudhavade With

Enrollment No. 1801340177 has successfully completed Industrial

Training (22049) in General Motors & Process Quality Control from

23/06/2020 to 20/07/2020 for partial fulfillment towards completion of

Diploma in Mechanical Engineering from Y.B Patil Polytechnic, Akurdi

Institute Code - 0134

Head of the Department Institute Head of the Institute

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 2

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 3

grateful to all the staff of “Y.B PATIL POLYTECHNIC AKURDI”

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 4

Chapter 1 :- Introduction Of Organization 6-7

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 5

commercialization of autonomous vehicle technology.

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 6

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 7

 Organizational Structure Of General Motors Company:-

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 8

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 9

 Types Of Machines & Instruments In GM:-

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 10

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 11

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 12

GM has adopted a number of innovations to reshape its manufacturing operations. An

carbon, water and waste intensity.

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 13

The GMI manufacturing has in it three major shops as follows:

welders, Projection welders, Mig welders, etc.

booths in Paint Shop are Pre Treatment plant, electro dip

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 14

ventilation. Maintenance Team 4 is responsible for this area.

the brand name of Chevrolet.

 Testing Of Raw Materials:-

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 15

 Quality Policies Of Company:-

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 16

achievement of both personal and company goals. GM International Single Administrator is

determined to increase brand awareness, through crystal-clear communication towards

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 17

GM International S.r.l is committed to implementing, maintaining and improving the current

are then taken.

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 18

and smaller cars as well.

 These Products Include:-

 Cars, Trucks, Vans, Buses And Sport Utilities

 Locomotives, Diesel Engines, And Gas Turbines

 Heavy Duty Automatic Transmissions

 Information Management And Communication

 Ventilators In Recent Covid19 Crisis

 General Motors features several popular vehicle models, including:-

feet. The cab has room for 6 or 7 passengers.

muscle car, heralding a trend that resulted in numerous competitors.