Rejection Control and Increase in Productivity used by Mindarika Pvt. Ltd. (MRPL) for making Tata Nano Lever

Combination Switch

(A Summer Training Project Report

Submitted for partial fulfillment of PGDM)

Submitted by

Abhijeet Chandel

Roll No- M2011001

(Batch - 2011-13)

Under the Guidance of

Mr. Anurag Bharadwaj

Associate Professor

APEEJAY INSTITUTE OF TECHNOLOGY

School of Management, Greater Noida

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PREFACE

Summer training is an integral part of our academic curriculum. During the

training a student gets an opportunity to set the practical aspects of theory.

I feel great pleasure in submitting this piece of work as my summer training

project. I hope that this work will create a will to read and learn from this project.

It is expected that creation of this study shall benefit reader in all aspects regarding

Production of Automobile Switch and method to control rejections.

I have used my best efforts to cover nearly all the aspects related to

Rejection Control and Increase in Productivity in MRPL, Pune. The working title

of the project is “Rejection Control and Increase in Productivity used by

Mindarika Pvt. Ltd. for making Tata Nano Lever Combination Switch”. It

was conducted in a very cordial manner. This research is an attempt to present a

report based on practical knowledge acquired during my training. In my opinion,

the readers will be satisfied with the project and its application. I assure that this

work is my original work and its authenticity it true to the best of my knowledge

and believe.

ABHIJEET CHANDEL

ROLL NO - M2011001

AIT – SCHOOL OF MANAGEMENT, GREATER NODIA

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ACKNOWLEDGEMENT

A journey is easier when we travel together. Interdependence is certainly more important than independence.

It will always be my pleasure to thank those who have helped me generating this project, a lifetime experience for me. I would like to express my heartiest gratitude to AIT – School of Management, Greater Noida, for providing me an opportunity to accomplish this summer training in Mindarika Pvt. Ltd., Pune in the Department of Production. The important persons associated with this study did add value to this study and without their guidance and my hard work it would have never been possible to avail a real life experience of working with N. K. Minda Group, an original equipment supplier for TATA Motors having a national importance. The major objective of the study was to understand the problems related to rejection and searching a reason and method of rejection control.

I feel pleasure to extend my gratitude to Mr. D. N. Bajpai (Director of AIT-School of Management, Greater Noida) for providing me an opportunity to work with Mindarika Pvt. Ltd. And learn various aspects of the Rejection Reduction process and Increase the Productivity of the organization.

It is my privilege to thank Mr. Sunil Kulkarni (Manager, Assembly Dept., Mindarika Pvt. Ltd., Pune) and Mr. Anurag Bharadwaj (Asst. Prof, AIT-School of Management, Gr. Noida) whose guidance have enabled me to learn and understand the finer and complicated aspects of Production, in general and of Rejection Control and Increase in Productivity, in particular. The help and guidance which he has extended to me has made me feel as being an integral part of the continuous learning.

The greatest credit goes to the blessings bestowed upon me by Almighty God without whose yearning; I could not have even moved a step forward and to my parents who are always a constant source of inspiration in all my endeavors.

ABHIJEET CHANDEL

Roll No – M2011001

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CERTIFICATE

This is to certify that the project "Rejection Control and Increase in Productivity used by Mindarika Pvt. Ltd. for making Tata Nano Lever Combination Switch” is the bonafide project work done by Abhijeet Chandel student of Apeejay Institute of Technology- School of Management, Greater Noida during the Summer Internship Training, in partial fulfillment of the requirements for the award of the Degree of “Post Graduate Diploma in Management” and that the project has not formed the basis for the award previously of any degree, diploma, fellowship or any similar title. To the best of my knowledge and belief the project represents independent and original work on the part of candidate under my guidance.

Name and Signature of Mentor

Name and Signature of Director

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DECLARATION

This is to declare that the facts and figures used in this report have been true to the best of my knowledge. All the data provided has been authentic as far as their sources are concerned.

ABHIJEET CHANDEL

Roll No – M2011001

AIT-School of Management, Gr. Noida

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TABLE OF CONTENTS

1. INDRODUCTION(A) About the UNO MINDA-where the study was

conducted…………………………………………………..08(B) About the Mindarika Pvt. Ltd., Pune...................................20(C) About the Tata Nano………………………………………30(D) About the Tata Nano Lever Combination

Switch..................................................................................32

2. Research Objective……………………………………………...52

3. Research Methodology……………………………………….....54

4. Data Analysis and Interpretation………………………………...56

5. Findings…………………………………………………………68

6. Suggestions and Conclusions…………………………………….71

7. Limitations……………………………………………………….74

8. Bibliography……………………………………………………76

9. Questionnaire…………………………………………………...78

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Introduction

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About the UNO MINDA

Foreword the Uno Minda

This identity manual defines the corporate identify of the N K Minda Group and determines the various areas of the application. The main aspect in this is that of correct logo usage. These guidelines are to be strictly followed in all communication. Deviations from this, where absolutely necessary, have also been explained. The manual also attempts at simple application and an easy understanding.

These guidelines and design specification have a binding effect on all custodians of the UNO MINDA brand and shall as a general rule apply to the company’s internal and external communication. Only if these specification are consistently complied with, will the desired uniform appearance of the brand UNO MINDA can be achieved.

The Logo Deciphered

The term UNO connotes leadership and stands for beings the best (No. 1 as in Numerous UNO). The sans serif font of ‘UNO’ the timeless while beings contemporary. Its slim contours and smooth curves coupled with the sharp edges convey balance and precision giving a sense of sophistication in an understand manner. The UNO in reserve against blue is nicely balanced and commands attention without shouting.

The 3 arrow mnemonic has been modified and contemporized and is now an internal part of the logo. In their current form, the arrows signify: A forward looking approach, change and evolution and the global thrust of the group (the arrows are actually drawn around a sphere, to signify straddling the globe) with passion and energy.

The new group logo in its entirely reflects a combination of Stability with Growth, of Tradition with forward Thinking, of Continuity with Passion and energy, and of course, the global orientation of the N K MINDA Group.

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The baseline Decoded

Think. Inspire. FlourishThe UNO MINDA baseline is reflective of the core characteristics that define the N K MINDA Group

Think

We are a thinking entity.We accord value to applying thought in all aspects of operation.We appreciate bold and loud thinking; we place a premium on original thought.We encourage it. We celebrate it.For, we truly believe that it is the quality of our collective thought that makes us who we are.

Inspire

Inspiration is the key to our being. A cornerstone in our belief and value systems.We inspire and in turn are inspired.We aim to inspire trust, confidence, convocation and commitment in all who come in our contract.In turn, we are inspired by the higher ideals of growth, of value creation, of contribution and of the possibility of being the best we can be. Always

Flourish

Our destination is beyond mere growth; for we believe the quality of growth is an important as the growth itself.So while at heart we are a business, our soul beats for responsible and inclusive growth.Growth in human capital.Growth with professional values.Growth in the happiness quotient all around.We believe that when everyone grows, all stakeholders flourish

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Vision, Mission and Values

Vision

Group to be the Global Benchmark in QPCDSM by 2012-13 and pioneer Technology by 2014-15.Group turnover – 10k crore by 2014-15International business to be 25% 0f turnover by 2014-15.

Mission

To continually enhance stakeholders’ value through global competitive while contributing to society.

Values

The N K Minda Group has identified 5 core values and works towards inculcating these in its day-to-day working.

Customer is supreme

We understand and anticipate customer need and exceed their expectations.We aggressively pursue new business, determined to add value for our customer with ingenuity, determination and a positive approach to every task, a ‘can-do’ sprit We always ask “How can we serve our customer best?”

Live Quality

We nature quality as an attitude at UNO MindaWe are quality driven and “Apply a Quality Minded Approach to everything we do”.We are passionate about quality and its continuous improvement through teamwork.

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Encourage Creativity and Innovation to Drive 3 ‘P’s (People, Processes and Products)

We demonstrate leadership by advancing new technologies, innovative manufacturing techniques, enhanced customer service, inspired management and the application of best practice throughout our organization.We aggressively pursue new business, determined to add value for our customer with ingenuity, determination and a positive approach to every task and a restless determination continually improve and excel.We utilize our ability to combine strength with speed in responding enthusiastically to every new opportunity and every new challenge.We encourage and inspire learning amongst our people.

Respect for Individual

We have a strong belief that our employees are the most valued assets of our company, and they are essential participants with a spread responsibility in fulfilling our mission.We inspire, empower and enable people to achieve high expectations, standards and opportunity and every new challenges.We support mutually beneficial and enduring relationships with our stakeholdersWe treat all people with dignity and courtesy.

Respect for Work- Place Ethics

Work smartly with passion, integrity, conviction and commitment.We work in team with a shared purpose and value individually ability and diversity as essential to promote harmony and open communication. Each of us succeeds individually – when we as a team achieve success.We respect and adhere to company policies, systems and procedures.We will be well informed and respect the regulations, rules and compliance issues that apply to our businesses around the world.We respect the values and cultures of the communication in which we operate.

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Corporate Office of UNO MINDA:Minda Industries Limited Vill. Nawada Fatehpur, P.O. Sikanderpur Badda, Manesar Distt. GurgaonHaryana – 122004

 

Registered Office: B-64/1, Wazirpur Industrial Area Delhi 110052

Chief Executive of UNO MINDA : Mr. N K Minda - Chairman and Managing Director 

UNO Minda Group Companies

Minda Industries LimitedMinda Industries Limited (Battery Division)Mindarika Pvt. LimitedMinda Acoustic LimitedMinda Autogas LimitedMinda Emer Technologies LimitedTokairika Minda India Private LimitedMinda International LimitedMinda Auto Components LimitedMinda Autocare LimitedPT Minda Automotive AseanMinda Vietnam Company Limited

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Achievements of UNO MINDA

2011 - MRPL Manesar received ACMA Bronze Trophy for Excellence in Technology in the Non SME Category

2010 - MRPL Manesar received ACMA Gold Award for Manufacturing Excellence

2010 - BAL TPM EXCELLENCE AWARD to Minda Switch Pune Plant

2010 - MINDA Acoustic received “ Outstanding Performance Award - 2010“ from Mahindra – Automotive & Farm Equipment Sectors

2010 - MIL Blow Molding received “Best Localization Award” from Toyota Kirloskar Motor, Bangalore

2010 - MRPL Manesar received Gold Trophy in Good Green Governance Award

2010 - MRPL Manesar Received Gold Award from Quality Circle Forum – Delhi Chapter

2010 - MRPL Manesar received Energy Conservation Award from Government of India

2010 - “Grand Development Award 2010-11” to MIL – Switch Div. from HMSI

2010 - TAFE has awarded Minda-Lighting Sonepat as a “SELF CERTIFIED SUPPLIER”

2009 - ACMA Silver Trophy for Excellence in Technology in the NON SME Category this year. (MIL 2wh Switch - Gurgaon)

2009 - ACMA Gold Trophy for Recognition under Manufacturing excellence this year – (MINDARIKA PVT. LTD)

2009 - ACMA Gold Trophy for Recognition under Quality & Productivity excellence this year. – (MIL 2wh Switch – Pantnagar)

2008 - "Excellence in Quality" award from TATA Motors. The award was conferred on 16th Oct 2008 during Tata’s Annual Supplier’s Meet 2008 held in Mumbai.

   

 

 2007 - Minda launches Automotive batteries for OEM and Aftermarket

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2007 - Minda Industries Limited wins the National R&D Award 2007 by Department of Scientific & Industrial Research, Ministry of Science & Technology 

2005 - Bajaj Award for Excellence to Minda Industries Limited

2005- Achievement Award from Honda for quality & delivery to Minda Industries

Limited

2004 - Received TKML cost achievement award for Mindarika

2004 - NABL accreditation for Minda Industries Limited labs

2003 - Received TS 16949 certification for Lighting Division

2003 - Received TS 16949 & ISO 14001 certification for Horn Division

2003 - Received ISO 14001 and OHSAS 18001 certification for Switch Division

2003 - Received TS 16949 and ISO 14001 certification for Mindarika

2003 - Received Maruti's Manufacturing Excellence Award for Mindarika

2003 - Received FORD Q1 award for Mindarika

2001 - Implemented ERP-BAAN in Mindarika

2001- Won 1 st prize in Honda Supplier Quality Circle Competition for 2nd time in

Mindarika

2001 - Won 1 st prize in CII North Region Quality Circle Competition in Mindarika

2001 - Received QS 9000 certification for Horn Division

2001 - Implemented ERP-BAAN in Mindarika

2000- Started BEST (Business Excellence through Simple Techniques) journey in

association  with CII

2000 - Won 1st prize in Honda Supplier Quality Circle Competition in Mindarika

2000 - Won Runners Up trophy in CII North Region Quality Circle Competition

2000- Won Safety & Environment Award from Haryana State Labour Department

in Mindarika

1998 - Received Maruti's Best Performance Award 2 nd time in Mindarika

1998 - Received QS 9000 certification for Mindarika

1987 - Received Maruti's Best Performance Vendor Award in Mindarika

1997 - Received ISO 9001 certification for Switch Division  other switches1996 - Received ISO 9001 certification at Mindarika

1996 - Got approval as R&D Centre for Ministry of Science and Technology

Products of UNO Minda

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2/3 Wheelers Switchers

Minda Industries produces a variety of world-class switches for the 2/3 wheelers and off road vehicles. 

The various product offerings include:

2 wheelers

Handle Bar System Assembly

Handle Bar Switches

Electronic SystemsLever & Holder AssemblyBrake SwitchGrips

Gear Shift SwitchModular SwitchPanel Switch

   Off Road 

Panel Switch

Rotary SwitchesStarter Switches

Plunger SwitchesRocker SwitchesLever Combination SwitchIgnition Switch

On an average, Minda Industries develops 140 distinct products across categories each year and puts in place 26 new assembly lines to manufacture them.

 4 Wheelers Switchers

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Mindarika is consistently winning accolades across categories of products in the automotive switches segment. The belief is to offer innovative solutions for clients’ problems and to serve them better through customer-centric solutions.

The range of products includes:

Lever Combination Switches

Signal SwitchLight SwitchDimmer & Passing SwitchWiper SwitchWasher SwitchHazard Switch

Besides these, on offer are additional features like:Intermittent Time ControlRR Washer / Wiper SwitchesHorn Switch

Panel SwitchesHazard Warning SwitchRR Defog SwitchFR Fog Lamp SwitchRR Fog Lamp SwitchRR Wiper Washer SwitchBlower & A/C SwitchA/C Switch

Power Window switches

Auto Up & Auto Down functions.Window LockDoor Lock

In addition:The switches are with child safety features.Master Control Switch is with the Driver

Oil pressure switchesOperating Pressures ranging from 0.25 to 1.0 kg/sq cm.Variety of End connectionsFor use by heavy vehicles & agricultural equipment

HVAC panel Assemblies

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A/c SwitchBlower SwitchAir Direction ControlFresh & Re-circulation ControlTemperature Adjustment Control

Ashtray & Lighters

Cigar Lighters with or without Illumination.Ashtrays with or without Illumination.

Plunger Type Switches

Stop Lamp SwitchesReverse Lamp SwitchesDoor Lamp SwitchesTrunk Lid/ Parking Brake Switches

2/3 Wheelers Horns

Minda Acoustics Limited prides itself on its development skills and capabilities. It has developed horns right from fundamental horn design stage.

K-95 (95mm dia Disc horn) - 12V ( High Tone & Low Tone)K-90 (90mm dia Disc horn) - 12V ( High Tone & Low Tone)D 82 (82mm dia Disc horn) - 12V ( High / Mid / Low Tone)SD7 (70mm dia Disc horn) - 12V ( High /Mid / Low Tone)

D65 (65mm dia Disc horn) - 12V ( High /Mid / Low Tone) This product suits all 2-wheeler requirement as it is cost effective, consumes less current and is very durable, since it has been specially developed for Indian ConditionsElectronic Beeper

4 Wheelers Horns

Minda Acoustics Limited prides itself on its development skills and capabilities. It has developed horns right from fundamental horn design stage.

HN9 ( 90mm dia Disc horn) - 12V / 24V ( High Tone & Low Tone)Trumpet Horn - 12V / 24 V (High Tone & Low Tone)K-95 (95mm dia Disc horn) - 12V / 24V ( High Tone & Low Tone)

Customer of UNO MINDA-

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Domestic Customers

2 Wheelers

4 Wheelers

Off Road

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International Customers

About the Mindarika Pvt. Ltd., Pune

Mindarika Pvt. Limited, with Rs. 1.30 billion (USD 32.12 million) in revenue, is India 's largest four wheeler automotive switch manufacturer. 

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Mindarika Pvt. Limited has consciously evolved into a complete design and development centre for four wheeler automotive switches. It offers customised solutions to the automotive industry in the realm of product improvisation and new product development and has very strong localization capabilities. 

The core strengths at Mindarika are skilled manpower, adherence to the highest quality standards and providing cost effective solutions. 

Milestones:   

1992 Ist TAA with Tokairika Japan for OPS & others.

1994 2nd TAA with Tokairika Japan for Combination Switches.

1995 Certified for ISO-9002.Established Joint Venture company Mindarika Limited.

1996 Received ISO 9001 certification.

1996 Start of Production at Gurgaon PlantReceived Maruti's Best Performance Vendor Award

1998 Achieved QS 9000 (Design Responsible) certificationReceived Maruti's Best Performance Vendor Award

2000 Started Exports to Japan

2001 Implemented BaaN IV ERP package

 Received Safety and Environmental Awards from Haryana Labour Department

2002 Started Exports to USA

2003 Achieved TS 16949 & ISO 14001Received Maruti's Manufacturing Excellence AwardRecommended for Ford Q1 Award

2004Received award for BEST COST PERFORMANCE (INNOVA Program) from TKML

2005Runners up award for "Supplier Of The Year" from Toyota Kirloskar Motors Limited

2006Received awards for Tier 2 Vendor upgradation and Kaizen & MPS from Maruti Suzuki

   Joint Venture Partner: 

Established in 1948, Tokai Rika Company Limited is the foremost player in the world when it comes to automotive switches. The main product lines are Human Interface Systems and Controls, Security Systems, Safety Systems, Exterior Components and Electrical Appliances & Devices. It has 24 subsidiaries and joint venture companies that span the world. 

With pioneering work on Human Interface Technologies which help cars

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communicate better with people and makes driving more interactive, the Endeavour at Tokai Rika is to make the car feel as an extension of human senses and impulses and make driving as any other natural human function. 

These "Human Interface" technologies enable Tokai Rika to produce automobile control systems and components that accurately relay human commands, as well as security devices that prevent unauthorized entry and safety systems that protect human lives.

Mindarika Products –

Lever Combination SwitchPower Window Switch Head Lamp Leveling (HLL) SwitchStop lamp SwitchDoor Lamp Switch

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Clutch SwitchReserve Light SwitchHeater Ventilation Air Condition (HVAC) SwitchBlower SwitchCigarette Lighter SwitchHazard Warning SwitchPanel SwitchMirror Switch

Photo of Mindarika Products -

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Customer of Mindarika Pvt. Ltd.-

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1. Tata Motors Ltd. (TML)

2. Mahindra & Mahindra (M&M)

3. Fiat

4. General Motors (GM)

5. Ford

6. Honda

7. Maruti Suzuki

8. Volkswagen(VW)

9. Toyota

10. Hyundai

Engineering & Development Facilities of Mindarika Pvt. Ltd.The focus at the Mindarika is on collaborative designing with the OEMs. The

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Group has the capability to improvise existing products as well as offer cost-effective solutions for products already available in the market. With strong focus on R&D, the company has been constantly evaluating and employing emerging technologies to benefit its customers. Mindarika provides its customers with all the facilities under one roof be it design and development, prototyping, testing, validation and quality, or manufacturing the final product.

At the Mindarika, the USP is an association with the customer right from the concept stage to black box design and development of new products. The company has the competencies and resources to create products and solutions for specific customer requirements.

Styling & Designing of Mindarika Pvt. Ltd.Mindarika has two design studios located at Manesar & Pune with top-of-the-line CAD-CAM software with 68 dedicated CAD seats, with more than 100 experienced and technically competent product designers and well-developed facilities to create the latest innovative designs for the customers. 

The company has 50 Workstations of PRO-E Wildfire 2 and is the largest user of the same among Tier-1 suppliers in India. It also has 13 Workstations of I-DEAS 10 NX. 

Some of the finest design software’s like PRO – Engineer Wildfire II, I-DEAS Simulation NX 12, Alias, Rhinoceros, Adobe Photoshop, Adobe Illustrator and Image ware are used by the designers to produce the designs best suited to customer requirements. This software’s are extensively used for 3D styling and to check the surface details, assembly, mating parts and seamless movements.

Mindarika Pvt. Ltd. Focus Area –

Customer Satisfaction:

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We strive to give all our customers Best Value for their Money.

Quality Planning:

With the help of our Product Quality Assurance Plan, we build Quality into our Products from the Initial design stages itself.

Continuous Improvements:

Our approach is to continuously improve upon our past performances.

Human Resource of Mindarika Pvt. Ltd.

Recruitment: - We appoint appropriately qualified people at all levels.Training: - Staff & Operators is being trained in relevant fields as per Need & Requirements.Appraisals: - Generalists & Specialists are identified based on appraisals. These are used as instruments of feedback for Improvement.We have various Welfare & Social Activities for Employees.We have started TQM Journey using Kaizens, Quality Circles, 5S, Visual Control, Monthly Unit address, Birthday meetings & others.

Mindarika Pvt. Ltd. Culture

Total Quality ManagementIn order to achieve our Goals and to improve our Human Capital, we

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have started the TQM Journey by means of the following activities:– Kaizens – Quality Circles– 5 S– Visual Control– Monthly Unit Address– Birthday Meetings– Interdepartmental Customer Rating

1. Kaizens –Annual Targets for each employee.Monthly / Quarterly Kaizen Awards for motivation.

2. Quality Circles –Quarterly Inter-unit competitionSending teams to QCFI, CII Quality Circle meets.

3. 5S Activities - Special emphasis is paid to 1S & 2S1S- Seiri (Sorting Out) 2S- Seiton (Organising) 3S- Seiso (Cleaning) 4S- Seiketsu (Standardization)5S- Shitsuke (Disciline)

4. Visual Control –Helps in Information sharing, monitoring & control.Easy accessibility of relevant information.

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5. Morning MeetingMorning meetings (lasting 5-10 minutes) are held everyday in all departments.This is for Information sharing and action on most critical issues of the day.

6. Morning ExerciseLight Exercises are conducted everyday morning.It sheds all traces of fatigue and laziness after the journey to the plant.

7. Monthly Unit AddressImportant Information & monthly Company results are shared by Management with all members of the organization.Awards for significant achievements are distributed to

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employees.

8. Birthday Meeting –All employees with birthday in a given month celebrate.The occasion is also used to take feedback and suggestions from employees. Action is taken by the management on these suggestions for implementation.

About the Project

About the Tata Nano-

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The Tata Nano is a city car manufactured by Tata Motors. One of the smallest as well as lowest powered (35 PS (26 kW)) cars in the world, it was designed to be the cheapest car in India aimed mainly at the lowest price segment in the Indian domestic market.[5]

The Nano sold in India is a 624cc, rear-engine (for a less complex and hence cheaper transmission), manual transmission, four-passenger, four-door car. The car lacks power steering and safety features like air-bags and ABS.

The car was launched in the Indian market in March, 2009. With a pre-launch price offer of 100,000 (US$ 2100). Among other reasons, new emission regulation forced Tata to refine the engine with a higher price tag.

History of Tata Nano –

Seeing an opportunity in the great number of Indian families with two-wheeled rather than four-wheeled vehicles, Tata Motors began development of an affordable car in 2003. The purchase price of this no frills auto was brought down by dispensing with most nonessential features, reducing the amount of steel used in its construction, and relying on low-cost Indian labour.

The introduction of the Nano received much media attention due to its low price and the car was available to buy throughout India in early 2011.

The Nano's development was foreshadowed by the 2005 success of the affordable, 4-wheeled Tata Ace truck.

Expectation of Tata Nano -

In 2008 the Financial Times reported: "If ever there were a symbol of India’s ambitions to become a modern nation, it would surely be the Nano, the tiny car with the even tinier price-tag. A triumph of homegrown engineering, the Nano encapsulates the dream of millions of Indians groping for a shot at urban prosperity. Homegrown engineering" is a relative term here as many of the systems and parts used in the Nano may not have been developed or produced in India.

Many have had great expectations for this small car, some perhaps going a bit too far. One study, by Indian rating agency CRISIL, thought the Nano would expand the nation's car market by 65%. It was also anticipated that the 2009 launch of the car would greatly affect the used-car market, with prices dropping 25-30% in the lead up to the launch. However, due to limited supply (customers had a waiting period of up to one year) used-car prices reverted to their

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former figures.

Sales of new Suzuki Alto-based Maruti 800s (considered the Nano's nearest competitor) dropped by 20%, and used ones by 30% immediately following the unveiling of the Nano. As Autocar journalist Mark Rainford summarizes: “People are asking themselves—and us—why they should pay, say, 250,000 Rupees for a Maruti Alto, when they can wait and get a brand new Nano for less in a few months’ time, a car that is actually bigger.

Cost Cutting Features of Tata Nano –

The Nano's design implements many cost-reducing measures.

The Nano's trunk is only accessible from inside the car, as the rear hatch does not open One windscreen wiper instead of the usual pairNo power steering, unnecessary due to its light weightThree lug nuts on the wheels instead of the usual fourOnly one wing mirrorRadio or CD player is optionalNo airbags on any model. 624cc rear engine has only 2 cylindersNo air conditioning in base model

About the Tata Nano Lever Combination Switch –

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MRPL is one of the leading manufacturers and suppliers offering a wide range of precision engineered Combination Switches to the valued clients. These switches are widely used in electrical & automobile industries for their various applications. Moreover, this switch is produced in compliance with the set industry norms and standards. 

MRPL holds expertise in offering a wide range of combination switch to the Tata Group. This switch is manufactured using quality raw material, which is obtained from vendors of the market and also some material are manufactured in MRPL. MRPL switch is extensively demanded in the automobile industry for Tata Nano. These products have gained immense appreciation from Tata Group for the following features-

Accurate FinishOptimum PerformanceHigh Efficiency

Photo of Tata Nano Lever Combination Switch-

Single Stalk (Light Module) Double Stalk (Wiper Module)

Material Name used for making Tata Nano Lever Combination Switch

Body CP and Body

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Mounting and Cancel ClipCancel Cam SpringHorn Pin and SpringRetainer PlateScrew, Clamp Screw and Screw Tapping Traplight-ALighting Body CoverReturn Cancellation Slide, Lifter, Slide Spring, Lifter Spring and CamLight Lever HolderSpring Moving ContractKnob Light Lower RHCord CP RR WiperKnob WiperLight Detent PieceSpring Wiper DetentKnob WiperLight Piece and Lever LightPin Slotted6 Pole ConnectorTerminal A, B, C, D, E and FCam DimmerContract PointPlunger WasherHazard Contract Holder Push RODKnob HazardStickerGrease Marutemp-D, Pamarabu-JH-10Solder WiperContractTerminal Rivet

Production Process of Tata Nano Lever Combination Switch

Process of Light Module

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Insulator Soldering

Cord CP RR Wiper

Low Version Soldering

Contract Soldering

Wiper and Fog Testing Doubling

Becket Holding

Terminal Reverting

CAM Dimmer

Wiper and Contract Holder

Hazards Contract Holder Sub Assembly

Body Cover Sub Assembly

Light Model Locking Assembly

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Light Model Triaging

Final Testing

Process of Wiper Module

Insulator Soldering

Cord CP RR Wiper

Low Version Soldering

Contract Soldering

Wiper and Fog Testing Doubling

Becket Holding

Terminal Reverting

Cam Dimmer

Lower Doubling

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Wiper Contract Holder Doubling

Wiper Lever Contract Holder Doubling

Wiper Contract Holder Sub Assembly

Washer Sub Assembly

Wiper Body Batch Making

Wiper Sub Assembly

Wiper Screwing

Final Testing

Tata Nano Lever Combination Switch Line Layout

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Quality Circle Tata Nano Lever Combination Switch

Original -

Quality Circle Concept is a small group to perform voluntarily quality control activities

37

within the same workshop. This small group carries on continuously as a part of companywide quality control activities for self development and mutual development and improvement within the workshop, utilizing quality control techniques with the entire member participating.

Revised -

A Quality Control Concept is a small group consisting of first-line employees who continually control and improve the quality of their work, products and services.

These small services – Operate autonomously, utilize quality, control concepts and techniques and other improvement tools, top members creativity and promote self and mutual development.

Quality Control Circle activities aim to –

Develop member’s capabilities and achieve self-actualization, make the workplace more pleasant, vital and satisfying, improve customer satisfaction and contribute to society.

Executives and manager ensure that Quality Control Circles activities contribute to improving the health of the enterprise by-

Treating Quality Control Circles activities as an important part of employee’s development and workplace vitalization, personally practicing companywide improvement activities such as TQM and providing guidance and support for total participation while respecting the humanity of all employees.

The basic principles of Quality Control Circle activities –

Fully reveal human capabilities and eventually draw out infinite possibilities. Respect humanity and build a pleasant, vital and satisfying workplace. Contribute to the improvement and development of the enterprise.

Suggested steps for problem solving of Quality Control

A systematic approach not only helps in studying the problem in the proper perspective but also to make use of problem solving

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technique at the appropriate place –

Step 1 - Identification of work related problem

Method – (a) Generate a list of problem using ‘Brainstorming’

(b) Prioritize problems using ‘A’, ‘B’, ‘C’ analysis given below-

‘A’ category problem- Minimum involvement of other departments in solving them.

‘B’ category problem – Involvement of other departments is a necessary.

‘C’ category problem – Management sanction may be need in implementing the solution.

Step 2 – Selection of problem

Method – (a) ‘Pareto Analysis or Rating’ based on the past data or system.

(b) Register the selected problem with coordinating agency.

Step 3 – Define the problem

Method – By using ‘Flow Diagram’

Step 4 – Analysis the problem

Method – ‘Data Collection’ on the problem on all possible aspects.

Step 5 - Identification of Causes

Method – Brainstorming and make causes and effect Diagram.

Step 6 – Finding out the root causes method

Method – Identifying the main causes in ‘Causes and Effect Diagram’ by Data Collection and Discussion

Step 7 – Data Analysis

Method – Using techniques Line Graph, Bar Graph, Pie Chart, Area Graph, Histogram

39

Stratification, and Scatter Diagram.

Step 8 – Developing Solution

Method – Brainstorming

Step 9 – Foreseeing Probable Resistance

Method – Identifying the probable constraints and finding ways to overcome them, Make a presentation to all involved with the solution i.e. Department Head, Facilitator, other officials and nonmembers involved with the implementation. Discuss and evaluate a system for implementation.

Step 10 – Trail Implementation and check performance

Method – Data Collection after implementation compared with the data collected with the data collected before solving the problem. Collect fresh data using control chart and watch process trends. Analysis the result, discuss and incorporate the changes needed.

Step 11 – Regular Implementation

Method – Once validity is checked and improvement observed with data, regular implementation can be effected.

Step 12 – Follow up

Method – Implement evaluation procedure, use Control Chart, have six monthly reports for evaluation. Make modification if necessary.

7’s Popular Quality Circle Tools

Brainstorming

40

Data Collection HistogramPareto DiagramControl ChartScatter DiagramStratificationFlow Diagram

(1) Guidelines for conducting Brainstorming –

Guidelines for conducting Brainstorming in a structured manner –

Keep the participants, preferably, between six to ten.Give required time for incubation.Make it very clear to all the participants on what subject the Brainstorming is done.Enter the points on Black Broadly Flip Chart or in a Transparency for all to see.Explain the guidelines.One idea only at a time. Contribution in turn.You may pass.Clarify the point but don’t explain the ideas.No criticism.If session losses grip, have a break or change.To bring creativity use five Ws and one H (When, Where, What, Who And Why and How)Get maximum number or ideas.Clarify each rule.Agree on an evaluation criteria.

(2) Guidelines for Data Collection –

Useful points for Data Collection –

41

Be clear in mind about the objective.Prepare the question which will make it clear and precise.Collect data relevant to that.Use data sheet, check sheet and/or check list as per the requirement.Keep them simple and easy.Reduce opportunities for error.Capture data for analysis, reference and traceability.Form should be self explanatory.Analyze the collected data for its creditability and relevance.Present data in a way that clearly answer the questions.

(3) Guidelines of Cause and Effect Diagram –

How to use Cause and Effect Diagram –Preparing itself is an education process.It can be used as a guide for discussion.You can use it to find out reasons behind the causes in a systematic manner.A detailed Cause and Effect Diagram making exercise helps to have an in-depth knowledge about the process. It can be used for any kind of a process.

Some Dispersion Analysis Type of Cause and Effect Diagram –

(a) An arrow with the box made and the defect is written.

(b) Four main cause identified

(c) For each main cause sub cause identified.

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Defect in a cricket match

Machine Man

Method Material

Parts not OK and continuity missing

Inadequate Pace Attack

(d) For each sub cause sub cause identified

Not enough steamers in India

Fitness problem too few steamers

(4) Guidelines for making Histogram -

Take some observation and put them in data sheetFind the minimum and maximum in each line and circle them. Make the lowest and highest value.Compute the range.Calculate the approximate width of class intervals based on the formula (R + W)

(5) Guidelines for making Pareto Diagram –These are data of 150 defectives out of 100 fans inspected and to make Pareto Diagram

43

Bowling Lacked Punch Not Enough Experience

Defect in a Cricket match

Inadequate Pace Attack Spinner unable to Exploit Conditions

Bowling Lacked Punch Not Enough Experience

Defect in a Cricket match

and rearrange data table.

Types of Defect No. of QuantityMotor Winding 20Bend in fans blades 15Cracks on central rob 14Capacitor 10Scratched on Surface 12Regulator 40Bend in screws 25Others 14

Now arrange them in a table showing –Types of defectNumber of defectCumulative%age of defect to totalCumulative %age

Types of Defect No. of Quantity Cumulative %age of total Cumulative %ageRegulator 40 40 27% 27%Bend in Screws 25 65 17% 44%Motor Winding 20 85 13% 57%Bend of Winding 15 100 10% 67%Cracks in Central Rob 14 114 9% 76%Scratches 12 126 8% 81%Capacitor 10 136 7% 91%Others 14 150 9% 100%

44

1

Bend in

Screw

s

Motor Winding

Bend of W

inding

Cracks

in Centra

l Rob

Scratc

hes

Capaci

to

Others0

20

40

60

80

100

120

140

160

ProblemCode%age of total Cumulative %age

(6) Guidelines for constructing Control Chart –Collect samples at fixed internal and record the measurement.Total the value for each subgroup. Calculate the average for each subgroup (X). Calculate the overall average. This is called X.Determine the range for each subgroup.Calculate the average range.Calculate the control limit for XDetermine the scale for the graph and plot the graph.

(7) Guidelines for Stratifications –Try to have the clarity of the problem. This will normally help to identify the stratification variables to be selected.If we have ready information and if they are reliable they can be straightaway used, otherwise start collecting data needed.Make sure that all stratifications variables are identified for data collection.Data collected may be enormous, which will call for establishing categories for each stratification variable.The categories may be discrete values or range of values.Sort out the data into the categories of stratification variables.Now summarize the number then total them.If it is arrange of values and need further classification provide it.Present the result in graphic form to enable effective communication.Study the display.

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Standardized Problem for Manufacturing Tata Nano Lever Combination Switch

Shot Mould of MaterialDamage of MaterialShrinkage become in MaterialFlash become in Material Gate Mark ScratchPin Hole in MaterialAppearance Not OkDimension Not OkBend on MaterialSilver MarkBurrPunch Mark Dent MarkOxidizedHole ShiftCrackIllumination Not OkCutMovement HardLock DamageFitment Not OkInsert Not OkWire MissingWire Inter ChangeLight Leakage

46

Problem Observed in Tata Nano Lever Combination Switch Defects

1. Parking Not Working

Cause and Effect of Lever Combination Switch

Machine – Preventive maintenance not done. Machine operator at high pressure. Pretesting not available for sub assembly testing.

Man – Wrong assembly in process. Process Quality Control Sheet(PQCS) and Operator Guidance Sheet(OGS) not followed. Check points not check properly. Unskilled associate.

Method – Handle of Material improper. Poor checking at Standard Quality Control (SQC) end. Improper Contract.

47

LCS NANO Defects

89 80

3344%

84%100%

0

50

100

150

200

Parking Off Passing/ContinuityMissing

High Speed WiperNG

Defects

Nos

0%20%40%60%80%100%

Cum

u

Material – Sequence not followed. Production Control Chart (PCC) not followed. Incorrect inspection at Right Control Chart (RQC).

2. Passing Not Working

Cause and Effect of Lever Combination Switch

Machine – Preventive maintenance not done. Machine operator at high pressure.

Man – Wrong Assembled. Careless in process. Process Quality Control sheet(PQCS) and Operator Guidance Sheet(OGS) not followed. Unskilled Associate.

Method – Handling of material improper. Dimensionally material not ok. Poor Checking at Standard Quality Control (SQC) end.

Material – Sequence not followed. Production Control Chart (PCC) not followed. Check point not check properly.

3. High Speed Wiper Not Working

High speed wiper not working

Contract not made

Extra plastic on contract demand

Sample checking in parts production

Agreed to take action

100% inspection StandardChanges in Tata Nano Lever Combination Switch by 4M’s Change Sheet to help Rejection Control and Production Increase -

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Man – New Operator. Operator resumes work after internal of > 1 month. When required work sequence is changed on assembly line.

Machine – New Machine/tooling. Setting of Machine is changed. Machine is started against after repair due to failure. Any improvement, modification or replacement due to failure.

Material – Any change through ECN i.e. source, material gradual etc. Defect occurred the component.

Method – Change in process. Change in inspection method. Working method change due to quality concerns. Change in layout.

Change in 4M’s Change Sheet Benefits in Q P C D S M

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Parameter Before AfterQuality No Line Rejection We will Maintain

60479 PPM 0 PPMProductivity 3.0 SW/OP/HR 6.0 SW/OP/HR

Cost More Overtime- Rs 5000 No Overtime - Rs o For 4 Hrs/Day with 11 associate

DeliveryProduction Planing Control VS Actual Plan

75%Production Planning Control VS Actual Plan

100% Bulk Storage on Line Space for Everything as per Kanban

Safety Mixing of OK and Not OK Components Changes Elimated One Accident No Accident

Morale More Rejection Less Rejection More Fatigue due to Rework No Work Mentally Ill Feeling Confidence Improved

50

Research Objective

Research Objective

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Rejection Reduction and Production Increase for making Tata Nano Lever Combination Switch.

It’s Action - To study how to control the rejection.To study how to increase the production.To study the aspects of better utilization of (3Ms)- material, man and machine.To study to take necessary corrective actions to control the rejection and its impact on increasing the production.To study to locate and identify the manufacturing process faults in order to control and minimize scrap and waste.

52

RESEARCH

METHODOLOGY

RESEARCH METHODOLOGY

53

Type of research: Descriptive

Descriptive research includes surveys and fact finding enquiries of different kinds. The major purpose of descriptive research is description of the state of affairs as it really exists at present. The main characteristic of this method is that the researcher has no control over the variables; he can only report what has happened or what is happening.

Type of data collected: Primary Data as well as Secondary Data

Primary data is facts and information collected specifically for the purpose of the investigation at hand.

Data collection method: Survey method.

Data collection technique: Interview and telephonic.

Universe of the study: Pune

Sampling technique: Convenient Sampling.

The researcher chooses the sample based on who they think would be appropriate for the study. This is used primarily when there are a limited number of people that have expertise in the area being researched.

Sample size: 100

Presentation tools to be used: Percentage, Pie charts, Bar Charts

etc.

54

DATA ANALYSIS

AND

INTERPRETATION

Q1. Which age group of people buys Tata Nano?

55

20 - 30 22%30 – 40 37%40 – 50 27%

50 & Above 16%

20 - 30 30 – 40 40 – 50 50 & Above0%

5%

10%

15%

20%

25%

30%

35%

40%

Series1

Interpretation - The above diagram exhibits that 22% of the respondent 20 – 30 age group, 37% of the respondent 30 – 40 age group, 27% of the respondent 40 -50 age group and 14% of the respondent 50 & above age group to buy Tata Nano.

Q2. Do you think that Tata Nano should be banned from largely populated city?

56

Yes 67%No 33%

YesNo

Interpretation - The above diagram exhibits that 67% of the respondents were of the opinion that it should be banned from city and 33% of the respondent agreed to use in city travel.

Q3. Do you think Tata Nano Lever Combination Switch is easy to handle and convenient in its operation?

57

Yes 89%No 11%

YesNo

Interpretation - The above diagram exhibits that 89% of the respondents prefer this switch and 11% of the respondent did not prefer.

Q4. Are you satisfied with quality of Tata Nano Lever Combination Switch?

58

Yes 91%No 9%

YesNo

0%10%20%30%40%50%60%70%80%90%

100%

Series1

Interpretation - The above diagram exhibits that 91% of the respondent are satisfied this switch and 9% of the respondent are not satisfied this switch.

Q5. If no then how to improve it?

59

WorksProductService

WorksProductService

Interpretation - The above diagram exhibits that 43% of the respondent improves by works, 32% of the respondent improves by products and 25% of the respondent improves by service.

Q6- Which module of Tata Nano Lever Combination Switch needs to be improved?

60

Light Module 65%Wiper Module 35%

Light ModuleWiper Module

0%

10%

20%

30%

40%

50%

60%

70%

Series1

Interpretation - The above diagram exhibits that 65% of the respondent light module to be improved and 35% of the respondent wiper module to be improved.

Q7. In Light Module, which material needs to be improved?

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Light Body Cover 27%Light Lever Holder 22%Lever CP Light RH 21%6 Pole Connector 17%

Others 13%

Light Body Cover Light Lever

Holder Lever CP Light RH 6 Pole

Connector Others

0%

5%

10%

15%

20%

25%

30%

Series1

Interpretation - The above diagram exhibits that 27% of the respondent light body cover to be improved, 22% of the respondent light lever holder to be improved, 21% of the respondent lever CP light RH to be improved, 17% of the respondent 6 pole connector to be improved and 13% of the respondent others materials to be improved.

Q8. In Wiper Module, which material needs to be improved?

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Light Body Cover 30%Light Lever Holder 21%

Insulator CP Wiper RH 21%6 Pole Connector 17%

Others 11%

Light Body CoverLight Lever HolderInsulator CP Wiper RH6 Pole ConnectorOthers

Interpretation - The above diagram exhibits that 30% of the respondent light body cover needs to be improved, 21% of the respondent light lever holder needs to be improved, 21% of the respondent insulator CP wiper RH needs to be improved, 17% of the respondent 6 pole connector needs to be improved and 11% of the respondent others materials needs to be improved.

Q9. At what stages inspection should take place in manufacturing of Tata Nano Lever Combination Switch?

63

Process Flow 44%Quality Flow 56%

Process Flow Quality Flow

0%

10%

20%

30%

40%

50%

60%

Series1

Interpretation - The above diagram exhibits that 56% of the respondent process flow needs to be improved and 44% of the respondent quality flow needs to be improved.

Q10. In Process Flow, at what stages inspection should be considered in manufacturing of Tata Nano Lever Combination Switch?

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Trial

Run Insp

ection

First

Off Insp

ection

Inspecti

on by Self

-Control

Decentra

lized/Fl

oor/Patr

olling I

nspecti

on

Centra

lised/C

rib In

specti

on

0%

10%

20%

30%

Series1

Interpretation - The above diagram exhibits that 29% of the respondent trail run inspection to be considered, 23% of the respondent first off inspection to be considered, 21% of the respondent inspection by self-control should be considered, 16% of the respondent decentralized/floor/patrolling inspection should considered and 11% of the respondent centralized/crib inspection should be considered.

Q11. In Quality Flow, at what stages inspection should be considered in manufacturing of Tata Nano Lever Combination Switch?

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Trial Run Inspection 29%First Off Inspection 23%

Inspection by Self-Control 21%Decentralized/Floor/Patrolling

Inspection 16%Centralised/Crib Inspection 11%

Average Out Going Quality(AOQ) 32%Accepted Quality Level(AQL) 27%Rejected Quality Level(RQL) 23%

Operation Characteristic Curve(OC-Curve) 18%

Averag

e Out G

oing Quali

ty(AOQ)

Accepted

Quali

ty Lev

el(AQL)

Rejecte

d Quali

ty Lev

el(RQL)

Operation Chara

cteris

tic Curve

(OC-Curve

)

0%10%20%30%

Series1

Interpretation - The above diagram exhibits that 32% of the respondent average out going quality (AOQ) should be considered, 27% of the respondent accepted quality level (AQL) should be considered, 23% of the respondent rejected quality level (RQL) should be considered and 18% of the respondent operation characteristics curve (OC-Curve) should be considered.

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Finding

Finding

67

An old Chinese saying goes: If you don't know where you are going - you will never get there.

The Rejection Reduction and Increase in Productivity in Tata Nano Lever Combination Switch is a holistic exercise which starts from the time a prospective borrower walks into the plant and culminates in control the quality and monitoring with the objective of ensuring and maintaining the quality of material and managing production.All the efforts have been made to portray a close picture of the approach of rejection reduction and increase in productivity in switch. The telephony and the interview taken gives a clear indication of a general attitude of individuals towards the credit undertaking and their knowledge regarding the terms and conditions of the plant.

30 – 40 age group of people to buy Tata Nano.

Most of people are satisfied with the quality of Tata Nano Lever Combination Switch that is manufactured in MRPL.

Most of people want to improve the switch functioning.

Most of people want to improve light module of Tata Nano Lever Combination Switch because there have single handle in light module.

Most of people want to improve light body cover in light module of Lever Combination Switch.

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Most of people want to improve also light body cover in wiper module of Lever Combination Switch.

Most of people want quality flow inspection should take place in manufacturing of Tata Nano Lever Combination Switch.

Most of people want trail run inspection in process flow should be considered in manufacturing of Tata Nano Lever Combination Switch.

Most of people want average out going quality (AOQ) in quality flow should be considered in manufacturing of Tata Nano Lever Combination Switch.

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Conclusion

And

Suggestion

70

Conclusion and Suggestion

Rejection Reduction and Increase in productivity should be perceived just

as a regular activity for manufacturing Tata Nano Lever Combination

Switch.

There should be review of quality control and increase in productivity

based on manufacturing Tata Nano Lever Combination Switch.

It should bring more clarity to the goal and vision of the organization.

It should provide more quality control and increase in productivity by the

employees for manufacturing Tata Nano Lever Combination Switch.

New method of quality control and increase in productivity adopted for

completing the target of manufacturing of Tata Nano Lever Combination

Switch.

Employees and Customer should provide the feedback regarding the

products. It will help the organization to improve the weak areas of quality

and performance.

Adopt new technology for rejection reduction and increase in productivity for which employees would be motivated to produce quality switch.

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New mechanism should be evolved to reduce the time factor involved in procedure of quality control and increase in productivity.

The frequency for training program for quality control and increase in productivity should be increased and this session should be interactive.

The awareness sessions for the employees should be made more

interactive and the views and opinion of the production regarding quality

control and increase in productivity should be given due consideration.

Assistance should be sought from specialists for framing a proper quality

control production system that suits the organization target for

manufacturing of switch. Constant monitoring of the quality control and

production system should be done through discussions, suggestions and

interactions.

Use of modern quality control techniques like Average Out Going Quality

(AOQ), Accepted Quality Level (AQL), Rejected Quality Level (RQL) and

Operation Characteristics Curve (OC-Curve) which are more effective.

More transparency should be brought in the quality control and production

system.

Information regarding the quality control and increase in productivity of the

switch should be kept in proper manner.

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LIMITATIONS

73

LIMITATIONS

The following are the limitations with this report

Limited time available for study.

Difficulty in getting data as data provider (staff) where quick busy in their work.

The research is confined to a certain parts of Pune and does not necessarily shows a pattern applicable to all of Country. Thus, the study might not produce absolutely accurate results as it was based on small sample taken from the population.

Some respondents were reluctant to divulge personal information which can affect the validity of all responses.

In a rapidly changing industry, analysis on one day or in one segment can change very quickly. The environmental changes are vital to be considered in order to assimilate the findings.

74

BIBLIOGRAHY

75

Bibliography

1. Dr. B. S. Goel, Production & Operations Management, Pragati Prakashan, Meerut,

Eighteen Edition 2005.

2. Kothari C.R., Research methodology methods & techniques,

3. Prakasan publishing Co. Ltd., New Delhi, Sixth edition 2001.

4. Materials Management by B. S. Goel

Search engines

1. www.google .com

2. www.unominda.com

3. www.mindarika.com

4. www.wikipedia .com

76

QUESTIONNAIRE

77

Study on Rejection Control and Increase in Productivity used by Mindarika Pvt. Ltd. for making Tata Nano Lever

Combination Switch

I am Abhijeet Chandel, student of PGDM-IV trimester from AIT-School of Management, Greater Noida. I am doing field survey on “Rejection Control and Increase in Productivity used by Mindarika Pvt. Ltd. for making Tata Nano Lever

Combination Switch.” Please cooperate and help me by giving your valuable answer to the Questionnaire given below. Which help me in reaching to my goal?

This document will be kept confidential and will not be shared with anyone. The study is purely academic and it is a part of our curriculum of PGDM course.

PERSONAL PROFILE

NAME _ ----------------------------------------------------------------

Age_ -----------------------------------

Occupation_ ---------------------------------------------------------

Address_ ----------------------------------------------------------------------------------

Gender_ Male [ ] Female [ ]

Contact No_ ------------------------------------------------------------

Marital status_ Marriage [ ] Unmarried [ ]

78

QuestionnaireQ1. Which age group of people to buy Tata Nano?

(1) 20-30 [ ] (2) 30-40 [ ]

(3) 40-50 [ ] (4) 50 & above [ ]

Q2. Do you think that Tata Nano should be banned from largely populated city?

?

(1) Yes [ ] (2) No [ ]

Q3. Do you think Tata Nano Lever Combination Switch is easy to handle and convenient in its operation?

(1) Yes [ ] (2) No [ ]

Q4. Are you satisfied with the quality of Tata Nano Lever Combination Switch?

(1) Yes [ ] (2) No [ ]

Q5. If no then how to improve it?

(1) Works [ ] (2) Products [ ]

(3) Service [ ]

Q6. Which module of Tata Nano Lever Combination Switch is to be improving?

(1) Light Module [ ] (2) Wiper Module [ ]

Q7. In Light Module, which material to be improves?

(1) Light Body Cover [ ] (2) Light Lever Holder [ ]

(3) Lever CP Light RH [ ] (4) 6 Pole Connector [ ]

(5) Others [ ]

79

Q8. In Wiper Module, which material to be improves?

(1) Light Body Cover [ ] (2) Light Lever Holder [ ]

(3) Insulator CP Wiper RH [ ] (4) 6 Pole Connector [ ]

(5) Others [ ]

Q9. Where inspection should take place in manufacturing of Tata Nano Lever Combination Switch?

(1) Process Flow [ ] (2) Quality Flow [ ]

Q10. In Process Flow, where inspection should be considered in manufacturing of Tata Nano Lever Combination Switch?

(1) Trail Run Inspection [ ](2) First Off Inspection [ ](3) Inspection by Self-Control [ ](4) Decentralized/Floor/Patrolling Inspection [ ](5) Centralized/Curb Inspection [ ]

Q11. In Quality Inspection, Where inspection should be considered in manufacturing of Tata Nano Lever Combination Switch?

(1) Average Out Going Quality (AOQ) [ ](2) Accepted Quality Level (AQL) [ ](3) Rejected Quality Level (RQL) [ ](4) Operation Characteristics Curve (OC-Curve) [ ]

Thank you for your kind support and valuable time

ABHIJEET CHANDEL

AIT- School of Management, Gr. Noida

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