CAREER EPISODE 3 (CE-3)

CE3.1 INTRODUCTION The details concerning my work experience as a Graduate Engineer Traineeis given below,

 The chronology: From 13thMay 2006 to 23thOctober 2007 Duration: Seventeen months.

 Geographic Location: Ponni& co (Mahindra & Mahindra dealers) 5 roads, Salem Tamilnadu India Ph-0427-2333733

 Name of the organization : Ponni& Co (Dealers in Three wheelers four wheelers for Mahindra & Mahindra).

 The title of the position: Service Engineer in Three wheeler Section

CE3.2 BACKGROUND:

I successfully completed my Bachelor of Mechanical Engineering from Coimbatore Institute of Technology (CIT), Coimbatore, an autonomous institution affiliated to Anna University, Chennai. I got placed in Ponni& Co one of the main Dealer for Mahindra &

Mahindra Groups, in various parts of TamilNadu, India. The ponni& co doest stop themselves with the dealership they also have their mechanical Service centre were the components are fixed to the customers need and they also constructed the special body for the vehicles according the customer need. CE 3.2.1: OBJECTIVES OF MY WORK The principal objectives at Ponni& Co were,

 To ensure that the product out from their company has no defects and also make sure that customer receives a good quality Service.  Continuously monitor the service process and analyze the problem areas and suggest the components alteration for better performance of the Vehicles.  Customer satisfaction over the altered vehicles.  Installation of gas kit to the vehicles so that the vehicles can run in petrol and LPG.  Fuel Injection work in Three Wheelers. As Im the Mechanical engineering so as to that they put me in the Fuel Injection Test sector. There I Check the Smoke condition according to Standards, which they are provided us.

 To design & Fabrication of Body for Three & Four Wheelers. We design the body for our both the Three wheeler & Four Wheelers using CAD.  Assembly the Engine parts in three wheelers. Re-assembled work also done in our unit for the three& four Wheelers. CE 3.2.2: THE NATURE OF MY WORK AREA IN THE COMPANY OR MY DUTIES IN THE COMPANY

The nature of my work area in the Quality Assurance department of the company were,  Initially I got trained in detail about the components in that is used in the vehicles.  My job was to ensure the quality of the altered product at all stages of production.  My responsibility was to analyse the causes for the occurring of problem in the components fitted in the vehicles using the experience. Take corrective actions for the causes identified.  My duty was to train the Diploma trainees in fitting the components for the compliance with the standards.  My job was to ensure the quality of the products delivered after being fixed.  My job was to review and authorize the working procedure for the process on daily basis.  My job was to give a presentation to management every month about the improvement in the service revenue and the working procedure adopted to ensure the new technique were employed.  My responsibility was to make continuous improvement in my work place.  My duty was to ensure that the welding, drilling, fitting machine operators are aware of the quality issues.  My responsibility was to make the process charts for work process of installing the new product taking into consideration the quality issues.  My duty was to reduce the rework of the components.  My job was to visit our customers periodically and inspect their vehicle efficiency and the condition of the vehicle at the customers place and give them the detailed sketch of using the vehicles in proper way.  My job was to inspect the componentspurchased for various mechanical activities.  I was responsible for calculating the process capability of existing machines and also newly purchased machines for various process.

CE 3.2.3: POSITION:

ORGANISATIONAL STRUCTURE HIGHLIGHTING MY

Managing Director

General Manager

Sales Manager

Service Manager

Service Engineer[my pposition] Sales Team Service Operator

CE 3.2.4: GENERAL TRAINING PROVIDED BY THE COMPANY:

y y y

A thorough overview about PONNI &CO. The basic understanding about the vehicles sold and serviced in the company. Trained about the vehicle inspection and basic service of the vehicle to the specific alteration required in the vehicles for the customer need

y y y y y y y

Terms and conditions of the company. Use of safety equipments and actions to be taken during emergency. Introduction to the higher officials in the company. Job responsibility of various departments. Company quality policy and dedications. Quality system in general. Understanding all the mechanical equipments, operational processes and applications of the products.

Out bound training to make us realize our responsibilities and the teamwork. Also trained in physical activities.

CE 3.3 PERSONAL WORKPLACE ACTIVITY

During my induction training for a period of 2 months, I was trained by the engineers in various departments about the process carried out in every machine in their area, current quality issues in the corresponding machines, and also about the machine maintenance. The company is installing the LPG kits and Fuel pumps, Injectors and Fuel Filter supplied by various leading original equipment manufacturers. I was mainly engaged with the assurance of the quality of the components used in each Vehicle and the final product after the assembly.

CE 3.3.1: TECHNICAL DETAILS OF MY WORK As Engineer- service Maintenance at PONNI & CO, I was dealing with the LPG kit and Fuel injector alteration line. I was responsible for the defects produced in my sector due to material, method, man and machine. My core job was to analyze the various defects occurred during the installation and finds the causes for the defects, identify the actions to be taken and implement them. I also recorded the number of defects, and worked towards reducing the defects.

CE 3.3.2: APPLICATIONS OF ENGINEERING KNOWLEDGE AND SKILLS. I was a fresh engineer when I joined PONNI & CO. I had experience in using Quality instruments like screw gauge, vernier caliper, height gauge etc., during my laboratory classes in my college. Any dimension can be measured by First principle method using these instruments. This was very helpful for me in handling these equipments in my work place. Even though we had sophisticated equipments, I was encouraged to use these basic instruments, so that it becomes easier to study any type of dimension. Moreover, my knowledge about Engineering Design, which I gained during my Engineering, was useful in studying the component drawings used for inspecting the components produced in my line. I was trained in using Convention machines like Lathe, drilling machine, etc., and my theoretical knowledge about machining processes together with the practical knowledge gained in my college made me feel convenient in understanding the various processes in my workplace. This was useful in the analysis of the defects produced.

CE 3.3.3: TASKS ALLOTED TO ME. There were number of day-to-day technical tasks to perform at PONNI & CO which I listed in the nature of my work. After a period of 6 months, I was asked by my mentor (Senior Manager) to access one of our new suppliers. It was an important task for me because if I finish this task successfully, we will be localizing a component, which was previously imported. So I went to the suppliers company to see the capability of them and made sure that they can provide us components satisfying our quality standards. First I did was, checked whether they have made identifications in the componentrequirement that we provided, so that ensuring that they use the right material. Then had a look at whether all processes in the company are in place as per the process layout provided. I designed quality inspection equipments that are required to measure the critical dimensions with least effort. Since, the dimensions are measured manually there is a higher possibility of manual errors. So the design was in such a way that it eliminates those errors (Poka Yoke). I also provided various Poka Yoke points such as in process measurement in the LPG kit to increase capability of the engine. When all these were satisfactory, then I asked our supplier to produce a trial batch of 50 components. Numbered all the components, inspected them and recorded all the dimensions. For the critical dimensions, I made a control chart and found the variation in the process. Based on this data, I made minor changes in the process to eliminate the variation. Again a sample batch was produced, repeated the above method of analysis and then found that the process was stable. As a next step, since we are very much concerned about dirt level in the components, I gave them certain instructions to keep the component clean from dust, rust etc., I also trained the quality persons in the suppliers company about the ways to measure the components with the specially designed equipments. I had a meeting with the senior manager explaining him in detail about the instructions given to their personnel and took his commitment to fulfill the instructions and meet the requirements. I prepared a Minutes of Meeting (MOM) and both of us duly signed in it. Then I gave initial approval to produce a batch of 1000 components and send it to our company with their inspection reports.

Meanwhile, I prepared a report to the management stating various issues with the suppliers and actions that are requested to be taken, the results obtained by at the supplier end in the form of control charts, my views about the supplier, and the minutes of meeting with the factory manager. First I produced the report to the senior managerQuality. Then I got the 1000 components from the supplier with inspection reports as requested. I inspected a batch of components and checked the reports provided by them comply with that obtained by me. It was found satisfactory. So, then I prepared control charts for critical dimensions to see the process capability. I compiled all these data as a report and gave to my senior manager. He had a look at the reports and appreciated for my work. The reports were presented to the management. Then approval was given for regular production of these components at the suppliers end. Then I was asked to monitor the supplier process periodically. One of my other important tasks was to analyze new engines for its capability and produce a report and comments about the new change in the engine. I completed the task well before the time frame provided.

CE 3.3.4: WORKING ENVIRONMENT. I was constantly under the guidance of my senior manager. I was working with other engineers in various departments. Whenever a problem arises I had a brain storming with other engineers and gathered ideas. Since, I worked in the shop floor; I had a good understanding about the mechanical repairers. They are those who have a good knowledge about their process. So, I also used to discuss with the operators about the various quality issues. This gave me an opportunity to nurture me well in the team. I was an active member in the team bring up new ideas. We gather every day to have a meeting about the issues in our work. We will take responsibility to solve certain issues. We, the engineers also have daily meetings with the administration and show the issues, actions taken and improvements in our workshop.

CE 3.4 Summary:

The position of Engineer- service maintenance gave me a lot of experience in handling the Quality, calibrating the quality instruments, understanding of various processes, setting quality standards based on requirements, making a process layout, improving the process capabilitydealing with our suppliers and customers etc., I was successful in making continuous improvement in my workshop. I also met the requirements and delivered the results within the given time frame. Working with knowledgeable professionals and other engineers provided me an intellectual growth in the field of Engineering. My communication with the higher officials of the company gave me the best industrial exposure. I was very much satisfied with my work duties and tried to learn as much as possible and always delivered outputs to my level best.