Summer Training Report (August 5th, 2019 ~ Aug29, 2019)

Project Theme: Optimisation of Process flow using Lean Tools &

Techniques

Department: Product Logistics Control (PLC)

Submitted by:
At: Balakrishna Rao
Honda cars India LTD.(HCIL) 1MS16IM052
SPL-1, Tapukara Industrial Area,, Industrial Engineering and Management
Tapukara, Rajasthan 301707 MS Ramaiah Institute of Technology
 ACKNOWLEDGEMENT

The writing of this dissertation has been one of the most significant academic
challenges I have ever had to face. Without the support, patience and guidance of
the following people, this study would not have been completed. It is to them that I
owe my deepest gratitude.

I would like to express my sincere regards and gratitude to, my project supervisor and
mentor, Bhaskar-San who undertook to act as my project supervisor despite their
many other industrial and professional commitments. Their wisdom, knowledge and
commitments to the highest standards inspired and motivated me.

Also, I would like to thank Shika-San (Human Resource) for providing me the
opportunity to add a new dimension in my knowledge by getting trained in the
esteemed company of Honda Cars Ltd. Tapukara industrial area.

Special thanks to the Head of Department, Dr. G S Prakash, for their constant
encouragement and support.

Extended gratitude to our Hon’ble principal of MS Ramaiah Institue Of Technology,

Dr N.V.R Naidu for their support and encouragement to carry out my internship and
project successfully.

And hearty Gratitude to the good people at Honda, my sensei, friends and family
who directly and indirectly helped and supported me in carrying out my internship
successfully.

Balakrishna Rao
Table Of Contents

S.no Topic Page no.

1. Introduction to HCIL
2.
 Introduction to HCIL
Honda Cars India Ltd (HCIL) is a subsidiary of Honda of Japan for the production,
marketing and export of passenger cars in India. Formerly known as Honda Siel Cars
India Ltd, it began operations in 1995 as a joint venture between Honda Motor
Company and Usha International of Siddharth Shriram Group. In August 2012,
Honda bought out Usha International's entire 3.16 percent stake for ₹1.8 billion in the
joint venture. The company officially changed its name to Honda Cars India Ltd
(HCIL) and became a 100% subsidiary of Honda.

HCIL's first manufacturing plant at Greater Noida began operations in 1997. Set up at
an initial investment of over ₹4.5 billion, the plant is spread over 150 acres (0.61
km2). The initial capacity of the plant was 30,000 cars per year, which was later
increased to 50,000 cars on a two-shift basis. The capacity was further enhanced to
100,000 units annually in 2008. This expansion led to an increase in the covered area
in the plant from 107,000 square meters (1,150,000 sq ft) to over 130,000 m2
(1,400,000 sq ft).

In 2015-2016 revenue of 16,870 crore, 360 crore net profit after 6 years losses in
Indian operations. In July 2017, monthly sales touched over 17,000 cars thanks to the
launch of WR-V. The City and WR-V sales figures were over 4,500 units a month.

Honda set up its second plant in India at Tapukara in Alwar District of Rajasthan,
spread over 450 acres (1.8 km2) with an investment of ₹3526 crores. It operates
under the ISO 9001 standard for quality management and ISO 14001 for environment
management.
 4

HCIL Plant Location

Tapukara Plant
 India Operations
Head Office
Honda Cars India LtdPlot No. A-1, Sector 40/ 41
Surajpur-Kasna Road,
Greater Noida Industrial Development Area
Distt. Gautam Budh Nagar
U.P. 201 306
Established
1995

President & CEO

Gaku Nakanishi

No. of Manufacturing Facilities : 02

Greater Noida, Uttar Pradesh Plot No. A-1, Sector 40/ 41
Surajpur-Kasna Road
Greater Noida Industrial
Development Area
Distt. Gautam Budh Nagar
U.P. 201 306

Tapukara, RajasthanSPL-1, Tapukara Industrial Area,

Khushkhera, Distt: Alwar,
Rajasthan 301707

Zonal Office - Mumbai

Honda Cars India LtdZonal Office - West
D-126, TTC Industrial Area,
MIDC Shiravane, Nerul,
Thane-Belapur Road,
Navi Mumbai,
Maharashtra - 400706.

Zonal Office - Chennai

Honda Cars India Ltd
Technical Support Centre,
Old No 26/New No46,
Opp. ICICI Bank,
Ambattur Industrial Estate,
Ambattur,
Chennai - 600058

Zonal Office - Kolkata

Honda Cars India Ltd
Zonal Office - East
Ambuja Eco Space Business Park
Plot No. Ii/f/ii, Block 4A, Newtown Rajahaat
Kolkata
 Honda Philosophy
The Honda Philosophy consists of Fundamental Beliefs (including "Respect for the
Individual" and "The Three Joys"), the Company Principle, and Management Policies.
This philosophy is not only shared by all associates, but also forms the basis for all
company activities and sets the standard for the conduct and decision-making of all
associates throughout the Honda Group. Driven by its dreams and reflecting its
values, Honda will continue taking on challenges to share joys and excitement with
customers and communities around the world to strive to become a company society
wants to exist.

The Passion behind the White Coveralls

At Honda’s R&D centers and factories, associates wear white work clothes that stain
and smudge easily, from the philosophy that “good products come from clean
workplaces.” The white outfit also symbolizes the equality of all that work at Honda,
including the CEO. White symbolizes Honda’s philosophy for making products
wholeheartedly not only in its Japanese facilities, but all over the world.

In addition, it is also required to address the colleagues as “san” as a courtesy to your

fellow colleagues.

White coveralls and colored caps to be worn by the employees at all times to maintain
equality but to distinguish among rankings.

Fundamental Beliefs
Respect for the Individual

・Initiative
Initiative means not to be bound by preconceived ideas, but to think creatively and act
on your own initiative and judgment, while understanding that you must take
responsibility for the results of those actions.
・Equality
Equality means to recognize and respect individual differences in one another and
treat each other fairly. Our company is committed to this principle and to creating
equal opportunities for each individual. An individual's race, gender, age, religion,
national origin, educational background, social or economic status has no bearing on
the individual's opportunities.
・Trust
The relationship among associates at Honda should be based on mutual trust. Trust is
created by recognizing each other as individuals, helping out where others are
deficient, accepting help where we are deficient, sharing our knowledge, and making
a sincere effort to fulfill our responsibilities.
The Three Joys

・ The Joy of Buying

The joy of buying is achieved through providing products and services that exceed the
needs and expectations of each customer.

・ The Joy of Selling

The joy of selling occurs when those who are engaged in selling and servicing Honda
products develop relationships with a customer based on mutual trust. Through this
relationship, Honda associates, dealers and distributors experience pride and joy in
satisfying the customer and in representing Honda to the customer.

・ The Joy of Creating

The joy of creating occurs when Honda associates and suppliers involved in the
design, development, engineering and manufacturing of Honda products recognize a
sense of joy in our customers and dealers. The joy of creating occurs when quality
products exceed expectations and we experience pride in a job well done.

Company Principle (Mission Statement)

Maintaining a global viewpoint, we are dedicated to supplying products of the highest

quality, yet at a reasonable price for worldwide customer satisfaction.

Management Policies

・ Proceed always with ambition and youthfulness.

・ Respect sound theory, develop fresh ideas, and make the most effective use of time.
・ Enjoy your work and encourage open communications.
・ Strive constantly for a harmonious flow of work.
・ Be ever mindful of the value of research and endeavor.

Products Of The Company

Current Production Models:

 Honda City — 1998 – present

 Honda Accord — 2000 – present

 Honda Jazz — 2009 – present

 Honda CR-V — Imported Since 2003; 2013 Model Locally Assembled

 Honda Amaze — April 2013 – present

 Honda BR-V — 2017 – present

 Honda WR-V — March 2017 – present

 Honda Civic – 2006-2013 - 8th Gen | 2019 – present - 10th Gen

Former Production Models:

 Honda Mobilio — July 2014-2018

 Honda Brio – 2011-2019; on sale until stocks last.

HCIL has 331 dealership outlets across 121 cities in 20 states and 3 Union
Territories of India.
It sold 189,062 units during the period between April 2014 and March 2015 as against
134,399 units during the same period a year ago, recording an increase of over 44%.
Honda, the Japanese car-maker, launched a new compact SUV on the Jazz platform
called WRV in March 2017.

Eighth gen Honda Civic Second gen Honda Jazz

Honda Cars- Supplier of Raw materials:

 RPSC-
Fifth genRajasthan Eighth
Honda City Primer Steel Processing Center( Raw material for gen Honda Accord
pressing)
 Musashi Auto Parts
 Suzuka(Secret region in Japan)
 Saitama(Secret region in Japan)
 Indonesia
 Thailand
 UK
 Vietnam
 Brazil
 USA
Plant Layout HCIL
Organisational structure
 Departments in HCIL, Tapukara
1) HR
2) EHS(Environmental Health and Safety)
3) Supply Chain Management
4) Product Logistics Control(PLC)
 5) EXIM(Export Import)
6) Production Control
7) IPDD(Internal Parts Delivery Department)
8) CBU(Complete Built-up Unit)
9) Kanri
10) Marketing(Before Product and After Product)
11) QDD(Quality Development and Delivery)
12) Utility
13) Legal
14) Manufacturing
 AE – Engine assembly
 FE - Ferrous
 MISSION – Transmission
 AF – Assembly Frame
 AL - Aluminum
 IPD - International Parts Delivery
 Welding Shop
 POPA- Paint Shop
 Press

Among all of these departments, PLC plays an important role in all the manufacturing
shops in receiving of parts, local parts and KD (knockdown parts). They are
associated with storage of these parts and delivering them to the line side of various
shops just in time with no defective parts moving to the next step.

After the Finished goods are produced, PLC is associated with delivering the FGs to
the next shop within the same plant or ship it to GNU( greater noida) unit.

Parts which are to be exported are packed and stored by PLC and later picked up by
EXIM associates who import the parts overseas and receive the exported parts and
deliver it to PLC so that they can be sent to the line side.

Introduction to PLC and its Associate Partners:

While Manufacturing is taken care of by the production controller, PLC acts as a
support function to Manufacturing Dept.
PLC has its roots in all the manufacturing departments.
PLC plays an important role in receiving of parts, local parts and KD (knockdown
parts). They are associated with storage of these parts and delivering them to the line
side of various shops just in time with no defective parts moving to the next step.

It also takes care of inter-department movement of parts.

PLC delivers the FGs to the next shop within the same plant or ship it to GNU(greater
noida) unit.

Parts which are to be exported are packed and stored by PLC and later picked up by
EXIM associates who import the parts overseas and receive the exported parts and
deliver it to PLC so that they can be sent to the line side.

Partners:
There are excruciating amount of departments to be taken care of just by PLC alone.
Hence PLC has Outsourcing partners who take care of part of the work that PLC does.
The various parties involved are:
 Honda Logistics India(HLI)
 Nippon Konpo India LTD.
 Kaling(Manpower solutions)

Note- PLC is the department which controls the logistics and under PLC- HLI, NKID
and Kaling are operational who execute the orders given by PLC.

PLC Department Vision and Mission

VISION:
TO MANAGE CKD & LOCAL PARTS AND DELIVER TO CUSTOMER ON TIME
WITH GOOD
QUALITY TO ENSURE SMOOTH PRODUCTION WITH OPTIMUM COST.

MISSION:
TO CREATE SAFE WORKING ENVIRONMENT WITH STRENGTHENING OF
EFFICIENT LOGISTICS FLOW WITH OPTIMUM COST

DAILY OATH:
MAINTAINING GLOBAL VIEW POINT WE ARE DEDICATED TO SUPPLYING
THE PRODUCTS OF THE HIGHEST QUALITY YET AT A REASONABLE
PRICE FOR WORLDWIDE CUSTOMER SATISFACTION.

DAILY MORNING EXERCISE DAILY GENERAL

DISCUSSION
WORKING TIME : 0750 Hrs. ~ 0755
Hrs. TIME : 0755 Hrs. ~ 0800

Daily Quality Oath.