INDUSTRIAL TRAINING REPORT

On

"KWPM"

Undertaken at

"JU-SHIN LIMITED,MANESAR"

Submitted in partial fulfillment of the requirement for

the award of the degree

BACHELOR OF TECHNOLOGY

in

Mechanical Engineering

Maharshi Dayanand University, Rohtak

Under the Guidence of Submitted By:

Name- Ramesh Panchal Vipin Yadav
(Senior Manager) 18429
Ju-shin limited

SESSION 2015-2019

Dronacharya College of Engineering

Khentawas, Farrukh Nagar, Gurgaon
 CERTIFICATE

This is to certify that Industrial training report entitled "KWPM" by VIPIN YADAV (18429), at "JU-
SHIN LIMITED" is an original work and the same has not been submitted to any other institute for the
award of any other degree. A Presentation of the Industrial Training report was made on "Kwpm" and the
suggestions as approved by the faculty were duly incorporated. The project has been submitted in partial
fulfillment of the requirements for the degree of Bachelor of Technology in Mechanical Engineering of the
Maharshi Dayanand University, Rohtak, Haryana, during the academic year 2018-2019.

Prof. Vineet Kumar Mishra

Head of Department (ME)
 Acknowledgement
I take this opportunity to express a deep sense of gratitude to Company Ramesh Panchal sir, Senior
Manager, Ju-shin limited, for his/her cordial support, valuable information and guidance, which helped me
in completing this task through various stages.

I am also obliged to staff members of (Ju-shin Limited), for the valuable information provided by them in
their respective fields. I am grateful for their cooperation during the period of my Industrial Training.

I would like to express my sincere gratitude to my Head of Department Prof. Vineet Kumar Mishra for
giving me the opportunity to complete my industrial training. It would never be possible for us to take this
project to this level without his innovative ideas and his relent less support and encouragement.

Vipin Yadav
(18429)
(ME VIII Sem)
 TRAINING SUMMARY

JAY-USHIN LTD a JPM Group Company is a joint venture firm with Ushin Ltd. Japan. It has a name in the
field of Original Equipment Manufacturing. After being established in 1986 in few years it has developed a
reputation of providing world class products with a technology to suit Indian conditions. No doubt the policies
and procedures followed by JU-Shin are of world standards but with growing competition and to cut cost in this
price competitive market scope of improvement is always welcomed.
In my stint of training from 15th Feb 2019 to 15th June 2019. It was held at JPM Group Jay-Ushin limited
Gurgaon. The things which I had read only in the books, were practically seen and experienced in this
memorable time span.
I was admitted to Assembly plant in lockset and switches department. Where OEM products were produced first
at raw condition. My mentor were Mr. Ramesh Panchal Senior Manager at Jay-Ushin ltd. for the first 15 days I
observed various products being assembled at the plant and the types of materials and machines used for it. Thcn
I was shifted to Section-2 of switches department. My Training Project was on Kwpm . I was introduced to
various inspection technologies to detect defects in molding and their prevention. I was also introduced to the
assembly line where Heater panel Assembly and Hazardous Switch assembly takes place. During this project I
learned a lot of things about the 5- S rule, cause and effect analysis & counter measure, TPM (Total Productive
Maintenance) etc. which was very important from the industrial point of view. Apart from this I got the chance
to take part in extra activities, which goes side by side with the regular work. I also got the opportunity to visit
various other departments of assembly line and inspection department of the company to know & understand
how the final product was taking shape.

4
 CONTENTS

1. Company Profile ............................. (7)

2. Plant layout and working structure .............................. (19)
3. Company Departments & Policies .............................. (24)
4. Introduction to project ............................... (29)
5. Project work .............................. (32)
6. Roles during internship .............................. (39)
7. Rules used in company ............................... (42)
8. Drawings ................................ (46)
9. Bibliography ............................... (50)

5
List of Figures
Fig- 1(Kwpm lockset without switch)

Fig- 2 (SW ASSY COMB & lock)

Fig-3. (Shutter)

Fig- 4(Seat lock working mechanism)

Fig- 5 (key)

Fig -6 (kwpm lockset)

Fig – 7 (Integrated seat mechanism)

Fig-8 (keyset, switches and locket)

Fig -9 (Switch assembly seat opener)

6
 Chapter -1
Company Profile

JPM GROUP

JAY-USHIN MANESAR

GURGAON

7
1.1 COMPANY INTRODUCTION

JPM Group is a major entity on the corporate scene having diversified business interests in automotive electrical
and body pans, alternative fuels, energy, sponge iron etc. The group is growing at a rapid pace and is an industry
leader in most parts manufactured by the group. Quality is the essence, and JPM Group have always stressed of
the Customer Satisfaction. Consequently in this run for quality, quantity has always pursued us. Group has
ambitious plans to consolidate its position in India and abroad.

Jay-Ushin Ltd. a JPM Group company was incorporated as a Joint Venture company with U-Shin Ltd. Japan br
manufacture of auto electrical, mechanical & electronic components for four wheelers in 1986. It is a leH1ing
OEM manufacturer of automotive assemblies in India. Its products include lock sets, latches, switches & body
parts. The company is a major OE supplier to almost all makers of four wheeler as well as two wheelers in India
includes Maruti Suzuki Limited. Hyundai Motors India Ltd., General Motors, Honda Motor Cycle & Scooters
Division, Mahindra & Mahindra and Tata Motors Ltd .
U-Shin Ltd. engages in the design, Development, manufacture, sale, and export of various system devices and
control machines for automotive, industrial machinery, and home security units. It also other mechanical,
electrical systems, and components for automotive, industrial machinery, and home security unit.
The company operates in three divisions: Automotive Parts, Industrial Equipments and Home Security Unit. The
Automotive Parts division offers steering lock unit, lock sets, keyless entry, door latches, heater control panels,
door handles, switches, and sensors. The Industrial Equipments division provides equipments for
agricultural/constructive/industrial machines, equipments for telecommunication, meter gauge for medical use,
harness, cable wire, lump, operator’s seat, electric fuel pump, electric measurement and communication device.
The Home Security Unit division offers security system for home, hotel, and office buildings; touch keys: handle
sets; and electronic locks. The company, formerly known as YUHSHIN SEIKI KOGYO CO. LTD. was founded
in 1926 and is headquartered in Tokyo, Japan.

8
1.2 COMPANY HISTORY

In 1959, Shri J. P. Minda wondered why locksets and switches could not be made in India, when he noticed the
Indian Market Share of the same in the Global village. The envisaged idea started taking shape to his idea by
starting a locksets & switches unit. No one at that point of time dreamt where this visionary would take this
innovative beginning.
Then he thought to produce products like Key sets, switches, winker and lockset. Today, the group is a multi-
million, multi-location, multi-product business empire. Products are Key sets, Switches, Instrument Clusters,
Ignition Switches, Relays, Remote Keyless entry systems, Body Pans, Batteries, Sponge Iron, Moulds and Tools
& Dies.
The group has recently ventured into Solar Power Generation and CNG Kits for automotive use. The group has
hundreds of vendors & associates, manufacturing parts as per our customer’s and group’s specifications. The
group has manufacturing facilities across India & globe.

The core team of the group comprises the founder’s two sons. who are extending the legacy forward and
manage group companies:
• Mr. Anil Minda
• Mr. Ashwani Minda
Growth has been a way of life for the JPM Group. The group’s strength lies in its individual companies with
each one committed in consolidating its core strengths and excelling in its chosen field.
The technology-driven group employs around 6.000 people across India. Over the years Shri J. P. Minda has
built a reputation of integrity and dynamism with customers and his two sons are continuing with his rich legacy.

9
1.3 REGIONAL HEADQUARTERS

Anu Industries Limited

Jay Auto Components Limited
Jay FE Cylinders Limited
Jay Iber Private Limited
Jay Iron & Steels Limited
Jay Nikki Industries Limited
Jay Ushin Limited
JNJ Electronics Limited
JNS Instruments Limited
JPM Automobiles Limited
JPM Tools Limited
Jay Ace Technologies Limited

10
11
1.4 JPM PRODUCTS

Various JPM Products are as follows:

•Security system - Key sets, Immobilizer, Keyless Entry, Remote Locking etc.
•Switches - Combination switches, Panel switches, Handle Bar. Hazard Warning, Power Window, and Defogger
switches, Stop & Back-up Lamps etc.
•Body Parts - Door Latches, Central Locking, Door Handles, Hood Latches, Striker etc.

1. AUTOMOTIVE
a. Key Sets
b. Body Parts
c. Switches
d. Heater Control panel
e. Cap Noise Suppressors
1. Ignition Coil and Relays
g. Security System
h. Washer Tank with Motors
i. CNG Cylinders

2. NON AUTOMOTIVE
a. Gravity Die Casting
b. Pressure Die Casting

3. ENERGY
a. Batteries
b. Solar Power

4. STEEL

12
5. TOOLS & DIES

13
14
1.5 CUSTOMERS OF THE COMPANY

Two Wheelers Customer

Four Wheelers Customer

15
1.6 JU-SHIN Plant Features are:

Plant Location
Gurgaon, Haryana (1989)
Chennai, Tamil Nadu (1997)
Manesar, Haryana (2001)

No. of Employees at Plant- 1600

Facilities & Technologies

1. Product and Tool Design
2. Tool Room
3. Production Engineering
4. Die Casting Machines
5. Injection Molding Machines
6.Press Shop
7.Assembly
8.Test Lab

16
1.7 ORGANISATION AND EMPLOYEES

MANAGEMENT STRUCTURE

17
Equity share

18
 CHAPTER-2
PLANT LAYOUT AND WORKING STRUCTURE

Jay –ushin plant layout

19
2.1 PRODUT RANGE

JAY-USHIN PRODUCT RANGE

 Lock set Scooter

• Activa
• Dio
• Etemo
• Aviator
• Pleasure

 Lock set Motor cycle

• Unicorn
• Shine
• Stunner
• Splendor
• Heat
• Zeus

20
 Switches Scooter
• Active
• Dio
• Beat
• Lead
• Etemo
• Aviator
• Pleasure

 Switches motor cycle

• Unicorn
• Shine
• Stunner
• Heat

21
Lock sets, Switches & Door latch-4 wheelers & 2 wheelers

22
2.2 COMPANY VISION

Maintaining a global viewpoint, they are dedicated to supplying products of the highest quality yet at a
reasonable price for worldwide customer satisfaction. JU-SHIN has a basic policy that is MSQCD. This basic
policy has the following description:

23
 Chapter -3

Company Departments & Policies

3.1WAREHOUSE

It is the place where all the raw material used for molding plastic is stored. The raw material is refilled daily
order to avoid down time.

3.2 INJECTION MOLDING MACHINE DEPARTMENT

An Injection molding machine, also known as an injection press, is a machine for manufacturing plastic
products by the injection molding process. It consists of two main parts, an injection unit and a clamping unit.
The manufacturing department of the plant where raw material is put into hopper and at certain temperature.
injection of material takes place in Dies to form desired product. After the production each product is inspect and
marked OK by the labour for further assembly.

24
3.3 ASSEMBLY LINE
After final inspection, various products are shipped here, in order to assemble all the small pans and create the
major product like Heater Panels. Glass lenses, Hazardous Switches, Control Switches etc.

Then the entire final product prepared are inspected once again and passed ahead for shipping.

25
3.4 Key bitting

In this department key bitting is takes place through automatic key bitting cnc machines which bites the key in
thousand different ways which help in making key different for different locks. Total six key bitting machines is
placed in key bitting department.

The different mounts on keys are

1st mount -5.8 to 5.9mm

2nd mount -5.0 to 5.1mm

3rd mount – 4.20 to 4.30mm

3.5 Quality Assurance

In Quality Assurance department, measurements and other standard specifications of final assembled product is
checked. In this dimensions are checked, fuel leakage test confirmation is made, continuity is re-checked of
ignition, seat and fuel lock, scratches, dent are checked. In continuity, various functions are checked such as key
insertion and removal in ignition, seat and fuel lock, rotation of key to LOCK, OFF, SEAT, ON should be
smooth, key should not rotate 360 degree and more. This is done daily 4 times on 5 pieces.

26
3.6 SAFETY USED WHILE WORKING IN JU-SHIN
Various safety precautions used inside the plant are given below:
I. Proper maintenance of machine is made.
2. If barrel gets heated or mould is changed after 2-3 times. PURGE OUT is done.
3. Each mould is placed with the model on cover.
4. Healed Part is not allowed to touch and only technician inspect them.
5. Mould is removed carefully, using gloves.
6. Default piece are removed before another moulding.

3.7 JU-SH IN ENVIRONMENT POLICY

As responsible members of society and industry. We Jay- Ushin Ltd. Gurgaon manufacturer of OEM products,
recognize that wellbeing of humans and conservation of earth’s environment is important. By adopting
Environment management system. JU-SHIN is fast moving towards realitation of JPM Green Factory Concept.
We shall endeavour to continually monitor improve and conserve the environment in which we operate.
JU-SHIN is committed to achieve, environmental excellence in all its Industrial activities, in the following ways:
• Conserving environment through preventing pollution at its source of generation and strengthening our existing
pollution control system.
• Promoting Conserving of resources such as energy, water, oil and grease and other Raw materials, by reusing,
recycling and minimizing the waste generation.
• Complying with all applicable legal! regulatory requirements and strive to go beyond wherever possible.
JU-SHIN will continually improve its environmental management system following PDCA Cycle to make it
more effective. The Policy will be well disseminated to our employees as Well persons working on our behalf
and to public at large.

27
Organizational structure

28
 Chapter -4

INTRODUCTION TO PROJECT

Kwpm is a name given to the smart lockset and switches combination of Activa 5G. In this project we learn
about the features and uniqueness of lock of Activa 5G which can only open through their own keys not from
other keys of same locks.

In this lockset magnet used for close the key area through magnet lock and which has some series from a to z
which makes more than 20 different pattern to just open the key inserted area. Also in this Activa 5G the seat
lock is in combination with lockset in which seat is just open by the switch which makes it unique from other
two wheeler. In this project we are going through the deep working of lockset and how the work is completed in
industry .

Figure 1(Kwpm lockset without switch)

29
4.1 MOTIVATION AND OBJECTIVE

I am thankful to our college , staff and HOD who motivates us to do the Final Training of not less than 4 months.
According to the university schedules it is compulsory to do the training in the last semester from industry which
gives you knowledge about the working environment of industry and saw the use of theoretical part in to
practical life.

I am greatly thankful to my mentor at company Ramesh Panchal who help us in every problem and giving
solution of them. My mentor MR. Ramesh Panchal sir encourages us to involve and learn from every
department. Basically this training build me and surely helpful in future which gives me so much things to learn.
Every employee of the company is ready to help in their own way and gives the best knowledge of the process
they have. Really such an good experience in the corporate life where everyone ready to help and motivates you
to do the things.

30
4.2 FLOW CHART
1. Customer’s Demand
2. Design of Product is made
3. Customer Feed back
4. Rapid Prototyping
5. Bulk production
6. Inspection
7. Asssembly

Flow chart gives us the information about the initial to final stage of the new product. In this new product need is
arises from customer demand and according to the customer demand and requirements best design or with best
uses the product is made and then on the behalf of the design customer feedback is taken which helps in
improving the product. After that rapid prototyping takes place if the prototype is passed then product is made in
bulk production. After bulk production inspection which is to check the part is in under required tolerance or not
and then assembly of the parts takes place to make the product.

31
 CHAPTER -5
PROJECT WORK
Since, this is a six months training, hence it was obvious that some project work will be given. The project was
quite simple and in this I needed certain documents in order to get to know how a new product is developed and
brought into mainstream production. For this project I needed to gather documents such as drawings, bill of
materials, child parts manufacturing method, standard worksheet, process flow diagram, failure mode and effect
analysis, control plan.

In this project, I was told to collect these documents of model KWPM which is of Honda Activa. The reason this
particular model was allotted because this is the largely manufactured model in Jay Ushin Ltd. as Activa is the
most manufactured product in Honda, since its demand is very high.

Although, these documents were collected and not made by me, it still gave a basic idea of how these documents
can actually be created. It is said that when a process is formulated, a process flow diagram is to be formed first,
so that it will give a basic idea of what happens in every single process such as storage, quality check, quantity
check and many more factors. It is after making a process flow diagram, that a Process Failure Mode and Effect
Analysis is made in which, function, failure mode, causes of failure, effect of failure, severity, occurence and
detection of every process is found and mentioned, on the basis of this data, a Risk Priority Number is made
which indicates a devastating a failure mode can be either to customer end or consumer or both. After this, a
control plan is made in which failures of various processes are mentioned and a method of how these failures can
be prevented to occur in future.

It was after this, that I started doing a PMEA on my own on key making processes, in which I also opted for
model KWPM, although key making is same for every key. For this, I first a made a Process Flow Diagram, then
PFMEA and then a Control Plan.

Although, I cannot claim that the FMEA and Control Plan that I made is entirely true but the way a PFMEA is to
be made looks just like this. The reason why I cannot claim is because such documents are verified by Cross
Functional Team and it is a long procedure.

32
 Fig 2 (SW ASSY COMB & lock)

5.1 Processes used for the assembly of locksets and keysets are of two types-

5.1.1) Manual processes

1) Key Magnet Assembly-

In this, read key's code and as per key combination, insert magnet and keep placing magnet one by one. Flip the
key and place it on jig, insert and put magnet in keyhole. Check if all three magnets are properly placed and
mark on key tag with marker. After putting magnets, place insert back in trays. Make sure not to drop any piece.

2) Key magnet check with shutter and marking-

In this, check magnet, film pressing in both keys. As per code put both keys in shutter and open it. Mark it. Make
sure not to drop any piece.

33
3) Seat lock assembly with shutter lock-

Make sure that in the assembly of shutter lock, there are no visible parts and printing should be correct. Screw
should not be loose. Two screws in seat lock and shutter lock should be correctly tightened and they should not
be loose. Tighten with screw driver. Don't use dropped piece for assembly.

4) Seat lock knob assembly-

Switch case R should be on transmission mode. First assemble action spring and the steel ball. With the help of
greasing dispenser barrel, apply MULTEMP-SA grease on switch case drop by drop. In greasing barrel, the level
of grease should be between maximum and minimum. Don't drop grease.

5) Seat lock assembly-

Check knob assy if any part is missing. First assemble switch shaft in switch case R. Now, assemble switch arm
shaft in switch case R. Apply MULTEMP-SA grease on switch arm shaft. Now, assemble washer and wire arm
in switch case R, wire arm should be placed as shown in image. Apply MULTEMP-SA grease on washer.
Perform locking of switch case L on switch case R. Grease level should be between minimum and maximum in
greasing barrel. Don't drop any pieces.

6) Lock plate insertion-

First, check that the shutter spring, shutter and shutter pin should not be missing and key should not have burr.
Place lock plates in the slot of ignition cylinder as per the mount on key after inserting and spring. Insert key and
check of all the lock plates are assembled. Don't drop any piece.

7) Body assembly slider and cylinder-

Make sure that grease is applied on ignition body, V- notch area and ignition cylinder, slider, cap caulking
should not be loose. In body, cylinder and lockbar, spring slider should be assembled as per given image. Slider
movement should be correct.

8) Rotor, washer and contact holder assembly-

Check that cover, washer caulking should not be missing in ignition body. Assembly of spring rotary washer and
contact holder and steel ball should be correct. First spring, rotary washer and contact holder assembly should be
done. Set ignition lock on lock position. Don't drop any piece.

9) Terminal base screw tightening-

Check if terminal base is not missing from ignition lock. Tighten screw with the help of screw driver on fixture.
After this, check ignition lock's movement. Use screw driver. Don't drop any piece.

10) Final assembly shutter lock with ignition lock and seat lock-

Check that shutter and seat lock should have 2 screws and in shutter 3 screws should not be missing. Check if
seat lock's movement is correct. In shutter, place rotor on OFF position and place it on jig. Pick up screw from
34
bean and dip it in lock tight liquid. Make sure sensor input is received twice. Then tighten screw. There should
not be any gap in ignition lock and shutter lock. Lock tight should be applied as per limit. Tighten screw with
screw driver. Don't use dropped pieces.

Fig-3. (Shutter)

35
5.1.2) Machine processes

1) Film pressing- Film pressing m/c-

Check if key tag is marked with marker, check magnet in key. Apply film on keys using plucker. Set key on m/c
jig and push button. Don't drop any piece.

2) Magnet code selection-

As per the code in bean, the magnet spring is in the Case. Every station should be green. Set push button on auto
and press start. After assembling part, take out hand from safety curtain. Don't drop any piece.

3) Action spring, steel ball and O-ring assembly- Semi automated rotary m/c-

Check if in any three holes of Case, magnet spring is not missing. Place O- ring in Case properly. Place action
spring in Case and on action spring, place steel ball. Don't drop any piece.

4) Shutter magnet assembly and part presence check by camera- Semi automated rotary m/c-

Check if in Case, action spring, O-ring, grease and magnet spring is not missing. In the Case, as per the magnet
combination number, place 3 magnets. Check the presence of magnet with the help of camera and will show on
display. There should only be one steel ball. If there is more than one, take it off. Assemble plate cylinder on
Case and place cover on Case and press start button, camera will check and display. After assembling part, take
out hand from safety curtain. Don't drop any piece.

5) Back plate assembly- Semi automated rotary m/c-

Assemble back plate, lock plate, spring, rotor. Check if the lock plate, spring area has Centoplex 1DLBH grease
is there. After assembling part, take out hands from safety curtain. Don't drop any piece.

6) Screw tightening- Semi automated rotary m/c-

Check if back plate is assembled. Tight all three screws from electrical screw driver. Pick up three screws from
feeder and tighten them properly in cover and should not be loose and press reset button. After assembling part,
take hands out of safety curtain. Don't drop any piece.

7) Key number marking- Marking m/c-

Check that current date and key number should be marked on ignition body. Place ignition body on jig. Tally key
number and ignition body number. Don't drop any piece.

8) Body and cylinder greasing with lubrication WD-40- Greasing m/c-

There should not be any burr on ignition body. Place ignition body on jig. On the lock plate area of ignition
cylinder, apply WD-40 lubricant. On the lockbar of ignition body, V-notch area and ignition cylinder, slider
movement area, apply Centoplex 1DLBH grease. Don't drop any piece.
36
9) Washer caulking- Caulking m/c-

Movement of cylinder in ignition body should be correct. Place body on jig and push button. Washer should be
caulked properly in ignition body. If piece is N.G then put it in POKA YOKE. Don't drop any piece.

10) Body cover caulking- Caulking m/c-

Check if washer is not missing in ignition body and movement of cylinder should be proper. Put ignition body on
jig and push button. After caulking, body cover should not be cracked or damaged. Don't drop any piece.

11) Terminal base greasing- Greasing m/c-

Check ignition lock's push movement, contact holder should not be missing. Now, place contact of terminal base
on jig of greasing m/c. Perform caulking of switch cover in terminal base, place it in the back side of ignition
lock and press lock. Grease level in barrel should be between minimum and maximum. Don't drop any piece.

12) Auto checking- Auto checker m/c-

Ignition and shutter lock should not be loose. Fit ignition lock on stamping jig. Press push button as shown on
checker, LOCK-OFF-ON and seat lock will be checked twice. If the continuity of ignition lock is OK, then auto
checker will inscribe current date. Place piece in packet for inspection. Check lockbar in lock position. Don't
drop any piece.

37
Fig- 4(Seat lock working mechanism)

38
 CHAPTER- 6

ROLES DURING INTERNSHIP

My various roles during internship

During the period of my internship, I was given an overview of every department such as production, quality and
others.

6.1 Production department

In production department, I used to observe various processes used for the assembly of locksets and keysets and
in key bitting department, the various processes used for the manufacturing of keys. I also took the work of final
inspection for sometimes and performed this work under the supervision of inspector. I also worked on manual
processes and few machine processes in order to understand how an operator really works for few pieces under
supervision. Also, I performed quality checking processes which is done after manufacturing and before final
inspection such as Fuel leakage check, continuity check etc. The various

assembly process of models and their final inspection methods are

1) KWPM- Honda Activa-

1. Key magnet assembly

2. Film pressing

3. Key magnet check with shutter and marking

4. Magnet code selection

5. Action spring, steel ball and O-ring assembly

6. Shutter magnet assembly and part presence check by camera

7. Back plate assembly

8. Screw tightening

9. Seat lock knob assembly

10. Seat lock assembly

11. Seat lock assembly with shutter lock

12. Lock plate insertion

39
13. Key number marking

14. Body and cylinder greasing with lubrication WD-40

15. Body assembly slider and cylinder

16. Washer caulking

17. Body cover caulking

18. Rotor, washer and contact holder assembly

19. Terminal base greasing

20. Terminal base screw tightening

21. Final assembly of shutter with ignition lock and seat lock

22. Continuity check

23. Final inspection-

a) Check if the keyset does not have any burr, crack, damage or any other defect. Body cover should be correct
and should also have impression.

b) Screw fitment of ignition lock and shutter lock should be correct and marking on screw should also be
checked.

c) Check if both keys does not have dent, scratch, plating or molding defect.

d) Both keys should have film and fitment of film should be correct.

e) Batch stamping code should be correct and visible on ignition lock.

f) Ignition lock should have mounting thread on both sides.

g) Check if fitment of terminal base/switch cover and body should be correct. crew should not be damaged or
loose and no gap.

h) Key movement should be smooth on ON, SEAT, OFF, PUSH and LOCK position and ignition lock position
should be smooth.

i) Check ignition lock's movement from both sides of key.

j) Operate seat lock lever by hand

k) Check if ignition ON, SEAT, OFF, PUSH, LOCK and OPEN, SHUT printing should be as per sample.
Printing should not be damaged.

l) Shutter lock's movement should be smooth and not hard.

40
6.2 Key bitting department

In key bitting, since keys are manufactured by CNC machines there is not much to be done by operator. So in
this, only dimensions are checked after processes such as milling and bitting, which is done of 10 pieces. I also
did this measurement job when I was allotted this department and at first it was difficult to understand key
mounts and other dimensions but eventually with practice I was able to do this measurements easily.
Measurements of milling can be taken from vernier calliper and mounting specifications can be checked from
mount gauge.

6.3 Required Quality Control

In quality department, there are two departments i.e., Required Quality Control and Quality Assurance. In
Required Quality Control department, measurements of child parts takes place which are received from vendor
and dimensions are various specifications are checked depending on the child part such as critical dimensions,
paint, scratch, burr, flash etc. This checking is done in order to make sure that there will be no problem at the
time of assembly or problems at customer end. RQC dept. uses instruments such as vernier calliper, height
gauge, project profile and various gauges for dimensions checking. test for checking if paint is removing
upon scratch or not and checked visually for burr, flash or scratch. In this department I worked for few weeks
upon few pieces alongside an expert and gained valuable experience on such instruments.

6.4 Quality Assurance

In Quality Assurance department, measurements and other standard specifications of final assembled product is
checked. In this dimensions are checked, fuel leakage test confirmation is made, continuity is re-checked of
ignition, seat and fuel lock, scratches, dent are checked. In continuity, various functions are checked such as key
insertion and removal in ignition, seat and fuel lock, rotation of key to LOCK, OFF, SEAT, ON should be
smooth, key should not rotate 360 degree and more. This is done daily 4 times on 5 pieces.

41
 CHAPTER -7

RULES USED IN COMPANY

7.1 TOTAL PRODUCTIVE MAINTENANCE

TPM descends from Japan and came into existence in the seventies. After Dr W Edward Deming made an
impact in Japan through his teaching of quality. Japanese organization felt a need for autonomous maintenance
and small group activities to support the quality movement. Today thousands of organizations all over the world
are implementing TPM and about 100 organisations are now doing it in India.
Total productive maintenance (TPM) is a proven strategy for medium to large industries to get superior business
results and develop people skills to take on future business Challenges. Unlike ISO certification process, in TPM
focus is on maintaining the equipment and process in perfect condition- to get best quality products and involve
all employees in Collectively carrying out loss elimination, using analytical problem solving tools. The
fundamental belief is that if the equipment is maintained well and setting is done by a conscious, skilled
operator, once can get the best quality product. The whole concept of TPM is built around this belief and hence
the name total productive maintenance. However, this concept can be applied to places other than plant and
equipment and instead we could name Total productive Management rather than just maintenance.

Some of the Principles applied in the Industry were:

7.2. KAIZEN RULE-A Japanese term used in the business sense and applied to the workplace, kaizen refers to
activities that continually improve all functions and involve all employees from
the CEO to the assembly line workers. It also applies to processes, such as purchasing and logistics, which cross
organizational boundaries into supply chain
By improving standardized activities and processes, kaizen aims to eliminate waste Kaizcn was first
implemented in several Japanese businesses after the Second World War, influenced in part by American
business and quality management teachers who visited the country. It has since spread throughout the world and
is now being implemented in environments outside of business and productivity.
7.3. 5 S Rule
There are five 5S phases: They can be translated from the Japanese as “sort”, “straighten”, “shine”,
“standardize”, and “sustain”. Other translations are possible.
Seiton (systematic Arrangements)

42
• Can also be translated as “set in order”. “straighten” or “streamline”
• Arrange all necessary items so they can be easily selected for use
Seiri (Sort)
• Remove unnecessary items and dispose them properly
• Make work easier by eliminating obstacles
Seisou (Shine)
• Can also be translated as “sweep”. “sanitize”, “shine”, or “scrub”
• Clean your workplace completely
Seiketsu (Standardize)
• Standardize the best practices in the work area.
• Maintain high standards of housekeeping and workplace organization at all times.
Shitsuke (Sustain)
• To keep in working order
• Also translates as “do without being told” (though this doesn’t begin with S).
Nakajima also known as the father of TPM describes its concept in the following five points:
1. Maximize overall equipment efficiency.
2. Establish through system of productive maintenance which involves maintenance prevention. Preventive
maintenance and improvement related maintenance for the entire life cycle of the equipment.
3. It is a team-based activity and requires participation of all departments.
4. Total employee involvement which involves all the employees from the top management to the workers at
shop floor.
5. It promotes and implements autonomous maintenance.
The above were the major information I came to learn during my training, while I also witnessed the whole
inspection process, setup and installation of Rotating Injection Molding Machine.

7.4. 7QC TOOLS

The 7 QC tools as defined by the American Society for Quality (ASQ) and accepted throughout the quality
engineering community include:

1. Cause-and-Effect Diagrams / Fishbone Diagram

2. Pareto charts
3. Control Charts
4. Scatter diagrams
5. Histograms
6. Flowcharts
7. Checklists

43
7 QC Tools: Cause-and-effect diagrams
The first of the 7 QC tools is the Fishbone Diagram helps organize ideas and understand the relationship between
potential causes and an effect or a problem by formatting, arranging and organizing potential causes into themes
and sub-themes in preparation for a cause identification effort. It helps stimulate thinking when developing the
list of the potential sources of a problem. It guides concrete action and tracks the potential causes during an
investigation effort to determine whether the item significantly contributes to the problem or not.

7 QC Tools: Pareto Charts

The second of the 7 QC tools is the Pareto chart is used to prioritize the contributors which make the biggest
impact on a problem, or which represents the largest areas of opportunity. A Pareto chart is a tool to focus
attention on priorities while trying to make decisions. It is a good communication tool that describes the data in a
simple and easy-to- read bar diagram. The chart helps to study and analyze the frequency or occurrences of an
event in a process and identify the biggest contributors. These diagrams communicate the principle of 80:20. It
states that 80% of an effect comes from 20% of the causes.

7 QC Tools: Control Chart

The third of the 7 QC tools is the control chart. The best tool to investigate variation in a process is a control
chart. A control chart is often called a time series plot that is used to monitor a process over time. It is a plot of a
process characteristic, usually through time with statistically determined limits. When used for process
monitoring, it helps the user to determine the appropriate type of action to take on the process depending on a
degree of variation in the process.

7 QC Tools: Scatter diagrams

44
The fourth of the 7 QC tools is the scatter diagram. The scatter diagram is also known as a scatter plot or a
correlation graph. It helps visualize the relationship between two variables. The graph helps check for outliers
too.

7 QC Tools: Histograms
The fifth of the 7 QC tools is the histogram. A histogram is a pictorial representation of a set of data. The
histogram is a bar graph that shows the frequency of values. It is created by grouping the measurements into
‘‘cells” or “bins.” Histograms are useful to understand the location, spread, and shape of the data. In addition,
potential outliers or missing data can be seen.

7 QC Tools Flow charts

The sixth of the 7 QC tools is the flow chart. A flow chart is a visual representation of a process that can
illustrate:

 What activities are completed, by whom, in what sequence

 Hand-offs between departments or individuals
 Internal and external operational boundaries

7 QC Tools: Checklists
The last of the 7 QC tools is the checklist. The purpose of a checklist is to summarize, and in some cases;
graphically depict a tally count of event occurrences. A checklist is used when users are interested in counting
the number of occurrences of an event, such as defects or nonconformances. In many instances, a checklist will
summarize countable data related to certain types of defects and will provide a rough graphical representation of
where, in a part or process, defects occurred.

45
 Chapter - 8

5.1 Drawings

In this, images which are being shown are of exploded view diagrams

Fig- 5 (key)

46
 Fig -6 (kwpm lockset)

Fig – 7 (Integrated seat mechanism)

47
Figure -8 (keyset, switches and locket)

48
Figure -9 (Switch assembly seat opener)

49
50