Honda Cars India Ltd.

SUMMER INTERNSHIP REPORT

On
Logistic Improvement in Beam Comp Steering Hanger

Submitted by:
SHIVAM SINGHAL
B.Tech(Automobile Engineering)
ARYA COLLEGE OF ENGINEERING & I.T.

Under the Supervision of:

Mr. VINEET MISHRA
(Manager – Dept. Head - New Model Cost Dept.)
(Planning & Control Division, Purchasing Operations)
HONDA CARS INDIA LIMITED (GREATER NOIDA)
 Honda Cars India Ltd.

ACNOWLEDGEMENT

I would like to express my profound gratitude towards my mentor

Mr. VINEET MISHRA (Manager - Department Head - New Model
Cost Dept., Planning & Control Division, Purchasing Operations),
HONDA CARS INDIA LIMITED (GREATER NOIDA) for giving his
invaluable guidance and providing direction to me in the course of
completion of the project and without whose co-operations & help
the completion of this project was not possible. His willingness to
motivate and teach unparallel quantum of knowledge, which he
posses about the industry, contributed tremendously to the project.

I am greatly indebted towards HONDA CARS INDIA LIMITED

(GREATER NOIDA) for giving me opportunity to undergo project with
them. It gave me opportunity to participate & learn a deal about
various aspects of strategic formulation and hands on aspects of field
work.

Finally, an honourable mention goes to my family & friends for their

understanding and support towards me in completing this project.
 Honda Cars India Ltd.

HONDA PROFILE

Mr. Soichiro Honda

(Founder of Honda Motor Co. Ltd., Japan)

Honda itself is an autobiography of its founder “Mr. Soichiro Honda”

which describes his achievements and tell us how he has made
motorcycle as a common man vehicle. Mr. Soichiro Honda was not
only a racer but also a successful business man. He was very
persistence man who not only dreams but achieves also. Dream was
only the key to his success. He established “Honda Motor Co. Ltd.,
Japan” on September 24, 1948.

Honda Motor Co., Ltd. primarily known as a manufacturer of

automobiles, motorcycles and power equipment. Honda has been
the world's largest motorcycle manufacturer since 1959 as well as
the world's largest manufacturer of internal combustion engines
measured by volume, producing more than 14 million internal
combustion engines each year. Honda became the second-largest
Japanese automobile manufacturer in 2001. Honda was the eighth
largest automobile manufacturer in the world.

Chief Products: Automobiles, commercial vehicles, luxury vehicles,

motorcycles, scooters, electrical generators, water pumps, lawn &
garden equipment, tillers, outboard motors, robotics, jet aircraft.
 Honda Cars India Ltd.

Honda Philosophy

The management standards to be shared by all Honda group

corporations worldwide as ‘a company present worldwide’

 Fundamental Beliefs:

1. Respect for Individual:

a) INITIATIVE: One must gain confidence by taking initiative

& actively suggesting his/her ideas.
b) EQUALITY: Honda treats each employee as equal. Every
employee has an equally important role to play for the
company’s development.
c) TRUST: Every member of the company has works with
the help of the others around him/her. So, he/she must
trust in the ability and the willingness of the others to do
their job in the best way they can.

2. The Three Joys:

a) JOY OF BUYING: It is our goal to satisfy all the needs of

the customer & provide them the best quality so that
buying our product is a joy to the customer.
b) JOY OF SELLING: We try to provide flawless products to
the dealers so that they can also extract joy from selling.
c) JOY OF CREATING: We as the creators of the products
should feel joyous & happy in creating cars of world-class
quality
 Honda Cars India Ltd.

 Company’s Principle:

The State Company Aims for vision statement “Maintaining

a global viewpoint, we are dedicated to supplying products of
the highest quality yet at a reasonable price for worldwide
customer satisfaction”.

 Company’s Corporate Culture:

a) Free thinking and open minded.

b) Challenging spirit.
c) Sincerity.

 Honda Management Policies:

a) Proceed always with ambition and youthfulness

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

 Honda’s Work Culture:

a) Total Quality Management (TQM) in all its processes and

operations.
b) Data based decision making.
c) PDCA practices (Plan, Do, Check & Act); Strong focus on ‘P’.
d) 3-S Approach (Simplicity, Concentration & Speed) to work.
e) NH Circle Activities / Kaizen / 5-S practices / San-Gen-Shugi.
f) Openness / Trust / Approachability.
 Honda Cars India Ltd.

Honda Cars India Ltd.(HCIL)

HCIL Ltd.’s state-of-the-art manufacturing unit at Greater Noida, U.P.

Honda Cars India Ltd. (HCIL) formerly known as Honda Siel Cars
India Ltd. (HSCI) was incorporated in December 1995 as a joint
venture between Honda Motor Co. Ltd., Japan and Siel Limited, a
Siddhartha Shriram Group company, with a commitment to
providing Honda’s latest passenger car models and technologies,
to the Indian customers. In August 2012 Shri Ram group ended its
collaboration with Honda and the company is now named as
Honda Cars India Ltd. (HCIL).

HCIL’s first state-of-the-art manufacturing unit was set up at

Greater Noida, U.P in 1997. The green-field project is spread
across 150 acres of land (over 6,00,000 sq. m.). The annual
capacity of this facility is 100,000 units. The company’s second
manufacturing facility is in Tapukara, Rajasthan. This is spread
over 600 acres.

HCIL at Greater Noida plant has a capacity of producing 440 cars

in a day (in two shifts) ,220 cars in single shift. In every 2 min a
new car is completely formed & ready to go dealer.
 Honda Cars India Ltd.

The company’s product range includes Honda Brio, Honda City,

Honda Accord, Honda CR-V, Honda Mobilio, Honda Amaze which
are produced at the Greater Noida facility. Honda’s models are
strongly associated with advanced design and technology, apart from
its established qualities of durability, reliability and fuel-efficiency.

PLANT LAYOUT:
 Honda Cars India Ltd.

Manufacturing Work Flow

Material Service Department

Required Materials
supplied to various
Departments

Engine Assembly

Welding Department

BUMPER (POPA)
Paint Department
(PLASTIC OBJECT PAINT)

Assembly Frame
Doors removed from
assembly in starting from Completed Vehicle
assembly frame line goes to various
quality check lines

Door Sub-Assembly
Vehicle Quality
Assembly doors send back
to assembly frame line

Completely Built Complete Quality

Cars Showroom
Unit (CBU) Yard Assurance
Department
 Honda Cars India Ltd.

Introduction to Work Division:

1. Material Service Department: Suppliesall the parts that are to
be welded in the Welding Department, also the parts that are
to be fitted in Assembly Frame Department and the parts to be
fitted in Assembly Engine Department.
2. Welding Department: All sheet metal parts - KD, supplied by
Vendors or HCIL-II plant are welded together here and BIW is
made.
3. Paint Department: The BIW goes through various processes
like Pre-Treatment, ED, Sealer Application, Base, Mid, Top
Coating of paint, etc. and completely painted body is
developed. From which doors are send to Doors assembly &
BIW to Assembly Frame.
4. Assembly Engine: Here the complete assembly of an engine
takes place. Most of engine parts are brought from Thailand or
Japan for all models.
5. Assembly Frame: Completely painted car comes and car is
fitted with all its accessories, engine, upholstery, etc. and
Complete Car is developed.
6. Parts Quality: Assures the quality of all the parts that are put in
Assembly Frame Department.
7. Vehicle Quality Department: The car has to pass all the tests to
be certified as OK and if it doesn’t pass through then it is send
to CQA i.e. Complete Quality Assurance Department.
8. Complete Quality Assurance Department: People from all
Departments are present here to remove the defect and then
OK certified car is send to CBU yard.
9. Completely Built Unit (CBU) Yard: Here the cars are parked and
are send to the dealers in various parts of India.
 Honda Cars India Ltd.

Work Division
MATERIAL SERVICE DEPARTMENT(MS)
Material service is a department which handles the surplus supply of
the material from gate to the production line. This is the initial step
of the production process. Material service department supply the
material to the weld department, paint department, assembly frame,
engine assembly department. This department has the link with all
the departments.

Types of parts supply:

A. Local Parts supply.
B. Complete knock down (CKD) parts (Import parts) supply.
C. Periodic/Hourly parts supply.
D. Weekly parts supply.

Local Parts supply:

Local parts are those parts which are purchased from the local
supplier of INDIA. For the entry of local parts on the gate the delivery
man must have following document -
 Honda Cars India Ltd.

a) Form 31: Form 31 is required for doing the transaction of goods

from one state to other state in India.
b) Consignment Card (C.C.): Consignment Card contains the
information about the supplier Name of the part, supplier code,
supplier location, ASN Number, Delivery Date & Time.
c) Advance Ship Note (ASN) NO: - ASN NO. Contains the
information about the ASN Number, Number of parts, and
means of transport (by Bus, Ship, and Air), Shipped Quantity,
and Delivery Date & Time.

Complete Knock down (KD) parts supply:

Knock down parts are those parts which are delivered from the
Thailand, Japan, America, Philippines, Indonesia through ship or Air.

Case: Case means the container in which knock down parts are
packaged and send by the foreign. These are the special type of
container which protects the parts from damage. Case slip is stick
on the case, which has whole information about the part name,
type of part, no. of parts, supplier name, and date etc.

For the entry of knock parts on the gate the delivery man must have
following document -

1. Form 31: Form 31 is required for doing the transaction of goods

from one state to other state in India.
2. Bill Of Entry (Invoice): Invoice contains the whole information
about the consignee (Name address), Number of parts,
quantity of parts, description of goods, parts rate/unit, Date of
issue, Challan no. & Date, Destination.
 Honda Cars India Ltd.

Periodic/Hourly supply:
Periodic parts are those Parts which come every hour in a day (like
seat). For the entry of local parts on the gate the delivery man must
have following document -

1. Form 31
2. consignment Card(C.C.)
3. Advance Ship Note(ASN) No.

Weekly supply:
Parts which comes weekly. For the entry of local parts on the gate
the delivery man must have following document -

1. Form 31
2. consignment Card(C.C.)
3. Advance Ship Note(ASN) No.

Quality check:
After taking the permission from the gate, the truck or container
send for quality/quantity check or unloading on a specific doc
location/number.

Doc number is a location code for truck or container.

In the quality check, they check the amount of quantity send by the
supplier to the quantity written on the document. if their have any
mismatch ,then they send the information to the department. After
unloading the goods, they load the empty bins and send back the
truck.

Whole process should be done with in 45 min.

 Honda Cars India Ltd.

WELDING DEPARTMENT

The welding department completes the white body or frame of the

car, the base on which the painting and assembly operations are
done to obtain the final product –’the car’.

Welding department basically divided in 4 zones:

 A-Zone(Floor Line)
 B-Zone(General Welding Line)
 C-Zone(Material Finish Line)
 D-Zone(Hemming Line)

A-Zone(Floor Line):
In this zone there have three different stations in which front floor,
Front comp, and Rear floor are made. At this station front floor skin
is fixing up with the front floor frame.

Front comp Front floor Rear floor

Rear panel (manual)

(Three point) station

Floor comp
 Honda Cars India Ltd.

B-ZONE (GENERAL WELDING LINE):

Parts from the three point’s station enter in to the b-zone; here five
parts are combined and followed to the pre-set (GW LINE)

a) Floor comp

b) Right side panel

c) Left side panel

d) Dash board

e) Parcel shelf

C-Zone(Material Finish Line):

In this some small parts like

a) Battery base

b) Front beam

c) Gusset plate

d) Fuel cap

e) Door hinge

f) Rear door

g) Front door

h) Fender

I) Hood

j) Trunk
 Honda Cars India Ltd.

All these small parts are fitted in this station.

Other Finishing and final inspection for Welding Departments are

done here.

D-Zone(Hemming Line):
It is the line where the 4 doors, trunk and the hood are assembled. It
includes various processes such as spot welding, hem processing.
Door trunk and hood all are the visible parts of the car so it can’t be
weld because it makes a great impact on the appearance of the
body. Hemming gives the better finish and good appearance. In the
hamming process parts are attached through the application of the
pressure. Hamming machine has the 150 tone capacity. But mostly
80-85 tone pressure is used.
 Honda Cars India Ltd.

Paint Shop

“Clothes make a man”, similarly we can say, “The paint makes the
car”. The condition of the car is based on the condition of the paint.

Paint not only makes the car look attractive and beautiful but also
protects it from the harsh atmosphere outside. The paint on the car
consists of many layers of different types of coats. Each coat is done
to serve a particular purpose. Each coat is explained below:

Different layers of paint done on base metal

Phosphating: Phosphating is done to remove any traces of dust or

oil present on the car surface. It is done by completely submerging
the car frame into the phosphate solution.

Electro-deposition: Electro-deposition is done to prevent the car

from rust and provide longevity to the base metal.
 Honda Cars India Ltd.

Mid-Coat: The mid-coat provides the synthetic look to the car. It

provides a smooth finish to the surface. A primer is applied for this
purpose.

Base Coat: The base coat is the final coat on the body. It gives the
actual colour to the surface. In addition to this, a clear coat may also
be applied to give a glossy/metallic look to the paint job.

Clear Coat: Clear coat is done on metallic colours like silver, gold,
beige etc. It provides a sparkling/shining glow to the surface and
makes it very eye catchy.
 Honda Cars India Ltd.

Assembly Frame
The Assembly Frame is the section where all Parts are assembled to
the vehicle frame to yield a finished car. The painted body frame
from Paint is received at the first station of the AF line. The assembly
processes are performed in a set sequence. The sequence is
designed Department in such a way that each part can be easily
fitted into the car and there is no need to remove any other
previously installed part to do the same. The assembly is done by
both manually or with robotic help. Pneumatic machines are used at
stations which require heavy load lifting, precision or delicate work
which if otherwise done manually may require large man-power or
may lead to damage or loss of precious time.

At HCIL Assembly Frame, Pneumatic machines are used at various

stations such as, Door Removal, Instrument Panel Installation, Rear
Suspension Docking, Engine Docking, Brake Bleeding, Door
Installation, Fuel & Coolant Filling Stations .These machines may be
Robot assisted Pneumatic jigs, Heavy lifting machines or Automatic
Coolant, Fuel, Water filling machines. Pneumatic jigs are used at In-
Panel Assist, Suspension & Engine Docking. Heavy lifting is done at
Suspension & Engine Docking and Door Removal/Installation
Stations.

The Assembly Frame is divided into 5 major sections:

a) Wiring.
b) Interior.
c) Chassis line.
d) Exterior line.
e) Complex line.
 Honda Cars India Ltd.

WIRING

STATION
a) Rear Wire Harness, Trunk Open Cable,
b) Cushion Wire Harness, Trunk Cable
1 Installation.

STATION Engine Mounting Install, Cabin Wire Harness,

Earth Bolt Install.
2

STATION Doors Removal. The doors removed from

the car are held onto jigs and are
3 transported to the Door Sub-Assembly.

STATION Wiper Motor Install, Master Power Cylinder,

Side Indicator Install.
4

STATION Hood Opening Wire, License Light Install.

5
 Honda Cars India Ltd.

STATION Auto Radio Antenna install.

STATION Roof Lining, Roof Handle, Map Light, Hood

Open Switch Install.
7

STATION Horn, Fuel Lid Lock, Trunk Lock Installation.

`
8

Quality Gate
(Wiring)
INTERIOR

STATION SRS Unit, Seat Belt Install.

9
 Honda Cars India Ltd.

STATION Rear Damper Install.

10

STATION Wiper Water Tank, Air Duct, RHS Tail Light,

Sun Visor Install.
11

STATION Floor Mat, Radiator Install.

`
12

STATION Accelerator, Brake, Clutch Pedal, Head

Light, Door Trim, Left Tail Light Install.
13

STATION Dash-board Installation.

14
 Honda Cars India Ltd.

STATION Front & Rear Bumper Install, Bumper Cover.

15

Quality Gate
(Interior)
CHASSIS

STATION Inner Fender, Complex Fuel Filler Pipe from

fuel lid to the fuel tank, Fuel Tank Install.
`
16

STATION Rear Suspension Docking, Rear wheels

install, Bearing Assembly, Hub Unit, Rear
17 Brake Drum Install.

STATION Engine Docking, Front Suspension, Wheels

install.
18
 Honda Cars India Ltd.

STATION Brake Hose Tighten, ATF Hose Connection,

Cover Control Wire Installation.
19

STATION Exhaust Pipe (from engine), return pipe

(with gearbox) connection.
20

STATION Splash Shield Install.

`
21

STATION 4 tyres + Spare tyre install.

22

STATION Brake Bleeding. Here the brake oil is filled

with the help of Brake Oil Machine. Also
23 the ABS Modulator is energized by using an
ABS Coupler.
 Honda Cars India Ltd.

Quality Gate
(Chassis)
EXTERIOR

STATION Trunk Garnish, Gear Select Lever, Tool Kit

Install.
24

STATION Seat side Garnish, Rear Seat Install.

`
25

STATION Central Console, Air Cleaner/Filter Install.

26

STATION Windshield Transfer.

27
 Honda Cars India Ltd.

STATION Front & Rear Windshield Install.

28

STATION Battery Install.

29

STATION Front Seat installation. It is done with the

help of Robot as heavy lifting is involved,
`
30 Emblem, Speaker cover install.

STATION Door Installation. The doors coming via

overhead conveyor are installed back onto
31 the car. Door Checker Install.

STATION First Aid kit, User Manual, Accessories install,

Bumper & Fender Cover Removal.
32
 Honda Cars India Ltd.

Quality Gate
(Exterior)
COMPLEX

STATION Petrol Filling.

33

STATION Coolant Filling.

`
34

STATION Rear Wiper, Steering Install. Car is started

for the first time.
35

STATION Overall check-up.

36
 Honda Cars India Ltd.

STATION Complex Repair Area.

37

Quality Gate
(Final Assembly Frame)
 Honda Cars India Ltd.

Vehicle Quality
VQ or Vehicle Quality Department is responsible for quality
assurance. The main objective of this department is the assurance of
good quality products to customers. This department is responsible
for performing comprehensive quality checks, inspections & repair-
works (if necessary) on all cars before they are dispatched to the
dealers. The V.Q line starts at the point where A.F line terminates.

Various tests performed here are as follows:

Station 1: The cars coming into VQ are checked again for any dents,
scratches, missing parts etc.

Station 2: Alignment testing

Car alignment is tested and set to the desired level.

Station 3: Headlight testing

Headlight level and brightness is tested.

Station 4: Speed testing

Car runs on rollers which can provide very high speed to the
wheels without the car moving forward. Any abnormal behavior
shown by the car at high speed is checked for.

Station 5: Brake testing

Brakes are tested here.

Station 6: Side Slip testing.

Station 7: LID checking

CVI Card is verified and any remaining problems are found.
 Honda Cars India Ltd.

Station 8: Road Test

Car is tested under actual driving conditions on a specially
constructed track with all types of terrain. Any signs of sound and
vibration are found out here.

Station 9: Shower Test

Car is passed through a series of jets of water at high
pressure. Any leakage from the car body is notified and repaired
here. The leakage may be due to sealer miss or blind plug miss.

CQA (Car Quality Assurance):- Defects detected in the vehicle quality

are repaired in the CQA. CQA has separate repairing zone of welding,
paint, AF, AE.

PDI (Pre delivery inspection):- In PDI the whole inspection of the

vehicle is done. Here vehicle is checked thoroughly from front to
rear, interior to exterior and bottom to top.Dent, ding, scratch,
proper fitment of parts etc.is checked. This is the last inspection zone
of the vehicle. After the PDI the car is send to the CBU yard and from
the CBU yard it is send to the Dealer.
 Honda Cars India Ltd.

Engine Assembly
The engine assembly line consists of 27 stations. All the parts and
sub-assemblies are assembled to the engine (cylinder block) at the
respective stations in the main assembly line. Of the 27 stations, 23
stations are along a conveyor belt. The last four stations are separate
and are used for oil filling and PDI.

A brief description of all the processes in every station is given

below:

Station 1: Cylinder block loading

Here the cylinder block is loaded on the moving line. Block is

fixed with the help of Jigs and Lower Block Bolts are loosened
and removed.

Station 2: Engine number punching

The engine number is punched on the Cylinder Block.

Station 3: Piston insertion

The Piston is inserted into the Cylinder Block. Then Connecting

Rod Cap is removed. Thrust Bearings are then installed.

Station 4: Crankshaft installation

First Crankshaft is installed. After that the Connecting Rod Cap

is tightened and thrust washers are fitted. The Lower Block and
Cylinder Block are then Spray Cleaned and all bolts are
tightened to the required torque.

Station 5: Lower block tightening

3-bond is applied on the Block. Angle torque is given to the

block. Oil Seal is applied and bush is installed.
 Honda Cars India Ltd.

Station 6: Guide B installation

First Bridge Bolts are installed followed by baffle Plates A and B.

Then Guide B Chain is installed.

Station 7: Flywheel fitment

Flywheel is installed followed by the pressure disc. Dowel pins

for transmission location are then inserted.

Station 8: Oil pump fitment

Oil Pump is installed with the oil strainer. After that the Crank
Rotation is checked.

Station 9: Oil pan installation

Oil Pan is installed after the Surface Cleaning.

Station 10: Mission docking

The transmission unit received from the Mission sub-assembly

is installed first followed by the Starter Motor.

Station 11: Oil filter

Oil Filter Holder is installed followed by the Oil Filter is installed.

The cylinder head gasket and oil pressure switch are also fitted
here.

Station 12: Cylinder head docking

The cylinder head sub-assembly is fitted over the cylinder head

gasket.

Station 13: Cylinder head tightening.

Cylinder Head Assembly is then tightened to the specified

torque.
 Honda Cars India Ltd.

Station 14: Rocker arm sub assembly installation

Cam Shaft is installed on the Cylinder head. Cam Holder

Assembly is then installed and tightened to the specified
torque.

Station 15: Timing chain fitment

Here Tensioner Comp C chain, Guide Comp C Chain and Pulsar

Plate are installed.

Station 16: Chain case installation

Water Passage and Chain Case are installed after 3-bond

application.

Station 17: Tappet clearance setting

Tappet clearance is set for cylinders 1 and 3 after crank

pulley installation (with a parallel key).This is done using feeler
gauges and a manometer.

Station 18: Water leak test

Station 19: Tappet setting

Tappet Clearance of cylinders 4 and 2 is set.

Station 20: Crank pulley angle torque

Cylinder Head Cover is first installed followed by Pipe, Tube

PCV and Oil Level Gauge. Crank pulley is then tightened (angle
torque).

Station 21: Oil leak test

Station 22: Engine harness fitment

 Honda Cars India Ltd.

Station 23: Exhaust manifold

Spark Plugs are installed first followed by the heater baffle

Plate. Then the exhaust manifold and manifold cover are
installed.

Station 24: Engine unloading

Station 25: Ignition coil install

First mission oil is filled. Then Spark Plug Coil is installed.

Station 26: P.S. pump

Here P/S Pump is installed.

Station 27: Compressor assembly

Here Stay Exhaust Manifold is installed. Then Compressor

Bracket and Compressor Assembly are installed.

Station 28: AC generator assembly

Engine Oil is filled. Then Stay Inlet Manifold is installed. ACG

assembly and compressor belt are also installed.

Station 29: PDI (Pre Dispatch Inspection)

A completely assembled engine is the checked thoroughly. All bolts

are checked for proper tightening. The engine is also checked for
loose parts, missing parts etc.
 Honda Cars India Ltd.

SUB-ASSEMBLIES

1. REAR SUSPENSION:
Two stations used for assembling rear suspensions.

These stations are present in the beginning of the chassis line.

The Various parts assembled are:

 Knuckle
 Calliper
 Bearing Fitment
 Sensor bracket
 ABS sensor
 Flash guard
 Half bearing
 Brake Plate fitment
 Hand brake wire
 Trailing arm

2. INSTRUMENT PANEL:
Nine stations are used for complete assembly of the instrument
panel.

The Various parts assembled are:

 Beam Comp Steering Hanger

 Dashboard Fuse Box
 Dashboard wire harness
 Instrument panel installation
 Combi-meter
 Speedometer
 Sensor Fitment
 Pad Assembly fitment
 Honda Cars India Ltd.

 SRS airbag unit

 Centre panel Heater Control
 Steering Column Assembly
 Meter display cover
 Glove box

3. WIND SHIELD:
Wind shield sub-assembly is done on both front & rear
windshield.

The Various parts assembled are:

 Clip fitment
 Dang fitment
 Moulding fitment
 Seal fitment
 Primer application
 Fastener fitment (for rear mirror)

4. TYRE
Assembly of all four wheels of the car is done here.

The Various parts assembled are:

 Alloy wheel mounting

 Soap solution application
 Tire Inflation (44 psi)
 Wheel balancing
 Honda Cars India Ltd.

5. DOOR
Twelve stations are used for door subassembly. Doors are
removed from the painted body frame entering wiring and are
sent to the sub-assembly stations. On complete assembly they
are reassembled in the car at the final assembly line.

The Various parts assembled are:

 Sub Seal
 Regulator
 Harness installation
 Door Checker
 Door Seal
 Sealer Application
 Outer Handle fitment
 Inner Handle fitment
 Quarter glass
 Door lock
 Run channel
 Mirror fitment
 Honda Cars India Ltd.

Purchase Operations
Purchasing is the “process of buying.” Obtaining the right material, in
the right quantities, with the right delivery (time and place), from the
right source, and at the right price are all purchasing functions.

The purchasing department has the major responsibility for locating

suitable sources of supply and for negotiating prices. Input from
other departments is required in finding and evaluating sources of
supply and to help the purchasing department in price negotiation.
Purchasing, in its broad sense, is everyone’s business.

Purchasing is responsible for establishing the flow of materials into

the firm, following up with the supplier, and expediting delivery.
Missed deliveries can create havoc for manufacturing and sales, but
purchasing can reduce problems for both areas, further adding to the
profit.

The objectives of purchasing can be divided into four categories:

 Obtaining goods and services of the required quantity and
quality.
 Obtaining goods and services at the lowest cost.
 Ensuring the best possible service and prompt delivery by the
supplier.
 Developing and maintaining good supplier relations and
developing potential suppliers.

To satisfy these objectives, some basic functions must be performed:

 Determining purchasing specifications: right quality, right
quantity, and right delivery (time and place).
 Selecting supplier (right source).
 Negotiating terms and conditions of purchase (right price).
 Issuing and administration of purchase orders.
 Honda Cars India Ltd.

Purchasing Cycle:

The purchasing cycle consists of the following steps:

1. Receiving and analysing purchase requisitions.

2. Selecting suppliers, finding potential suppliers, issuing requests for
quotations, receiving and analysing quotations, and selecting the
right supplier.
3. Determining the right price.
4. Issuing purchase orders.
5. Following up to ensure delivery dates are met.
6. Receiving and accepting goods.
7. Approving supplier’s invoice for payment.

Receiving and analysing purchase requisition:

Purchase requisitions start with the department or person who will
be the ultimate user. In the material requirements planning
environment, the planner releases a planned order authorizing the
purchasing department to go ahead and process a purchase order. At
a minimum, the purchase requisition contains the following
information:
 Identity of originator, signed approval, and account to which
cost is assigned.
 Material specification.
 Quantity and unit of measure.
 Required delivery date and place.
 Any other supplemental information needed.

Selecting suppliers: Identifying and selecting suppliers are

important responsibilities of the purchasing department.
 Honda Cars India Ltd.

Requesting quotations: For major items, it is usually desirable

to issue a request for quotation. This is a written inquiry that is sent
to enough suppliers to be sure competitive and reliable quotations
are received.

Determining the right price: This is the responsibility of the

purchasing department and is closely tied to the selection of
suppliers. The purchasing department is also responsible for price
negotiation and will try to obtain the best price from the supplier.

Issuing a purchase order: A purchase order is a legal offer to

purchase. Once accepted by the supplier, it becomes a legal contract
for delivery of the goods according to the terms and conditions
specified in the purchase agreement.

Following up and delivery: The supplier is responsible for

delivering the items ordered on time. The purchasing department is
responsible for ensuring that suppliers do deliver on time.

Receiving and accepting goods: When the goods are

received, the receiving department inspects the goods to be sure the
correct ones have been sent, are in the right quantity, and have not
been damaged in transit.

Approving supplier’s invoice for payment: When the

supplier’s invoice is received, there are three pieces of information
that should agree the purchase order, the receiving report, and the
invoice. The items and the quantities should be the same on all the
prices, and extensions to prices, should be the same on the purchase
order and the invoice.
 Honda Cars India Ltd.

Suppliers Map:
139

33

43

NORTH –139
( WITHIN 150 KMS
AROUND HCIL)
TOTAL WEST - 33 Local = 98
( WITHIN 1600 KMS
215 AROUND HCIL) JPN JV = 82
SUPPLIERS SOUTH – 43
[N=139,W=33,S=43] ( WITHIN 2500 KMS
EU JV = 35
AROUND HCIL)
 Honda Cars India Ltd.

Project:
Logistic Improvement In BEAM COMP STEERING HANGER of BRIO Base.

Beam Comp Steering Hanger

Beam Comp Steering Hanger is used to mount dashboard & other

accessories on the dashboard of the car. It is made up of two pipes
main pipe & assistant pipe which are joined together by welding &
other child parts are also joint to both these pipes at their particular
places.

Material for Main pipe & Assistant pipe is STKM-13C.

Material for child parts is JSC-270C.

Main parts which are mounted on it are Wiring Harness, Relays, Dash
board panel, Steering column, HVAC vents outlets, Controllers,
Sensors, Metre Assembly.
 Honda Cars India Ltd.

Supplier of BEAM COMP STEERING HANGER for BRIO at HCIL is

VEEGEE INDUSTRIAL ENTERPRISES Pvt. Ltd. which supplies from
FARIDABAD.

Currently From supplier it comes in a standing trolley whose

dimensions are (1500*1090*1500) mm. Each trolley consists of 12
pieces in 3 column & 4 rows. It comes in a truck whose container
dimensions are (6096*2100*2170). Total pieces in the truck is 96 in
number.

Truck Container back

CURRENT

Empty Space in container on top

210 Column - 3 Column - 3

1730
440
2170
Column - 2 Column - 2

1730
440
Column - 1 Column - 1

370

210
2300
 Honda Cars India Ltd.

Trolleys in container are arranged in such a way that they are 4 in

each row one after the other. So 8 trolleys are arranged in 2 rows in
container.

Dimensions of current trolley are:

 Length: 1500mm.
 Width: 1090mm.
 Height: 1530mm.
 Ground Clearance: 210mm.
 Thickness of main ground beam: 30mm.
 Height of side beam up till lower most point of first hanger
support beam: 370mm.
 Thickness of first hanger support beam: 20mm.
 Height of side beam up till lower most point of second hanger
support beam: 440mm.
 Thickness of second hanger support beam: 20mm.
 Height of side beam up till lower most point of third hanger
support beam: 440mm.
 Thickness of last hanger support beam: 20mm.
 Height of last hanger support beam with top main beam:
210mm.

All outer main members are of 30 mm square while hanger support

members are of 20 mm square.

In 8 trolleys in single truck there are 96 pieces of Beam Comp

Steering Hanger.
 Honda Cars India Ltd.

Proposal for using the empty space in truck such there is no problem
to person working on assembly line and to those loading & unloading
trolleys from truck is design change of trolleys.

Truck Container back

PROPOSED

T
R
O Same
L
L Sized
E
Y 2 trolleys
2
In
T
R 180 This
O
L Half
L 400
E also
Y
1 230

Coloum 2
600 300
80
170
Coloum 1
 Honda Cars India Ltd.

Trolleys in container are arranged in such a way that they are 8 in

each row one over the other. There is a pair of 4 trolleys in each row.
The whole container has 16 trolleys. These trolleys are modified in
such a way that it has only 2 columns & 4 rows. A single trolley has
only 8 pieces. But number of trolleys in container are increased to
double. So number of pieces in each trolley are increased to 128 in
number.

Dimensions of proposed trolley are:

 Length: 1500mm.
 Width: 1090mm.
 Height: 890mm.
 Large Ground Clearance: 150mm.
 Small Ground Clearance: 70mm.
 Thickness of main ground beam: 30mm.
 Height of side beam up till lower most point of first hanger
support beam from large ground clearance: 230mm.
 Thickness of first hanger support beam: 20mm.
 Height of side beam up till lower most point of second hanger
support beam: 370mm.
 Thickness of last hanger support beam: 20mm.
 Height of last hanger support beam with top main beam:
180mm.

All outer main members are of 30 mm square while hanger support

members are of 20 mm square.

In 16 trolleys in single truck there are 128 pieces of Beam Comp

Steering Hanger.
 Honda Cars India Ltd.

Total pieces in proposed trolley per truck are 128 in number.

Logistic cost per truck is=RS. 5000

Current :
Logistic Cost for 96 pieces is= Rs.5000

Logistic Cost per piece is= Rs.52.08

Proposal:
Logistic cost will remain same for proposed trolley also.

Logistic Cost for 128 pieces is= Rs.5000

Logistic Cost per piece is= Rs.39.06

Result:
Logistic Cost per piece of BEAM COMP STEERING HANGER is reduced
to 25% .