INDUSTRIAL TRAINING PROJECT REPORT

On

Global Institutes of Management & Emerging

Technologies

SUBMITTED BY: SUBMITTED TO:-

Aarti Mr. Manjeet Bohat
Roll No.:251704043
B.TECH ME4th year
U.I.E.T KUK
CERTIFICATE OF APPROtfAL
 CHAPTER - 1

INTRODUCTION
1.1 Honda Corporate Profile:

HONDA, one of the biggest brand names in the automobile world today, was
founded by Mr.Soichiro Honda at Hamamatsu, Japan in 1948, since then
the company has been growing by leaps and bounds satisfying customers
all over the world with its comfortable world class products having most
advanced technology.

Honda Motorcycle & Scooter India Private Ltd. (HMSI), a wholly owned
subsidiary of Honda Motor Company Ltd., was incorporated in 20th August
1999.

1.2 History of the Organization:

Mr. SoichiroHonda was the founder of the organization, and the first plant of
the organization was established at Hamamatsu (Japan) on 24th September,
1948.
He dreamed of providing people, everywhere in the world an economical
means of transportation. He thought of better ways of making piston rings
and found a company & began production. Then his company started
producing small motorcycles, including one built in 1949 called D-type dream.

Then he thought of making high capacity motorcycles and taking them to

racing. So his company made bigger and faster machines, two-, four-, five-,
and six- cylinder race bikes and participated in the Isle of Man TT race (125
cc motorcycle class).
He wanted to share his new motorcycles with the world and therefore he
opened American Honda Motor Co. in Los Angeles. Also Honda began
manufacturing motorcycles at its Suzuka factory in 1960. Honda launched
its first sports car, the S500 in Japan and entered Formula-1 in 1964.

In 1989, Soichiro Honda became the first Asian to be inducted into U.S.
Automotive Hall of Fame. In 1990, Honda wins its fifth consecutive 1st
ranking in the J.D. Power Consumer Satisfaction Index. In 1993, founder
Soichiro Honda passed away. He dreamed of changing the way people
looked at motorcycles and gave us machines that were powerful & fun to
rid
1.3 Six Regional Headquarters:

Six regional headquarters of the Honda throughout the world are written
below:

 North/ Central America

 South America
 Afro-Europe
 Asia & Oceania
 Japan
 China

Honda Motor Europe

Honda Motor Co. Ltd.

Honda North America

Asian Honda Motor Co. Ltd.

Honda Motor LTDA.

Moto rc ycles A ut omobiles

Regional
1.4 Honda’s Products around the World:
Various Honda’s products around the world are as follows:

a) Scooters & Motorcycles b) Automobiles (Cars)

c) Power Products (Generators) d) Robots (ASIMO)
e) Trimmers f) Lawn Movers
g) Jet Engines h) Honda Engine

Jet EngineFig: 1.1, Various Products of HONDA around the

world
PRODUCTS:

2001 Started with mass production of 1st scooter,

Activa. ‘Scooter of the year award’ for
Activa. ISO-9001-2000 Certification by TUV,
Germany
2002 Launched new motor scooter, Dio.
ISO-14000 Certification by TUV, Germany.
BBC Wheel Award for Dio.
Export started to Latin America

2003 Launched geared scooter Eterno.

Achieved status of No. 1 Scooter
manufacturing company in domestic
Market.
Achieved status of no 1. Exporter in scooter
egment Certification by ARAI for emission
lab
2004 Scooter of the year award for Eterno.
HMSI established new motorcycle plant.
Launched 1st 150 cc motorbike, Unicorn.
CKD export to Latin America. Bike of the
year award to Unicorn
2005 ISO-14001:2004 Certification by TUV,
Germany.
Unicorn Tops in TNS Consumer Satisfaction
Survey in “Premium Motorcycle” category
Activa achieved landmark sales target of 1
million units

2006 HMSI launched its 2nd Motorcycle model,

SHINE a 125cc segment Motorcycle. HMSI
successfully launched LEAD in
Australian Market.HMSI launched new
variant ACTIVA & BEAT CKD
2007 Launch of new scooter AVIATOR. It is a E-

class scooter

2008 Honda launched a new bike, Stunner a

125cc

bike with a sporty look.

2009 HMSI launched its 4th Motorcycle, TWISTER
a 110cc bike which was the first bike in
India with lower engine capacity and high
style.
2010 HMSI launched a new model of Unicorn with
the name Unicorn Dazzler, 150 cc bike.

2011 HMSI wowed Indian customers with its

latest

offering – CBR 250R

2012 HMSI introduced seven new bikes &scooters.
CBR 150R, DIO, DREAM YUGA, CB SHINE,

VT1300CX, CBR1000RR FIREBLADE &

CBR 250R (Red, Blue & White).

1.5 Introduction to HMSI:
Honda Motorcycle & Scooter India Pvt. Ltd. (HMSI), a wholly owned
subsidiary of Honda Motor Company Ltd. was incorporated on 20th
August1999 to manufacture two wheelers in India. It’s Symbol “Wings” is
recognized all over the world as the symbol of Honda two wheelers with
which they promise to initiate changes and make a difference in the lifestyle
of the people of India. It represents the flight that HMSI has taken to
achieve the goals and targets which conform to the international standards.
Honda’s commitment to India is to manufacture world class two wheelers
that are designed and best suited for local conditions. Ever since its
establishment in 1999,

:
Fig: 1.2, Honda Motorcycle &Scooter India Private Ltd. IMT Manesar

HMSI has striven to offer products of the highest quality at reasonable price
by following its fundamental belief of bringing joy to people. In a short span
of Eight years, HMSI has emerged as the largest scooter manufacturer and
the fourth largest two wheeler company in India. While endeavoring to meet
and exceed the expectations of the customers, the critical importance of
providing the product, technology and service that benefits the existing
employees but also beneficial for the newly entered employees to
understand the manufacturing flow process in plant. It is believed at HMSI
that by meeting these expectations, HMSI will enhance the quality of life
through products and services that reflect the spirit of today. Bringing joy to
people and contributing to social development will continue
to be the principles that will guide HMSI in future. It came into mass
production with Honda Activa in 2001. Since then, the company has
continued to grow in the Indian market along with regularly providing world
class, advanced and technically sound products. Living up to its illustrious
lineage of excelling in the manufacture of two wheelers of global quality,
HMSI has revolutionized the multi- dimensional Indian two-wheeler market
with products like Twister, Dio, Aviator, Unicorn, Shine, Dazzle, Stunner and
Dream yuga Apart from outstanding sales, Honda also caters its customers
with excellent service and spare parts support. The HMSI factory is spread
over 52 acres, with a covered area of about 85,815 square meters at
Manesar, Gurgaon district of Haryana. The foundation stone for the factory
was laid on 14thDecember 1999 and the factory was completed in January
2001. The initial installed capacity was 100,000 scooters per year, which has
reached 6, 00,000 scooters by the year by 2007 and motorcycle capacity
shall be 4,00,000 per annum. The total investment outlay for the initial
capacity was Rs.215crores and now the accumulated investment is
800crores.
HMSI mainly deals with
 Manufacturing and sales of two wheelers.
 Manufacturing and sales of two wheeler engines.
 Service and sales of spare parts and accessories.
 Export of Honda products (CBU, Engine & Parts).

6. Management Board of HMSI:

A name of the various management heads of the organization is given below:
 Mr. Keita Muramatsu (President & CEO)
 Mr. H Nagata (Vice President)
 Mr. Miutani (Director)
 Mr. H Iwakami (Director)
 Mr. M Kato (Director)
 Mr. T Oyana (ASH)
 Mr. M Takedagaw
1.7Few Key details about HMSI:

Plot No. 1, Sector 3, IMT Manesar, Distt – Gurgaon

1. Registered office

2. Incorporation August 20th 1999

3. Equity capital Rs. 300crores (Approx.7500 million yen)

4. Area Covered area 85,815 sq. m (41 %)

Motorcycle- Unicorn / Shine / Stunner /

5. Product Twister/ CBR/Dazzler/Dream yuga.

Scooters – Activa / Dio / Aviator

6. Plant capacity 1,000,000 per annum,

SC – 600,000, MC –400,000

7. Logo Wings

8. President & CEO Mr. Keita Muramatsu

Table: 1.1, Few Key details about

HMSI
 CHAPTER – 2

PLANT LAYOUT AND

WORKING STRUCTURE
1.1 Overview of the
HMSI
Area: 210,000 sq. m.
Production: 1.55million units/
year
Location: IMT Manesar, Haryana
Incorporation: August 20th, 1999

Fig: 2.1: Overview of the HMSI

Plant
2.2 Plant Layout of the HMSI
HMSI deals with the both the products in the two-wheeler segment. In this
plant there are two sections one is scooter plant and other is motorcycle
plant. In scooter plant all the models Activa, Dio, Aviator, Lead and Beat are
being made. In Motorcycle plant Unicorn, Shine and Stunner, Aviator is
being made.

Fig: 2.2: Plant Layout of the

HMSI
2.3 Flow Chart:
Various departments or sections within the HMSI are given
below:
 Raw Material Storage
 Brought Out Parts (BOP)
 Press and Weld
 Paint Shop
 Machining Section
 Engine Assembly
 Frame Assembly
 Vehicle Quality
 Logistics

Fig: 2.3, Flow Chart for the production in

HMSI
 Vendor Network

NORTH
(103) Total -
JPN Collaboration
15 -
HMSI,
MANESAR 7 19

Gurgao
n
1400
Kms

Mum
baiPu
ne EAST
LOCALISATIO
(1)
N:

ACTIVA - 100 % DIO-

100 %
WEST
ETERNO - 100 %
(29)

2200
Kms

Chennai

SOUTH
(24)
Market Network

DEALER –
PHASE 60 252
PHASE II 42
PHASE 64
CITIES
–
211
NORTH
il - 52
i SOUTH -
l 66

EAST -
31

WEST -
51

CENTRAL -
52
Employees

41 %

Appr. JPN AE &

Contract
257 15
Above
778
595
TOTA PERMANEN TEMPORA
L T RY

2213 385 2823 1035

Staff

8 62% 38%
2.4 Various Models
HMSI has a number of models of scooters & motorcycles; they differentiate
according to their model names & power. These are listed below:

Scooter & Motorcycle Model Name Power

Name
Activa KWP 109cc
Dio KRP 102cc
Aviator KVT 109cc
Shine KTE 125cc
Twister KWS 110cc
Stunner KWFG 125cc
Unicorn KSPP 150cc
Dazzler KSPL 150cc
Honda CBR KWJF 250cc
Dream yuga k-14 110cc

Table: 2.1, Various Model names & their

Power
 ORGANISATION STRUCTURE

PRESIDENT & CEO

Sr. VICE PRESIDENT

Purchase Admin & Manufacturing Sales Finance &

Manufacturing
General Affairs & Marketing Accoun

G.M.

QUALITY
FRAME MFG. ENGINEERING ENGINE
ENGINE MFG
MFG ASSEMBLY. PPC
CONTROL

MEFE (MC) HPDC GDC & MEAL NEAL MEFE (SC)

PLANT-1 PLANT-2 PLANT-3

RESEARCH METHODOLOGY
This project required me to collect a lot of data and analyze this data using various QC
tools or quality control tools. Before going on to the QC tools used by me I would like
to give a brief introduction to quality.
 INTRODUCTION TO QUALITY

Quality is defined as a conformance of the product with respect to

specification. Every manufacturing organization is concerned about the quality
of its product. This is due to the fact that the customer’s satisfaction is derived
from the quality products and services. Quality is a relative term and it is
generally used with reference to the end use of the product. Due to the stiff
competition in the national and international level and consumer’s awareness
require production of quality products and services for survival and growth of
company.

A component is said to possess good quality, if it works well in the

equipment for which it is meant. Quality is thus defined as fitness for purpose.
Quality is thus defined as fitness for the purpose. Quality is the ability of the
material to perform satisfactorily in an application for which it is intended by
the user.

Quality of a product means conformance to requirements. In general quality

is a total composite product and service characteristics of engineering,
manufacturing and maintenance through which the product and the service
meets the expectations of the customers.

Quality control is the process through which the actual quality

performance is measured and compared with the standards and takes
corrective action if there is a deviation. It’s a systematic control of various
factors that affect the quality of the product.
QUALITY CONTROL TOOLS

1) CAUSE AND EFFECT DIAGRAM

The cause and effect diagram sometime know as Ishikawa diagram after
its inventor. It is also known as a fish bone diagram because of its shape. A
cause and effect diagram describes the relation between the variables. The
undesirable output is shown as the effect, and related cause are shown as
leading to, or potentially leading to, the said
effect. This popular tool has one severe limitation, however in that user can
overlook important, complex interactions between causes thus; if a problem is
caused combination of the factors, it is difficult to use to depict and solve it.
2) PARETO DIAGRAM

A Pareto diagram puts data in a hierarchical order, which allows the most
significant problem to be corrected first. The main aim of the Pareto
analysis is to
identify the three top contributors for the problem. The Pareto analysis
technique is used primarily to identify and evaluate nonconformities,
although it can summarize all types of
data. It is perhaps the most often diagram.
3) HISTOGRAM
The histogram plots data in a frequency table. What distinguishes a
histogram from a check sheet is that its data are grouped into rows so that the
identity of individual value is lost. Commonly is used to present quality
improvement data, histogram works based with small amount of data what
vary considerably. When used in the process capability studies histogram can
display specification limit to show the portion of the data does not meet the
specification.
4) CONTROL CHARTS
A control chart is a simple graphical device for knowing at a given
instance of
time, whether or not a process is under control. In any manufacturing process
TYPES OF CONTROL
there variation from CHARTS
piece to piece.
 Variable
 Attribute
Variable control charts are used for plotting the measurement of the
characteristics like height ,weight ,temperature ,thickness etc.average range ,
median range, average standard deviation ,individual moving range are some of
the types of variable control charts. Attribute data’s are based on only two
values (conforming/ Non conforming, go /no go, present/absent) but they can
be counted for recording analysis. Examples are presence of defects in painted
panel. Other example is characteristics that
are measurable but the results are recorded in yes/no, such as conformation of
shaft diameter. Checked on go/no go gauge.
In the real world very few processes completely satisfies all the conditions
and
assumptions required for estimating Cpk. also, statistical debates and research
communities are still ragging in the strengths and weaknesse4s of various
capabilities and performance indices. Finally in order to achieve continuous
improvement, attempt must be made to refine the “voice of the process” to
match and then to surpass the “expectation of the customer”.

5) PDCA Cycle
Among the most widely used tools for continuous improvement is a four-
step quality model—the plan-do-check-act (PDCA) cycle, also known as
Deming Cycle or Shewhart Cycle:

Plan- Identify an opportunity and plan for change.

Do- Implement the change on a small scale.

Check- Use data to analyze the results of the change and determine whether it
made a difference.

Act- If the change was successful, implement it on a wider scale and

continuously assess your results. If the change did not work, begin the cycle
again
2.5HMSI Products:

CBR 250
6. Honda’s Philosophy:
Honda’s philosophy has the various characteristics that are listed
below:
 It provides every Honda associate around the world with a vision.
 It tells us the values of our business.
 It bonds everyone together towards a common mission.
 It provides a constant standard for correct action and ethical
behaviour.
 It shows the link between the company’s past, present and future.
 It challenges the organization to strive for the realization of its
vision
 It helps our organization to maintain its sense of uniqueness.

Fig: 2.10, Shows the Honda’s Philosophy

HONDA PHILOSOPHY

Management Policies

Company Principle

THE THREE JOYS

RESPECT FOR THE INDIVIDUAL

Fig: 2.10, Shows the Honda’s

Philosophy
2.7Company Vision:

Maintaining a global viewpoint, they are dedicated to supplying products of

the highest quality yet at a reasonable price for worldwide customer
satisfaction. HMSI has a basic policy that is MSQCD. This basic policy has
the following description:

Fig: 2.11, Shows the Company

vision
 HMSI being a company of Japanese origin, I also got acquainted with the
Japanese principles of manufacturing like

 JIT (Just in Time)

TQM (Total Quality Management Cause & effect analysis

 PDCA (Plan Do Check Act) cycle

 5-S rule:

Seiri = Organization
Seiton = Neatness
Seiso = Cleaning
Seiketsu = Standardization

Shitsuke = Self-discipline
 3-G principle:
Gemba = Go to actual place
Genbuts = See actual problem
u
Genjitsu = Take realistic
solution
 3-K principle:
Kiken = Dangerous
Kitana = Dirty
i
Kitsui = Inconvenie
nt
8. Two Fundamental Beliefs:
 Respect for the Individuals
 The Three Joys
1. Respect for the Individuals
Respect for the individuals recognizes the following core concepts:

 Initiative: Initiative means not to be bound by preconceived ideas, but

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 creating equal opportunities for each
individual.
 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.

2. The Three Joys

Our goal is to provide Joy through our business: for those who buy our
products ("The Joy of Buying"), engage in selling our products and
services ("The Joy of Selling"), and are involved in business of creating
our products ("The Joy of Creating").

The Joy of Buying is achieved through providing products and services

that exceed the needs and expectations of each customer. Importantly,
the Joy of Selling and the Joy of Creating cannot be achieved without
first bringing joy to the customer.
 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 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.
Formerly known as the "Joy ofProducing," the Joy of Creating occurs
when quality products exceed expectations and we experience pride in
a job well done.
 CHAPTER – 3

HMSI PLANT
3.1 Few of the In-House Facilities
High Pressure Die Casting, Gravity Die Casting & Low Pressure Die Casting
Gravity Die-Casting & Low pressure Die Casting Sections are for
manufacturing critical engine parts.

3.2 Welding Robots

Weld Shop has spot welding, seam welding and MIG welding wel
machines to various sheet metal parts to form the basic frame and d
other scooter panels.
3.3 Paint Shop Robots
Paint Shop has a conveyor system, which is unique amongst all Honda
Factories in the world. The conveyor car carrying the parts is rotated and
dipped so as to enable good paint adhesion, high gloss and superior paint
finish. Robots are used in painting for improved paint finish.

4. Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the
engine from dirt and dust. Each of the engines is then inspected for
various parameters.

5. Frame Assembly
 Frame Assembly is done at the slat conveyor. After the Frame Assembly
line is the rollertester to check the final scooter quality before handing
over to dispatch.

3.6Safety Used While Working in HMSI

Various safety precautions used inside the plant are given below:

a) Cotton Hand b) Arm

Gloves Guard
c) Arm Sleeve d) Face
Mask
e) f) Safety
Helmet Shoes
g) h) Apron
Goggles
i) Ear
Plug

3.7 HMSI Environment Policy

As responsible members of society and industry, we Honda Motorcycle &

Scooter India Pvt. Ltd (HMSI), Manesar manufacturer of two wheelers,
recognize that
wellbeing of humans and conservation of earth’s environment is important.
By adopting Environment management system, HMSI is fast moving
towards realization of Honda’s Green Factory Concept.

We shall endeavor to continually monitor, improve and conserve the

environment in which we operate. HMSI 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 Conservation 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.
 Regular monitoring and reviewing of environmental objectives and
targets. Increasing environment awareness and competence
amongst our employees and encourage Vendors and dealers to
adopt EMS.

HMSI 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 as persons working on our behalf
and to public at large.
 CHAPTER – 4

Certificatio
n
 4.1 Honda
Certification

There are some certifications that a organization take from ISO (International
Organization of Standard). These certification are very important for any organization
cause its provide quality and fame to an organization.

Similarly, HMSI is certified from 3 ISO certifications:- 1. ISO 27000

2. ISO 9001
3. ISO 14000

4.1.1 ISO 9001:-

(Standardization)
QMS is a system which is used to direct and control the environment of the
organization regarding quality

QMS
(Quality Management System)

1. The main Advantages of this Certification are:-

 Reduce product variation
 Reduce rejection waste
 Reduce potential failure
 Improve product reliability
 Improve profitability
 Improve process efficiency
 Reduce market claims
 Effective work management
 4.1.2 ISO 27000:-
(Information Security Management System)

1. Information:-

Its an asset like other important business assets, has value to an

organization and subsequently need to be suitably protected.
2. Information security :-
Its prevention of confidentiality, integrity and availability of information
assets of organization.
3. ISMS :-
As per ISO 27001:2005 standard ISMS is a part of overall management
system based upon business risk approach to establish, implement,
operate, monitor, maintain and improved.

Information Security
(Confidentiality)

(Integrity) (Availability)
Confidential:-
The property that information is not made available or disclosed to
un-authorized individual entities or process.
Integrity:-
The property of safe guarding the accuracy and completeness of
assets.
Availability:-
The property of being assessable upon demand by authorized entity.

Secrecy Label-
S- New models design etc
A-Develop schedule, cbst sheets etc.
M-Salary structure, performance evaluation, quotations.
B- Purchase requests, info of company site, extension norms.
 Plant Production layout
Purchase
Press

Weld
Paint

Assembly Vehicle quality

Dispatch
 CHAPTER –5

Raw Material
 5.1. Scooter Raw Material:
-
1. KVT CRCEDD 0.7*515*540
2 KWP CRCEDD 0.8*650*745
3 K24 CRCEDD 0.7*545*550

5.2 Motorcycle Ram Material:

-
S no. Model RH/LH Plate Bottom
1. KSP 0.8*510*800 0.8*565*690
2. KWF 0.8*530*750 0.8*500*680
3. KYJ/KPPR 0.8*540*720 0.8*500*610
4. K21 0.8*550*805 0.8*610*690
5. K23 0.8*515*760 0.8*590*690

For Motorcycle model EGIF

(JNC270E)
Grade material used for all tanks EG
(Electro Galvanized)
IF (Interstitials Free) Single side

coated (Zn+Ni)

Coating mass standard 20MG/m 2

CRCA:-cold Rolled Closed Annealing

 CHAPTER –6

Press
Shop
1. Classification of presses:-

1. Mechanical press:-
In this press, the load generation thro motor, flywheel, gear, transmission
through connecting rod. High production rate.

2. Hydraulic press:-
Load generation thro motor driven hydraulic pumps and transmission through
hydraulic
cylinders. Generally, low production rate.
There are 4 mechanical presses:-

Scooter Parts Motorcycle Parts

P1, P2, P3 & P4 are the mechanical presses. They are used because of their high
productive rate.

There is also a hydraulic press which is used for the

die maintenance. The productive rate of this press is less than that of mechanical
press. That’s why, mainly mechanical presses is used for the press operations in the
industries.
Note:-

The P2 is used for drawing operation and P1 is used for Trimming, Piercing and
bending.
The reason is that because the P2 press machine has
double pads and cushions which absorb the force exerted by the die.

Whereas, in the P1 only Trimming, Piercing and

bending which occurs at the principle on the cam and the follower that’s why we don’t
do the drawing operation on the P1 Press.
6.2 Press PPE’s:
-
1. Helmet 4. Hand
2. Arm gloves
guard 5. Safety
3. Ear shoes
gloves 6. Goggles

1.3Press Operation
6.3.1 Scooter line:-

Blank sheet Draw Trim & Piercing

Part

Hemming Side Bending Front bending

Rewor Supply to Paint

k

6.3.2 Motorcycle line:-

R/M sheet Draw Operation Trimming

Rewor Quality Guide

k Inspection

Rework Quality Guide

Inspection

Material Movement to
Weld
4. Defects in Press operation:-

1. Dent:- Due to presence of foreign substance in die.

2. Crack:- Due to high pressure and tight pins.
3. Wrinkle:- Due to tight feed.
4. Thinning:- Decreasing in the thickness of the product due to stretching and
uneven pressure.
5. Overlap:- Overlapping of the sheet on itself.
6. Burr:- Occur at the piercing.
7. Turn up:- Bending at the corners.

6.5 Rework Operation Random tool

Rotary tool

Hamme
r
Producer:-
1. Firstly, the dent is removed with the help of hammer.
2. Then, with the rotary tool, which rotate at 18000rpm is used for cutting.
3. At the last, with random tool, which rotate at 12000rpm is used for finishing of
the rework material.

Note: - The Rotary tool and random tool work on the principle of the compressed gas.
 CHAPTER –7

Weld
Shop
1. There are 4 types of welding done in HMSI:-

1. MIG welding
2. TIG welding
3. Spot welding
4. Seam welding

The filler metal used in the welding is mild steel coated with copper metal for the
preventing it from corrosion.

Robots are used for doing MIG welding and in the rework it is done manually. Then

this all frames are checked at the inspection shop.

The fame is manufactured in the weld shop.
2. Defects:-
1. Cracks
2. Beats
3. Blow holes
4. Coricity
5. Holes
6. Less penetration
The welding used:-

MIG welding Seam

welding

Spot
welding
The specification of MIG welding
are:-1. Filament MS wire coated with
used: copper Argon & Carbon
2. Gases used: Dioxide
Carbon :
3. Gases Ratio: Dioxide 80% :
4. Amper Argon 20%
e: 160-24
5. Voltag 0
e: Low
Frame
The frame of the bike is made of two
parts,:- Rear
Front

These parts are welded together with above mentioned parameters

These are are imported from different companies with their wanders who
ensure the quality and quanity of the products
Then this products are send to the line for the
operation and assembling work.
Weld Line

Total Manpower Required=

1. Associates=6
2. Supervisor=1 3.Wander=1

Total=8

–––––
Battery box &
––Dispatch

Quality
inspection
JIG

CO-2

CO-1
Rear

Front
Paint Shop
After then, the frames are put in the carrier on the conveyer for the painting.

Before painting, the fames are washed in the ionized water then dried in
the oven at 500 temperatures.

Then ED coating (electrode deposition) is done on them. Then, at paint booth the
base coating and top coating is done by the robots.
But for finishing and parts which are not painted is done manually.

Then, these frames are allowed to enter at the oven for drying
of the paint. The ED coating will get deposit and the paint will got attached metal.
Then, this paint coated is checked at the inspection booth.
The defected frame are sent to the manually paint
shop.

Then, all the OK frames are sending to the assembly line for the manufacturing of
the product.
Note:-
There are 4 conveyer line with different temperatures and components.

The metallic frames are kept at 1700 temperature where as fiber frames are
kept at 800 temperatures

The heat is generated in the conveyer by C.N.G and

steam is also used to create the heat for the drying of the paint on components.
 CHAPTER –8

(Project)
WIP
Management
 8.1 Introduction:-

While the time of manufacturing a product in the company, many defects

and faults come in front.
To make the processes and works on, these defects have to be
resolved and So that there would be no effect on the productive
efficiency of the company.

Defects coming in the process and opreations are as following:-

1. Dents and bends in the product

2. Not precision sizes of the products
3. Time lap in the assembly line
4. Rework of the product
5. Calling of the Maintanance team
6. Rejection of the product

These are the major defects that comes in a manufacturing company

while the time of the production.
To remove these failures, a lot of action are taken. But, there is
problem
that every failure have their own reasons and format to get resolved.
So, every falure required a different format of series to
get resolved,
Methods used toand this the
resolve will failures:
nlead to take wsateage of time and money and
- afforts. 2. Bottom
1. Top Down Approach Approach
Top-down and bottom-up are both strategies of information processing and
knowledge ordering, used in a variety of fields including software,
humanistic and scientific theories (see systemics), and management and
organization. In practice, they can be seen as a style of thinking, teaching,
or leadership.
Top-down investing involves analyzing the "big picture". Investors using this
approach look at the economy and try to forecast which industry will
generate the best returns. These investors then look for individual
companies within the chosen industry and add the stock to their portfolios.
For example, suppose you believe there will be a drop in interest rates. Using
the top-down approach, you might determine that the home-building
industry would benefit the most from the macroeconomic changes and
then limit your search to the top companies in that industry.
 Conversely, a bottom-up investor overlooks broad sector
and economic conditions and instead focuses on selecting a stock based
on the individual attributes of a company. Advocates of the bottom-up
approach simply seek strong companies with good prospects, regardless of
industry or macroeconomic factors. What constitutes "good prospects",
however, is a matter of opinion. Some investors look for earnings growth
while others find companies with low P/E ratios attractive. A bottom-up
investor will compare companies based on these fundamentals; as long as
the companies are strong, the business cycle or broader industry
conditions are of no concern.

Fig 8.1
1. Top Down approach:-
A top-down approach (also known as stepwise design and in some cases
used as a synonym of decomposition) is essentially the breaking down of a
system to gain insight into its compositional sub-systems in a reverse
engineering fashion. In a top-down approach an overview of the system is
formulated, specifying but not detailing any first-level subsystems. Each
subsystem is then refined in yet greater detail, sometimes in many
additional subsystem levels, until the entire specification is reduced to base
elements. A top-down model is often specified with the assistance of “black
boxes”, these make it easier to manipulate. However, black boxes may fail
to elucidate elementary mechanisms or be detailed enough to realistically
validate the model. Top down approach starts with the big picture. It breaks
down from there into smaller segments.

For E.g:-
This below picture shows exactly how the Top Down Approach
works.

Fig 8.2

2. Bottom- Up Approach:-
A bottom-up approach is the piecing together of systems to give rise to
more complex systems, thus making the original systems sub-systems of
the emergent system. Bottom-up processing is a type of information
processing based on incoming data from the environment to form a
perception. From a Cognitive Psychology perspective, information enters
the eyes in one direction (sensory input, or the "bottom"), and is then turned
into an image by the brain that can be interpreted and recognized as a
perception (output that is "built up" from processing to final cognition). In a
bottom-up approach the individual base elements of the system are first
specified in great detail. These elements are then linked together to form
larger subsystems, which then in turn are linked, sometimes in many levels,
until a complete top-level system is formed. This strategy often resembles a "
seed" model, by which the beginnings are small but eventually grow in
complexity and completeness. However, "organic strategies" may result in a
tangle of elements and subsystems, developed in isolation and subject to
local optimization as opposed to meeting a global purpose.
 Fig 8.3

Product design and development

During the design and development of new products, designers and
engineers rely on both a bottom-up and top-down approach. The bottom-
up approach is being utilized when off-the-shelf or existing components are
selected and integrated into the product. An example would include
selecting a particular fastener, such as a bolt, and designing the receiving
components such that the fastener will fit properly. In a top-down
approach, a custom fastener would be designed such that it would fit
properly in the receiving components. For perspective, for a product with
more restrictive requirements (such as weight, geometry, safety,
environment, etc.), such as a space-suit, a more top-down approach is
taken and almost everything is custom designed. However, when it's more
important to minimize cost and increase component availability, such as
with manufacturing equipment, a more bottom-up approach would be
taken, and as many off-the-shelf components
(bolts, gears, bearings, etc.) would be selected as possible. In the latter case,
the receiving housings would be designed around the selected components.

8..1.1 LEAK

Containers, vessels, enclosures, or other fluid system are sometimes tested for leaks -
to see if there is any leakage and to find where the leaks are so corrective action can
be taken. There are several methods for leak testing depending on the situation.
Sometimes leakage of fluid may make a sound which can be detected. Tires, engine
radiators, and maybe some other smaller vessels may be tested by pressurizing them
with air and submerging them in water to see where air bubbles come out to indicate a
leak. If submerging in water is not possible, then pressurization with air followed by
covering the area to be tested with a soap solution is done to see if soap bubbles form,
which indicate a leak. Other types of testing for gas leaks may involve testing for the
outleaking gases with sensors which can detect that gas, for example - special sensing
instruments for detecting natural gas. U.S. federal safety law now requires natural gas
companies to conduct testing for gas leaks upstream of their customer's gas meters.
Where liquids are used, special color dyes may be added to help see the leakage.
Other detectable substances in one of the liquids may be tested, such as saline to find
a leak in a sea water system, or detectable substances may even be deliberately added
to test for leakage.

8.2 OBJECTIVES OF THE PROJECT

Leak testing/Pressure testing is a test performed on a two-stroke engine to ensure that

the engine has no air leaks.
An air leak in a two-stroke engine can cause a lean
condition in engine fuel-air mixture. This in turn can result in engine overheating, piston
seizure, detonation etc.
Leak testing is part of the non-destructive test NDT portfolio that can be
applied to a part to verify its conformity; depending on material, pressure, leak
tightness specifications, different methods can be applied. International standards
has been defined to assist in these choices.
There are basically three types of problem in
Engine
 Machinig problem
 Functional Problem
 Bodily Problem

Machinig problem : The problem occur due to defective machining of the component
or casting problem. Hole Dia. Oversize, drilling or tapping NG,
milling NG etc are some of the machining problem.

Functional Problem : The problem which cannot be visualized easily on engine. Hair
point hole, valve leak, tapping NG are some of the functional
problem.

Bodily problem : The problem occur due miss management/handling of component

engine during assembly. Piston ring miss, oil pump cap miss etc
are some of the bodily problems.

Responsibility: Being a Mechanical Engineer Trainee at Honda

I was responsible for “functional problem” analysis.

Following is the procedure for pressure
testing.

Leak Testing Machine

 To leak test the engine: cylinder, head, reed cage, intake manifold and spark
plug must all be installed and torque correctly. Exhaust pipe and carburetor
must be removed.

 Seal round exhaust ports with the correct size rubber expansion plug. For
1986-1991 Honda CR250R and 1985-2001 Honda CR500R, remove the
exhaust manifold and seal the exhaust port using one of the flat metal plates
with a rubber gasket. Optional plate 08-071O is available separately for
1987-1989 CR125R.

 Insert the correct size carburetor adapter (#1, #2 or #3) into the intake
manifold and tighten the manifold clamp. Teflon tape the thread on the quick
coupler and install coupler into the carburetor adapter.

 Push the nylon hose (from the pump/ gauge assembly) into the quick coupler.
If the nylon hose leaks where installed into the coupler, push the hose into the
coupler assembly while under pressure. It is important to have the system
under pressure while attempting to seat the hose to coupler. To remove hose,
push green (or gray) ring on quick coupler towards brass fitting while pulling
and twisting hose out.

 With all test equipment in place and the piston at bottom dead center, use the
hand pump to pump 6 PSI of air pressure into engine. Never exceed 8 PSI of
air pressure or
 damage to the seals and/or engine may occur. If loss of air pressure occurs,
spray soapy water over mating surfaces to see where soap bubbles appear.
Repair any leaks that may appear and redo test. A leakage rate of 1 PSI per
minute is acceptable; however the lower the leakage rate the better your
engine will perform.

 6. By carefully listening at various points, you may be able to locate air leaks
that are not easily accessible with soapy water. Crankcase seal leakage may
be heard by removing the magneto cover or if on primary side may be heard
through the oil filler hole. Leakage at the power valve seals and O-rings can be
heard by removing the power valve linkage covers or through the
transmission oil filler hole. On water-cooled engines, head gasket leakage may
show up as bubbles in the radiator coolant.

 7. The center crank seal (labyrinth seal) will allow low velocity air to pass from
one side to the other side. Therefore, both the left and right cylinders/
crankcases are tested together. To do so, seal both exhaust ports and one
intake port. Then, install the correct carburetor adaptor into the remaining
intake port. Perform steps 1 thru 6. There is no way to check the labyrinth seal;
this seal will normally out last the crankshaft main sbearings.

 8. Each leak down tester is tested for leaks at Motion Pro. To insure that your
leak down tester remains leak proof it should be tested periodically. To test
simply connect leak down tester hose to a 1 quart leak proof container and
pressurize to 6 PSI. If no leakage occurs in ten minutes the tester is leak proof.
To locate leaks spray a soapy water solution over fittings and connections
and look for soap bubbles. On pipe fittings, use Teflon tape or pipe sealant.
Occasionally, the check valve between the hand pump and hose will leak.
Clean the check valve with contact cleaner and re-grease the ball in the check
valve to insure a good seal, and then retest.
CHAPTER –9

Analysi
s
A diagrammatic representation of my methodology for solution of this problem
is given below.

DATA COLLECTION CATEGORIZATION

1

7 2

SUGGESTION FOR PROBLEM IDENTIFICATION

FUTURE
3
6

RESULT OBSERVATION ROOT CAUSE ANALYSIS

5 4

PROBLEM SOLUTION

DATA COLLECTION :- Collect the data of machining rejection for a

month.
lines
CATEGORIZATION:- Categorize this data under various and
heads of components.
PROBLEM IDENTIFICATION:- The major contributors of machining rejection are
identified.

ROOT CAUSE ANALYSIS:- The root cause of major contributors is found using QC
tools.

PROBLEM SOLUTION:- An effective solution of the problem is found and put to

practice.

RESULT OBSERVATION:- The aftereffects of solution are observed to judge their

effectiveness.
 List of the problem coming during leak
testing

 Gear Spindle oil seal leak

 Head cover gasket miss
 Neutral switch bolt free
 Piston ring miss/bend
 Oil pump bolt free

9.1 GEAR SPINDLE OIL SEAL LEAK

Fig 9.1

Gear spindles are a critical component of the drive train. Strip quality and
thickness control can be influenced by the performance of the drive spindles.

Gear spindle seal is used to resist the lubricant coming out

 GEAR SPINDAL OIL SEAL LEAK
WHY 1?
NO PROPER INSTALATION OF SEAL

WHY 2? WHY 2?

MANUAL ERROR
N/G OIL SEAL LEAK

WHY 3? WHY 3?
OPERATOR NEGLIGENCE UNSKILLED OPERATOR

WHY 4?

LESS EXPERIENCE

PROBLEM SOLUTION

 No re-use of seal.
 Proper installation of seal.
 Don’t rotate the punch while inserting the
seal.
 Put the punch straight while inserting the
seal.
 Proper training of workers.
 9.2 HEAD COVER GASKIT MISS

Fig 9.2

A valve cover is on top of the engine and helps keep the oil splashed up to the
top of the motor in that pretty much its only function. A head gasket is a much
bigger deal. your engine has a block which is on the bottom and bolted to the
frame with motor mounts. And a head.which sits on top of the block. In
between the two is a head gasket. The two peices of metal that make up the
engine expand at different times as they are two different types of metal. The
head gasket sits in between and allows enough room for everything to expand
as it warms up, and contract as it cools off

Reason

HEAD COVER GASKIT may be leaking for a variety of reasons. It could be

shrunken, cracked or rotten, or your valve cover itself may be cracked or broken
or one of the bolts may just be lose, allowing a little leak.

PROBLEM SOLUTION

 No re-use of seal.
 Use good quality of seal.
 Proper training of workers.
 9.3 NEUTRAL SWITCH BOLT FREE

Fig 9.3.1 Fig 9.3.2

The neutral switch is built into the Transmission Range Selector switch located
on the top of the transmission.

Ensures that your car is in neutral before starting vehicle. In other words, its an
electrical fault built into your ignition system so you cant damage your
transmission by trying to crank your engine while in gear. The switch acts as an
open circuit in your starting system until your clutch is pressed in.

REASON

It can done by the improper working on assembly line, Over tapering, Less
tapping, maching problem.

PROBLEM SOLUTION

 No re-use of seal.
 Proper training of workers.
 9.4 Piston ring miss/
bend

Fig 9.4.1 Fig 9.4.2

Piston ring is a split ring that fits into a groove on the outer diameter of a piston in a
reciprocating engine such as an Internal combustion engine or steam engine.

The three main functions of piston rings in reciprocating engines are :

1. Sealing the combustion chamber so that there is no transfer of gases from the
combustion chamber to the crank.
2. Supporting heat transfer from the piston to the cylinder wall.
3. Regulating engine oil consumption.[1]
The gap in the piston ring compresses to a few thousandths of an inch when inside the
cylinder bore.

REASON

It can done by the improper working on assembly line, Over tapering, unskilled
working.

PROBLEM SOLUTION

 No re-use of ring.
 Process flow chart (with images)
 Proper training of workers.
9.5 Oil pump bolt
free

Fig Fig
9.5.1 9.5.2
The oil pump in an internal combustion engine circulates engine oil under pressure to
the rotating bearings, the sliding pistons and the camshaft of the engine. This
lubricates the bearings, allows the use of higher-capacity fluid bearings and also
assists in cooling the engine.
As well as its primary purpose for lubrication, pressurized oil is increasingly used as a
hydraulic fluid to power smallactuators. One of the first notable uses in this way was
for hydraulic tappets in camshaft and valve actuation. Increasingly common recent
uses may include the tensioner for a timing belt or variators for variable valve
timingsystems.
REASON

MULTI TAPPING TAP BROKEN

WHY 1?
R CASE WRONG LOADING

WHY 2? WHY 2?

MANUAL ERROR
SEAT CHECK NOT WORKING

WHY 3? WHY 3?
OPERATOR NEGLIGENCE UNSKILLED OPERATOR

WHY 4?

LESS EXPERIENCE

WHY 5?

NEW OPERATOR

The 5-why sheet above shows that the rejection at Multi Tapping Machine is due
to tap breakage which further is caused due to wrong loading of the
component.

The wrong loading occurs majorly due to the negligence of the operator
or the ignorance of the operator. The chances of wrong loading increases
several folds when the operator is new.
Number of defects in
Aviator

Aviator

Defect, Head cover gaskit

miss, 2, 15%

Defect, Neutral
ewitch bolt free, 1
8%

Head cover gaskit

Defect, Piston ring
miss
Defect, Oil pump
bolt free, 8, 62% mi s/ b euntdr,a2l,
N e
s
e1w5i% tch bolt free

Piston ring miss/bend

Oil pump bolt free