Balancing Sheet

DISCOVER-100 LINE BALANCING at 7.
7 m/min CONVEYOR SPEED
Sr. No.
Stage
LH
Number punching
Bar code scanning
Frame loading on conveyor
Flag loading
Flag loading
Fairing insertion
Engine insertion
Engine fr. Bkt. Matching

7
Fr. Fender tightening
Chain slackness
10
Chaincase Fitment
10
Chaincase Fitment
11
Chaincase Tightening
12
Silencer gaskit fitment
13
Stem nut tightening
14
Thermal sensor connection
15
Handle bar fitment
16
Battery connection
17
Seat cowl fitment
18
GSL fitment
19
Handle bar routing

& Coupler connection
20
LH. Bellow insertion
21
CDI fitment
22
Petrol tank fitment
23
Fr. No. platefitment
24
LH Side Panel Fitment
25
Fr.Brake connection
26
On Line Inspection
27
Scanning
1
Kit Bin Loading
1
Kit Bin Loading
2
Rear wheel fitment
3
Rr. Br. Connection
4
Fork fitment
5
Fr. Fender Fitment
6
Engine insertion
7
Engine Fr. Bkt. Matching
8
Fr. Wheel fitment
9
Engine Tightening
10
Focus
11
Rider step
12
Rr. Wheel alignment
13
Silencer fitment
14
RH fender tightening
15
Carburator Tightening
16
Cable routing
17
Coupler connection RH.
18
Throttel connection
19
Throttel cap prefitment
20
Starter motor connection
20
21
Seat cowl tightening
22
Grab handle fitment
23
Clutch connection
24
Kick fitment
25
On Line inspection
LINE BALANCING at 7.7 m/min CONVEYOR SPEED
Activity
LH
Frame unloading and move towards m/c

Bearing race collection
Race on m/c and clamp and cycle start
A.C. box polybeg remove
Move back to trolley
TOTAL TIME
Time (in sec)
6.4 8.3 8.8 3.1

1.9 2.8
3 3.2
3 1.1 4.6 2.6
5.3 5.3 4.6 5.2
4.5
4 2.3 3.2
21.1 21.5 23.3 21.4
Move towards conveyor

Unload kitbin empty
bar code scan & puton p v card
Move towards m/c
PV card on veh
Rubber band removal
Declamp frame and unload frame
Move towards conveyor
7.7
10.6
9.9
7.6
5.4
4.8
5.7
4.8
Open main stand and matching with rear wheel

Rear axle from kitbin
Chain removal from sprocket and rear axle insertion
Remove tackle and move back
TOTAL TIME
Tackle on flag and flag on conveyor
Ball cage on head pipe
5.1
5.8
5.7
5.4
18.2 21.2 21.3 17.8
4.1
4.8
5.5
Paint application on number punched
2.4
4.8
3.9
6.6
Fitment of battery acid drain pipe
5.9
6.7
6.7
4.5
Move back
TOTAL TIME
4.3
4.1
4.1
3.4
18.6 20.4 20.7
20
Pick fairing from trolley
6.5
6.3 11.2
6.9
Stem nut and washer prefit
5.6
8.1
2.2
5.9
Placing battery pad
3.1
2.6
2.8
3.5
3.3
Move back
TOTAL TIME
Engine 14 mm Rr. 2 bolt insertion
18.2
20 19.2 19.6
7.7 12.6
8.1 15.5
Magneto coupler connection
11.2
4.6 11.1
4.4
TOTAL TIME
18.9 17.2 19.2 19.9
Engine fr. Bkt. Insertion with 12mm 3 bolt.
8.2
4.9 10.8
9.2
Clutch wire bracket connection
7.7
8.2
5.7
Declamp fix.
Move back
TOTAL TIME
LH. Fender 2bolt prefitment & tightening
5.4
3.7
6.7
3.2
3.3
21.3 16.8 20.7 18.2

3.9
6.7
6.8
4.5
Clutch wire bkt. Tightening
4.6
4.5
6.1
Engine rr. Bkt. 2 bolt tightening
5.3
4.2
Shari Guard bkt. Bolt tightening
6.5
5.1
5.2
4.2
TOTAL TIME
Picking & inserting 2 bolts in front fork & Engine holding LH. Side
Chain routing
Chain adjustment
20.4 21.7 20.7 20.8

5.1
9
Move back
TOTAL TIME
6.5 13.7
8.9
4.5
2
4.5
10.8
1.5
15.1 17.4 19.2 16.8
Chaincase from trolley to vehicle

Lower chaincase fitment and 2 bolts prefit
10.5
16.7 10.3 11.9
10.5
16.7 10.3 11.9
Upper chaincase fitment

Stick barcode on head pipe
5.2
4.5
4.6
3.9
Move back & collect bolts
1.6
2.4
2.8
2.6
TOTAL TIME
17.3 23.6 17.7 18.4
tighten 4 bolts
11.3
Rr. Axle holding
4.8
Move back & collect bolts
2.2
TOTAL TIME
6.1
6.2
4.8
9 11.2
7.3
2.4
2.1
3.2
18.3 17.5 19.5 15.3
silencer gaskit fitment
4.2
3.6
5.2
brither pipe connection
7.4
5.6
6.7
3.5
TPS coupling
6.7
6.9
7.9
7.2
handle holder on frame
4.7
4.1
2.1
3.3
TOTAL TIME
23 20.2 22.7 19.2
Stem nut and fork upper bolts (2) tightening
7.6
7.2
7.4
6.7
Silencer front prefitment
7.6
7.9
7.7
8.2
Move back
3.2
2.5
3.1
3.4
3.5
3.2
3.8
Stem nut torque check
TOTAL TIME
tightening of silencer with gun
Thermal sensor connection
Move back
TOTAL TIME
Handle bar from trolley to frame
Fork rotation
Handle holder on handle bar from frame
Handle bar bolts tightening (4)
Move back
TOTAL TIME
11.3 12.7 13.5 13.6

2.8
2.1
2.2
17.6 17.9 19.4 19.8
5.2
5.3
5.5
5.9
6.6
4.6
5.9
4.1
5.3
4.7
4.9
1.50 1.50 1.40 1.50

17.30 16.7 17.5 16.4
battery fitment
R.R cover tightening
Move back
TOTAL TIME
7.8
7.5
6.5
10.7
5.3
7.7
1.5
2.5
2.2
20.00 15.3 16.4
seat cowl from flag & spark plug connection

seat cowl fitment
19.2
19.9 18.8 20.2
tail lamp coupler connection
TOTAL TIME
19.2 19.9 18.8 20.2
GSL fitment
8.4
8.1
8.8
arrester & flasher fitment
9.8
8.8
9.9
1.8
2.2
MOVE back
TOTAL TIME
tie band
SPM cable routing
3 coupler connection
TOTAL TIME
20.2 18.7 20.9

4.4
3.9
3.5
4.4
13.5 14.5 13.2 11.2

3.9
3.4
2.5
3.1
21.8 21.8 19.2 20.4
Throttal cap tightening
2.4
2.1
1.9
1.8
GSL tightening
5.7
3.4
3.2
bellow insertion & clamping
7.2
7.6 10.4
8.3
clutch cable routing
2.1
2.4
move back
3.5
2.5
4.1
2.4
TOTAL TIME
CDI connection & fitment
carburetter tightening
Move back
TOTAL TIME
20.9 19.6
3.4
3.4
22 20.5
4
2.5
16.2 14.1 13.3 14.6

2.3
2.9
2.6
2.3
21.9 20.4 19.9 19.4
reflector tightening
4.3
5.9
3.9
4.2
insertion of SPM wire
2.8
3.4
3.2
petrol tank fitment
12.9
Move back
1.6
TOTAL TIME
7.1 13.1 13.4

1.5
1.2
1.1
21.6 20.5 21.6 21.9
front no. plate tightening
9.6
5.4
7.8
Cable clamping
2.7
3.4
2.7
2.8
petrol tank lock fitment
7.6
5.8
Move back
1.5
1.9
1.1
1.6
TOTAL TIME
21.4 20.1 16.2 17.2
Picking lock from fairy and unpacking it

putting lock washer chromate in side panel
3.6
3.7
3.9
3.5
10.8 10.5 11.7
9.8
lock fitment in side panel & P.T.
5.3
4.7
5.7
move back
1.5
1.8
1.9
TOTAL TIME
21.2 20.7 22.3 20.3
Fr. Br. Connection
11.6 13.3 12.2
flag unloading
4.3
3.5
3.7
Move back
2.1
1.9
1.4
TOTAL TIME
18 18.7 17.3
15.9 16.3 21.2 15.6
Scanning
3.9
4.2
4.6
5.1
S P M Screw tightening
2.8
3.1
2.6
TOTAL TIME
6.7
7.3
7.2
8.1
R. H.
Rear wheel loading
kitbin loading
4.69
6.39 3.41
4.21 4.47 6.44
Rear wheel panel on wheel
1.6 2.81 3.15
Move back
3.1 1.45
TOTAL TIME
2.3
13.6 15.12 15.3
rear wheel matching
4.8
4.6
6.6
adjuster fitment
nut & washer fitment
move back
4.8
4.8
6.5
3.6
TOTAL TIME
8.4
8.2
18.1
17.7 17.3 16.8
To put carburator in kitbin
3.8
2.7
2.1
bearing cage in upper bearing of head pipe
1.3
0.9
carburator clip
4.2
4.8
2.2
rear brake fitment

Move back
TOTAL TIME
6.6
1.2
13.8 13.4 14.6

1.5
2.2
2.3
22.8 24.1 22.1
Collect fork from trolley to frame

Collect lug nut, dust cap and bearing cone from kitbin
Insert fork in head pipe
21.6 20.9 21.9 21.8
Prefit nut, tighten and torque reset by torque wrench

Move back
fuel pipe in carburetter
2.5
1.7
2.6
1.9
front fender to frame & Insertion of fender in fork
6.9
8.6
8.2
6.9
Prefit bolts (2)

Carburator positionning on ac box bellow
Rr. Wheel nut washer prefitment
Move back
4.1
6.9
4.7
4.4
TOTAL TIME
6.7
4.6
3.8
7.6
20.2 21.8 19.3 20.8
Engine from trolley to vehicle and carburetor clip isert in engine bellow
Engine insertion with matching to carburetor
18.3
Move back to trolley
18.2 20.1 18.6
Engine Fr. Bkt. Match with LH. Bkt.

3 nut prefitment
Torque rod bolt insert in pannel & torque rod
TOTAL TIME
Fr. Wheel from trolly
11.9
16.5
8.4
6.3
13
13.5
6.2
6.5
20.3 22.8 19.2
20
5.4
4.1
9.9
9.1
9.8
axle insertion & nut washer prefitment
6.5
8.6
5.6
6.5
move back
1.9
1.4
3.7
1.2
match brake pannel & speser
TOTAL TIME
22.8 23.9 22.5 20.5
Engine Tightening complete
17.8 17.7 19.2 18.4
focus bolt insertion
4.9
3.1
5.1
nut washer prefitment
3.2
2.5
3.1
4.7
7.3
torque rod bolt nut washer prefitment
TOTAL TIME
13.1 10.3 15.5
Fr. Wheel tightening
1.5
1.3
Rider step 2 bolt prefitment & tightening
19 15.3 17.8
16
TOTAL TIME
1.9
20.5 17.2 19.8 17.3
right side reflector
6.1
3.4
5.3
3.7
Rr.wheel alignment & tightening
8.2 10.3
7.9
8.4
Torque rod tightening
3.9
3.3
3.6
4.7
Rr. Br. Play adjusment
1.9
1.4
2.2
2.8
move back
1.5
1.3
1.2
1.3
TOTAL TIME
Silencer front matching with engine stud
Silencer Rr.bolt , nut & washer prefitment & clamp fix.& move back
21.6 19.7 20.2 20.9

6.6
7.1
7.1
14.4 13.5 13.5
TOTAL TIME
21 20.6 20.6
2 bolt tightening of fender
6.3
6.8
5.6
3 coupler connection & move back
16.4 15.9 16.2
TOTAL TIME
22.7 22.7 21.8
insulator insertion
7.7 12.4
7.5
8.9
6.7 10.9
9.6
Carburator clip Tightening & carburator tightening
10.9
TOTAL TIME
18.6 19.1 18.4 18.5
RH. Cable routing
17.1 15.9 14.7
silencer rear bolt tightening
3.7
3.4
3.8
move back
1.5
2.2
TOTAL TIME
22.3 21.3 20.7
2 coupler connection
5.8
bellow insertion
11 12.1 11.2
auto-choke coupler connection
5.9
3.6
4.2
move back
1.5
1.2
1.3
TOTAL TIME
tie band of accelerator wire
Throttel connection
move back
TOTAL TIME
2.4
2.3
2.8
3.4
3.2
1.9
2.1
20.1 21.1 17.9 18.7
Throttel cap prefitment
11.9
2.6
15.4 15.3 13.2 13.2
TOTAL TIME
6.5
24.2 23.4 23.2
throttel lock pin fitment

move back
6.5
2.9
6.3
5.7
14 13.1 13.6
2.4
2.5
2.2
18.8 22.7 21.6 21.5

7.60
7.5
8.90
over flow pipe from carburator to frame
4.60
3.4
3.20
Earthing connection with engine
2.90
3.5
4.00
move back
3.50
2.9
2.60
TOTAL TIME
18.60 17.3 18.7
Seat cowl prefitment & tightening

RH. Adjuster tightening
9.2 11.6
13
11
3.2
3.8
focus bolt tightening
8.2
4.3
9.4
move back
1.9
1.5
1.2
1.2
TOTAL TIME
RH reflector tightening
23.3 22.3 24.5 25.4

2
2.2
2.3
Grab handle pre fitment & tightening with RH. S/P clip insertion
20.2 19.2 20.1
TOTAL TIME
22.2 21.4 22.4
clutch cable routing from outside with clutch play adjustment
19.1 18.2 18.3
move back
TOTAL TIME
2.2
2.5
2.8
21.3 20.7 21.1
RH. S/P fitment & tightening

kick fitment & tightening
Rr. Br. Light adjusment
18.2 17.8 17.3 17.2
MAN/P
AVG.
6.6
2.7
2.8
5.4
3.5
21
9
5.2
5.5
19.6
5.1
4.4
6
4
19.5
7.7
5.5
3
3
19.2
11
7.8
18.8
8.3
7
3.9
19.2
5.5
4.8
5.4
5.2
21
7.4
8.3
1.4
17
12.4
12.4
4.6
2.4
19.4
7.1
8
2.5
17.6
4.7
5.8
7.2
3.6
21.2
7.3
7.9
3.1
18.3
3.6
12.8
2.3
18.7
5.5
5.3
4.7
1.50
17.0
7.3
7.9
2
17.2
19.5
19.5
8.4
9.5
2
19.9
4
13.1
3.2
20.3
2
3.8
8.3
3.4
3.1
20.6
3.3
14.5
2.5
20.3
4.5
3.8
11.6
1.4
21.2
7.9
2.9
6.3
1.5
18.6
3.7
10.7
5.2
1.6
21.1
12.4
3.8
1.8
18
17.3
4.5
2.9
7.6
27
4.8
5
2.5
2.3
14.5
5.7
5
6.8
17.5
2.3
1.1
3.8
14
2
23.2
21.6
1
2.1
7.6
5
5.7
20.3
18.8
13.7
6.8
20.5
4.1
9.5
6.8
2
22.4
18.3
4.4
2.9
5.7
13
1.6
17
18.6
4.6
8.7
3.8
2
1.3
20.4
7
13.8
20.8
6.2
16.2
22.4
9.2
9.5
18.7
15.9
3.7
1.9
21.5
6.3
11.4
4.5
1.3
23.5
2.8
14.2
2.4
19.4
5.5
13.2
2.5
21.2
8.0
3.7
3.4
3.0
18.1
11.2
4.3
7
1.4
23.9
2.1
19.8
21.9
18.5
2.5
21
1
1
18
25

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Balancing Sheet

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DISCOVER-100 LINE BALANCING at 7.

7 m/min CONVEYOR SPEED

Bar code scanning

Frame loading on conveyor

Engine fr. Bkt. Matching

Fr. Fender tightening

Silencer gaskit fitment

Stem nut tightening

Thermal sensor connection

Handle bar fitment

Seat cowl fitment

Handle bar routing

LH. Bellow insertion

Petrol tank fitment

Fr. No. platefitment

LH Side Panel Fitment

Seat cowl tightening

LINE BALANCING at 7.7 m/min CONVEYOR SPEED

Frame unloading and move towards m/c

Time (in sec)

6.4 8.3 8.8 3.1

Move towards conveyor

Open main stand and matching with rear wheel

18.2 21.2 21.3 17.8

Paint application on number punched

Fitment of battery acid drain pipe

18.6 20.4 20.7

Pick fairing from trolley

Stem nut and washer prefit

Placing battery pad

Magneto coupler connection

18.9 17.2 19.2 19.9

Engine fr. Bkt. Insertion with 12mm 3 bolt.

Clutch wire bracket connection

21.3 16.8 20.7 18.2

Clutch wire bkt. Tightening

Engine rr. Bkt. 2 bolt tightening

Shari Guard bkt. Bolt tightening

20.4 21.7 20.7 20.8

15.1 17.4 19.2 16.8

Chaincase from trolley to vehicle

16.7 10.3 11.9

16.7 10.3 11.9

Upper chaincase fitment

Move back & collect bolts

17.3 23.6 17.7 18.4

Rr. Axle holding

Move back & collect bolts

18.3 17.5 19.5 15.3

silencer gaskit fitment

brither pipe connection

handle holder on frame

23 20.2 22.7 19.2

Stem nut and fork upper bolts (2) tightening

Silencer front prefitment

Stem nut torque check

11.3 12.7 13.5 13.6

17.6 17.9 19.4 19.8

1.50 1.50 1.40 1.50

20.00 15.3 16.4

seat cowl from flag & spark plug connection

19.9 18.8 20.2

tail lamp coupler connection