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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

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CERTIFICATE
This is to certify that the project entitled “Study of various parts of Carrier and functions and its problem analysis” is submitted by Mr. RAMNEESH SINGLA of the NATIONAL INSTITUTE OF KURUKSHETRA, (HARYANA) for the award of the degree in B. Tech. (Mechanical Engineering) is a bona fide record of work carried out by him under my supervision. The contents of these theses in full or in parts have not been submitted to any other institute or university for award of any degree.

Mr. Vivek Sharma Executive Frame Maintenance HMSI

Ms. Shelly Juneja HR Department HMSI

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ACKNOWLEDEMENT
I, Ramneesh Singla, a student of mechanical 2nd year, National Institute of Technology, Kurukshetra(Haryana) would like to give my heartiest thanks to all under whom I completed my summer training. I would like to express my deep gratitude to Ms. Shelly Juneja & Ms. Kavita Pandey who gave me opportunity to do training at Honda Motorcycle and Scooter India Limited. I feel highly obliged and my heartiest thanks to Mr. K. K. Chauhan, Manager of Maintenance department who give wonderful project to do and a department, which has provided me an immense learning and practicalities of actual problems, faced at the strategic and functional level. I would like to thanks my project guide Mr. Vivek Sharma & Mr. Virender Singh who showed me the way throughout. My sincere thanks to Mr. Vishal Sharma, Mr. Jagtar Singh, Mr. Rajender Dev they actually explained me the system flow and made me well versed with the intricacies of the project and were always available to solve my queries however trifle they may be. The acknowledgement would be incomplete if contribution of whole manufacturing division is not applauded as a whole. I sincerely thank all of them for their cooperation and guidance during my tenure at HMSI.

[RAMNEESH SINGLA]

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In this span of my summer training I was deputed in the frame maintenance section (Scooter Plant).e. which were of utmost importance to the frame maintenance section i. This esteemed organization has a name in the field of motorcycles and motor-scooters. During this project I learned a lot of things about the 5S rule. reasons for the breakdown of a carrier and countermeasures and the preventive maintenance of the carrier.” I came to know about the working of the maintenance department. HMSI has always striven to provide the highest quality products in accordance with ISO 9001 for worldwide customer satisfaction. which was very important from the industrial point of view. in a short span of time it has developed a reputation of providing world-class products with a technology to suit Indian conditions.EXECUTIVE SUMMARY Honda Motorcycles and Scooters India (Pvt. section performance. various parts of a carrier. (HMSI) . I was assigned projects.) Ltd. After being established in 1999.The name speaks for itself and needs no introduction in the field of two-wheelers. its functions. analysis & counter measure. cause & effect analysis. HMSI is always known for its quality and I feel very proud to be a part of such an esteemed organization. No doubt the policies and procedures followed by HMSI are of world standard but with the growing competition and to cut cost in this price competitive market scope of improvement is always there and welcomed. “To study the various parts and functions of a carrier and its problem analysis. I also got the opportunity to visit various other departments in the motorcycle and scooter plant of the company to know & understand how the final NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 4 . the 3G approach. TQM (Total Quality Management) etc. its motion.

Contents • Company Introduction • Introduction to HMSI • Plant Overview • Flow Chart • Products • Honda Philosophy • Organizational Structure • Introduction to Maintenance Department • Project • Bibliography NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 5 . weld.vehicle was taking shape. I visited press. machining shops vehicle quality area. engine and frame assembly. paint.

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 6 .1 HONDA HISTORY FOUNDER: .1.COMPANY INTRODUCTION 1. A MAN AND HIS DREAM He dreamed of providing people. including one built in 1949 called D-type dream. 1948 MR.SOICHIRO HONDA ESTABLISHED AT :HAMAMATSU (JAPAN) ON 24TH SEP. He thought of better ways of making piston rings and found a company & began production. HONDA ………. Then his company started producing small motorcycles. everywhere in the world an economical means of transportation.

He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co. the S500 in Japan and entered Formula-1 in 1964. Honda wins its fifth consecutive 1st ranking in the J. four-. Also Honda began manufacturing motorcycles at its Suzuka factory in 1960. In 1989. Honda launched its first sports car. In 1993. Automotive Hall of Fame. He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful & fun to ride.Then he thought of making high capacity motorcycles and taking them to racing. Power Consumer Satisfaction Index. In 1990. SOICHIRO HONDA’S dreams changed the world of motorcycling. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 7 . So his company made bigger and faster machines. five. Soichiro Honda became the first Asian to be inducted into U. two-. founder Soichiro Honda passed away.and sixcylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle class).D. in Los Angeles.S.

Time Line of Honda and Its History NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 8 .

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First Hydrogen Engine Car Unveiled At Tokyo Car Show Honda Enters Indy Car Series Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race Market feasibility Study For Air Craft Engine Begins 2005 Asimo Inducted Into Hall of Fame NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12 . 5 Cylinder Motorcycle (Called RC211V) Mazda RX.And This Decade………… 2001 2002 2003 500 World Grand Prix Victories Race Debut of New 4 Stroke.

1.2 Honda’s Products Around The World Jet Engine NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13 .

Honda – At a Glance: 37th on fortune 500 companies (2007 Fortune 500 Global List) 26th on global most admired Capital .087.030. 2007) Unconsolidated: 26.881 million 405 subsidiaries (as of March31.¥86 Billion (as of March31.652 (as of March31.140 million Unconsolidated: ¥4. 2007) Employees HONDA worldwide – Consolidated: 167. 2007) Honda Global Network: Six Regional Headquarters: • North/ Central America • South America • Afro-Europe • Asia & Oceania • Japan • China NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14 .231 (as of March31. 2007) Sales (Results of fiscal 2007) Consolidated: ¥11.

LTD. ( H. 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.M. HONDA MOTORCYCLES AND SCOOTERS INDIA PVT. (HMSI). Ltd. It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15 .S. was incorporated on 20th August1999 to manufacture two wheelers in India.2. a wholly owned subsidiary of Honda Motor Company Ltd.I) Honda Motorcycle & Scooter India Pvt.

In a short span of Eight years. advanced and technically sound products. Bringing joy to people and contributing to social development will continue to be the principles that will guide HMSI in future. Dio. technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow process in plant. HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people. Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality. Shine. the company has continued to grow in the Indian market along with regularly providing world class. Dazzler and Stunner NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16 . HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India. Since then. Ever since its establishment in 1999. It came into mass production with Honda Activa in 2001. the critical importance of providing the product. Honda’s commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions. It is believed at HMSI that by meeting these expectations. Aviator. HMSI will enhance the quality of life through products and services that reflect the spirit of today. Unicorn. While endeavoring to meet and exceed the expectations of the customers.standards. HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister.

Plot No. :1.000 scooters per year. Sector 3. Registered office Manesar. 00.000 scooters by the year by 2007 and motorcycle capacity shall be 4. The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001. Ltd.00.215crores and now the accumulated investment is 800crores. The HMSI factory is spread over 52 acres. Export of Honda products (CBU. Service and sales of spare parts and accessories. Honda also caters its customers with excellent service and spare parts support. The total investment outlay for the initial capacity was Rs. HMSI mainly deals with:    Manufacturing and sales of two wheelers. Gurgaon district of Haryana.Apart from outstanding sales.815 square meters at Manesar. Manufacturing and sales of two wheeler engines. IMT Distt – Gurgaon NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17 . which has reached 6. Few Key details about Honda Motorcycle and Scooter India Pvt.000 per annum. 1. Engine & Parts). with a covered area of about 85. The initial installed capacity was 100.

Directors Mizutani (Dir. Incorporation 3. Oyama ( ASH ) . Nakazono ( HM-J ) Special features: ISO 9001: 2000 and 14001 Certified. Iwakami ( Dir. ) .Mr.000 8. H. Equity capital yen) 4.000 sq.Takedagawa (HSCI). M. m (41 %) 5. H.7500 million Land area 210. Nagata ( Sr. T.P. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18 3821 Associates – Japanese: 15 Scooters – Activa / Dio / Aviator Motorcycle.) Mr. 300crores (Approx. K. Kato ( Dir. Plant capacity 1. Mr. Y .V. Logo 9. Shinji Aoyama President & CEO Mr. M. m Covered area 85.000 CBU’s per annum SC – 600. ) . ). Mr. Area August 20th 1999 Rs. Employees 6.2. Mr. Product Twister / Dazzler 7.Unicorn / Shine / Stunner / WINGS Mr. Mr.815 sq.000.000 MC –400.

World’s No.55 million units/year NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19 . ARAI Emission Lab. PLANT OVERVIEW Area: 210. m.000 sq. Pune Certified.1 in Engine designing 3. Society Friendly Organization. Production:1.

Location: IMT Manesar Incorporation: 1999 Employees: 6500 PLANT LAYOUT NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20 .

In this plant there are two sections one is scooter plant and other is motorcycle plant. 4. Aviator are being made. Shine and Stunner. Dio. Aviator. FLOW CHART NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21 .HMSI deals with the both the products in the two- wheeler segment. In Motorcycle plant Unicorn. Lead and Beat are being made. In scooter plant all the models Activa.

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PRODUCTS:- NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23 .5.

Started with mass production of 1st scooter. 2003 Achieved status of No. Launched new motor scooter. HMSI established new motorcycle plant. Export started to Latin America. CKD export to Latin America. Unicorn. Germany. Launched geared scooter Eterno. Bike of the year award to Unicorn. Scooter of the year award for Eterno. 2007 Launch of new scooter AVIATOR. Unicorn Tops in TNS Consumer Satisfaction Survey in “Premium Motorcycle” category Activa achieved landmark sales target of 1 million units 2005 HMSI launched its 2nd Motorcycle model. 1 Scooter manufacturing company in domestic Market. Exporter in scooter segment Certification by ARAI for emission lab. 2002 ISO-14000 Certification by TUV. SO-14001:2004 Certification by TUV. Achieved status of no 1. Germany. 2004 Launched 1st 150 cc motorbike. SHINE a 125cc segment Motorcycle. BBC Wheel Award for Dio. HMSI launched new variant ACTIVA & BEAT CKD for NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24 Mexican Market. 2006 HMSI successfully launched LEAD in Australian Market. Activa. ISO-9001-2000 Certification by TUV. Dio. It is a E-class scooter . Germany. 2001 ‘Scooter of the year award’ for Activa.

6. 150 cc bike.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. HONDA PHILOSPHY HONDA PHILOSOPHY Management Policies Compa ny Principl e THE THREE JOYS NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA RESPECT FOR THE INDIVIDUAL Page 25 .

COMPANY VISION: Maintaining a global viewpoint. present and future. they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction.• 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 behavior. • It shows the link between the company’s past. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26 . • It challenges the organization to strive for the realization of its vision • It helps our organization to maintain its sense of uniqueness.

OUR FUNDAMENTAL BELIEFS:• Respect for the individual • The three joys NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27 .

reason and NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28 .The Human Being is born as a free and unique individual with the capacity to think.

educational background.create ---. Equality: Equality means to recognize and respect individual differences in one another and treat each other fairly. national origin. while understanding that you must take responsibility for the results of those actions. social or economic status have no bearing on the individual’s opportunities. An individual’s race. helping out where others are deficient. but think creatively and act on your own initiative and judgment. sex. Trust: The relationship among associates at Honda should be based on mutual trust. Respect for the Individual recognizes the following core concepts: Initiative: Initiative means not to be bound by preconceived ideas. "Respect for the individual" calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners.and the ability to dream. Trust is created by recognizing each other as individuals. Our company is committed to this principle and creating equal opportunities for each individual. accepting help where we NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29 . age. religion.

and making a sincere effort to fulfill our responsibilities. sharing our knowledge. acting appropriately within his or her role. Each individual. must translate the philosophy into actions. Importantly. Honda is comprised of individuals working together for a common purpose. The Joy of Buying is essentially the establishment of a relationship with the customer. And every associate should be honored for these efforts. the Joy of Selling and the Joy of Creating NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30 . THE THREE JOYS: Our goal is to provide Joy through our business: for those who buy our products ("The Joy of Buying").are deficient. It is this contribution from each associate that contributes to the company’s success. The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer. and are involved in business of creating our products ("The Joy of Creating"). initiated through the products and continued through the sales and service experience. engage in selling our products and services ("The Joy of Selling").

" the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31 . Formerly known as the "Joy of Producing. 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. dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer. Honda associates. Through this relationship.cannot be achieved without first bringing joy to the customer. engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers. development. The Joy of Creating occurs when Honda associates and suppliers involved in the design.

THE HONDA COMPANY PRINCIPLE:Maintaining a global view point. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32 . • Respect sound theories. • Strive constantly for a harmonious flow of work. • Enjoy your work and encourage open communications. HONDA MANAGEMENT POLICIES:• Proceed always with ambition and youthfulness. develop fresh ideas and make the effective use of time. we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction.

and achieve further growth. There are very few private offices  An Employee for Life  Other-centered. work centered long term relationships  How work is done often matters more than what is accomplished.” strengthen the core characteristics that make Honda unique. PHILOSPHY WITHOUT ACTION IS WORTHLESS.. Honda Motor Co. announced specific plans and initiatives in the following three areas. ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON.• Be ever mindful of the value of research and endeavor. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33 . Ltd. which will enable Honda to accelerate its efforts to strengthen Honda “at the spot. HONDA’S CORPORATE CULTURE:• • • • Free thinking & open mindedness Challenging spirit Sincerity & Integrity Co-evolution JAPANESE WORK CULTURE  A typical Japanese office is an open space with an over-crowding of desks or very little private work space.

SOICHORO HONDA HMSI Plant Facilities Few of the In-House Facilities: High Pressure Die Casting. seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels. Welding Robots: Weld Shop has spot welding. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34 . Gravity Die Casting & Low Pressure Die Casting Gravity Die-Casting & Low pressure Die Casting Sections are for manufacturing critical engine parts.

Robots are used in painting for improved paint finish. The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion. high gloss and superior paint finish. which is unique amongst all Honda Factories in the world. Engine Assembly: Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35 .Paint Shop Robots: Paint Shop has a conveyor system. Each of the engines is then inspected for various parameters.

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36 . After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch.Frame Assembly: Frame Assembly is done at the slat conveyor.

Purchase General Affairs Manufacturi ng Sales & Marketing Finance & Account Engg. V.ORGANISATION STRUCTURE President and CEO Sr.7.P. Engine Mfg. Assembl y PPC Frame Mfg. Quality Press Shop Weld Shop Paint Shop Maintenance Utility K K CHAUHAN NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37 .

detection. before they become actual or major failures is called as preventive maintenance. Introduction to Maintenance Department Introduction: The maintenance department is one of the most important departments of the organization where the organization has its own production.  Breakdown Maintenance: Repair or replacements performed after a machine has failed to return to its functional state following a malfunction or shutdown is called as breakdown maintenance. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38 .  Planned Maintenance: Preventive maintenance carried out according to a fixed plan is called planned maintenance. Some important definitions used by maintenance:  Maintenance: Action necessary for retaining or restoring an equipment. It includes planned and preventive maintenance. machine or system to the specified operable condition to achieve its maximum useful life.  Preventive Maintenance: Systematic inspection. maintenance team has to work efficiently so that there is no mistake committed by them by which production loss occurs. Maintenance department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the breakdowns which occur in the machines or where there is any production loss so when to overcome the problem of production loss. correction and prevention of incipient failures.8.

mechanical adjustments. It may be due to technical failures. it represents the average mean time required to repair a failed component or device is defined as mean time to repair.  Down Time: Period during which an equipment or machine is not functional or cannot work. a condition or system also called condition based maintenance is called as predictive maintenance. labor and power etc is called as down time. maintenance. Predictive Maintenance: Type of preventive maintenance performed continuously or at interval according to the requirement to diagnose and monitor.  Mean Time Between Failures (MTBF): Basic measure of the reliability of repairable items it represents the average number of a life units during which all parts of a device or system perform within their specified limits under specified conditions are called as mean time between failures.  Mean Time To Repair (MTTR): Basic measure of maintainability of repairable items. or non availability of inputs such as materials. Maintenance Department Engine Maintenance Frame Maintenance Page 39 NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA .

Press Section 2. Paint Section PRESS SECTION: Press section has mainly four machines. Weld Section 3. aviator. and body cover of the scooters like activa. Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation.Frame Maintenance: In this department there are three sections. All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes. 1. dio. coining and bending of pipes is done. fuel tank. twister. • Komatsu Press–3 • AIDA Press -1 • CNC bending machine • Hind Press These presses are mechanical presses and on this press mudguard. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40 . CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame. nose. unicorn and twister. shine. Process like blanking. Coining is the process of removal of extra material or to make work piece up to the limit.

WELDING SECTION: In welding section, there are six types
of welding machines used in manufacturing of frames and body covers.
1.

Gantry System: Gantry system is a system in which
gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage. On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots. This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer.

2.

MIG Welding: Metal inert gas welding in this inert gas
argon is used and argon acts as a shielding gas. 1-5% oxygen is used. This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool. MIG welding has some advantages over the other welding techniques. It provides a uniform weld, it provides a slag free weld beam and needs little clean up.

3.

Spot Welding: Spot welding is a process in which
contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter.

4.

Seam Welding: It is a process that welds at a surface of
overlapped parts along a length of a joint. Weld made by overlapping nuggets, this type of welding is done on the fuel tanks and mudguards of scooter.

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5.

Portable Spot Welding: It is a portable gun which can
be taken to specified range where other spot welding machine faces difficulty in welding. This type of the welding is done on body covers of scooters.

6.

Fine Boring: Fine boring is done on the frame where
handle has to fit after fine boring handle is attached to it.

When various operation of the welding on the different components of the scooter that is frame, mudguard, body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1, one for model 2 and the last for model 3. When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present. Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area. From storage area, hangers move to the unloading area and from unloading area, these body covers and frames are loaded on to a Carrier which takes them to the paint section. Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement, unloading of model frames and body covers is done. Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area. Similarly, when there is requirement of model 2, then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3, the operator presses the model 3 switch and then from storage model 3 moves to unloading bay.
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PAINT SECTION: Paint section is very important section. In
this section, different treatments are done on the body covers and frames and it is a step by step process done as follows.

Loading

Pre-Treatment

Electro-Deposition

ED Oven
1. Sanding Zone

Booth

2. Under Coat 3. Top Coat

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

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Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed. In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers. There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone. In general first we get hard water is converted to soft water by ion exchange mechanism.Loading: In this process. Pre-Treatment: In pre-treatment. Electro-Deposition: In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer. When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44 . degreasing and dust cleaning is done. frames and body covers are mounted on the carrier of the conveyor line.

base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth. second primary coat or under coat and third is top coat. Paint Booth: Paint booth has three sections first one is sanding zone. Top Coat Oven: In top coat oven. This process is repeated twice and after that it is passed to ED oven. these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45 . sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven. In sanding zone. ED Oven: In electro deposition oven.paint is deposited on the body covers and frames of the scooter.

Inspection Zone: In inspection zone. Parts which pass these tests get the OK mark and move to unloading area. Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have. body covers and frames have to pass infra-red zone. In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line. Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs. unloading of frames and body covers takes place. They are then unloaded and then loaded on to the hanger and the parts go to the paint body storage.temperature and from there it is sent to the inspection zone. Unloading: In this area. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46 .

Most problems and the breakdowns in the paint shop occur due to the carrier only.9. Carrier is a part of the conveyer system being used in the paint shop. Paint shop carrier is the most important moving part in the paint process. It causes loss to the net production. The parts are loaded on the carrier with the help of a jig and then the motion takes place. Project Introduction: Carrier is defined as a thing which supports or holds up a part during its movement. chain and chain NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47 . It is used to carry parts to the paint shop where various processes can be performed. Carrier forms the basis of the Paint Shop because the movement of the parts from one point to another in the paint shop takes place only due to carrier. Project Project Definition: To study the various parts of the carrier being used in the paint shop and its problem analysis. Bends or breaks due to load of body part applied on carrier causes distortions which ultimately results in the breakdown. The other components of the conveyer system are: the prime mover drive (works as the input motion source for chain).

carrier revolution (for revolving the carrier). auto feeder cylinders and drop lifters which support the motion of carrier. Part Description Of Carrier: Rail: Rail can be of two types i. pre rail and power rail. carrier locks. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48 . stopper (it temporarily stops the carrier on line).track.e. carrier. Power rail is used to drive the conveyer system. carrier turn (for turning the carrier). Pre rail is used to drive trolley of the carrier.

It consists of a worm and worm-wheel arrangement which turns the axis of rotation by 90° and reduces the speed of the parts. Velocity Ratio = 1:60 Tensile Strength of Material = 60 Kg/mm² NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49 . The gear box is coupled with the small sprocket. this is also called as reduction gear.Gear Box: Gear Box acts as a Speed Reducer. Gear transmits power to small sprocket which helps for carrier turn. The relation between the torque and diameter of worm shaft is given by: T (Kg-m) = π/16*d³τ where τ is the twisting moment.

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Trolley Wheel contains ball bearings. To stop the carrier the stopper (installed on the line) pushes down the Pivoting Dog to release the engagement with the pusher. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51 . Pivoting Dog is lifted by the own weight. A grease fitting is installed as a greasing port. The chain pusher engages to the Pivoting dog for transport. Swivel pipe is connected to the shaft of worm gear. Guide Roller is installed to reduce friction against free rail. Swivel Pipe: Swivel pipe is used to drive carrier during carrier revolution.Trolley: There are two trolleys present in a carrier namely Front and the Rear Trolley. Front Trolley stops the carrier at a specified position by the actuation of stopper while Rear Trolley stops the next carrier by engaging with the Front trolley of next carrier. The outer race serves as a wheel. thus it also gets its power from the gear box.

Big sprocket is attached to the spindle shaft plate.Big Sprocket: It comes in contact with the chain of the carrier turn and is responsible for rotation of the carrier. It is mounted on the spindle on which the pan cover is fixed. Four carrier dogs are attached to it which control the rotation of the carrier. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52 . Small Sprocket: It is attached to the shaft connected to gear box. It comes in contact with the chain of carrier revolution and is responsible for the revolution of the carrier.

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But when the load is applied. To avoid the flow of current in the rail of the conveyer system and to avoid damage to the whole system. It happens when there is no load on the spring. Post: It is mounted on the pan cover and holds the jig by locking it at its position.Tension Spring: Spring is used to lock turning plate thus stopping carrier revolution. post spacer and post spacer. Post mainly has three parts: post cover. Insulator Collar: It provides insulation to the carrier in ED process so that there is no current in the frame. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54 . insulator collars are provided. turning plate opens and hence carrier revolution occurs.

one touches the guide pin of the carrier turn and third is for the engagement and disengagement of big sprocket. Guide Pin Arm: It locks the turning of the Big Sprocket by elongating the spring connected to it. To avoid overloading at the gear box.Coupling: Bush Coupling transfers the motion from small sprocket shaft to input shaft. It has three contact points: one is the spring. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55 . bush coupling is provided.

ED Collector: ED collector is used to collect current during ED process and transmits it through the cables to the body parts. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56 .

While end striker controls the revolution of the carrier. Pan Cover: It is a cover which protects the carrier from paint and ED. It is 480*480 mm. Pan Cover NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57 .End Striker & Turn Striker: They are used to control the turning and revolution of the carrier respectively. turn striker controls the rotation of the carrier. It acts as a shield for carrier.

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Preventive Maintenance of Carrier: Preventive Maintenance can be described as maintenance of equipment or systems before fault occurs. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61 . Maintenance of 28 carriers is done in a month. Preventive Maintenance for the case of carriers is done semi-annually. correction and prevention of incipient failures. Preventive maintenance is the systematic inspection. detection. before they become actual or major failures.

small hook in the frame above the front trolley and big hook in the shaft pipe which is 4. Procedure: Lift the carrier with the hook of the hoist and remove it from the line.) LIFT AND TAKE OUT THE CARRIER FROM THE LINE: Tool Used: Hoist Time Taken: approx.) DISASSEMBLE THE POST: Tool Used: Ring Spanner (size 16-17 mm) Time Taken: approx. Procedure: Open the bolts with the specified tool which fasten the post with the big sprocket. 2 min. 2 min. 5. 6. 10 min. 5 min. 3. Then put it on the rail where preventive maintenance is to be done.) CLEAN THE BIG SPROCKET: Tool Used: Scrapper Time Taken: approx.Preventive Maintenance Procedure 1. Procedure: Open the nuts of the rail bracket by using the spanner of the above mentioned size. Procedure: Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper. 2 min.) OPEN RAIL OF CONVEYER LINE: Tool Used: D Spanner (size 18-19 mm) Time Taken: approx.) TIE CARRIER WITH THE HOIST: Tool Used: Hoist Time Taken: approx. Procedure: Fix the first attachment with the gearbox bracket. 2. 12 min. Procedure: Clean the arm of the carrier by removing the paint deposited with a scrapper. Page 62 NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA .) CLEAN THE ARM: Tool Used: Scrapper Time Taken: approx.

Procedure: Lift the big sprocket from spindle shaft panel. Procedure: Open the castle nut Time Taken: approx.) OPEN THE END PLATE OF THE BIG SPROCKET: Tool Used: Allen Wrench (size 4 & 6 mm) Time Taken: approx. 2 min.) OPEN THE CASTLE NUT OF ARM ROLLER: Tool Used: 18-19 mm) mm) Ring spanner (size 14. Procedure: Straighten up the crossed pin and pull them out of the castle nut of the roller using a long nose plier. Procedure: Open the castle nut . 2 min.) CLEAN THE BIG SPROCKET DOGS: Tool Used: Scrapper Time Taken: approx. 9. Procedure: Straighten up the fixed pin and pull them out of the castle nut of the roller using a long 11.) REMOVAL OF BIG SPROCKET FROM THE CARRIER: Tool Used: Time Taken: approx. Procedure: Insert the Allen wrench and rotate them to open up the Allen bolts which fasten the 10. 2 min. Procedure: Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers. 1 min. 5 min.) OPEN THE SPLIT PIN OF ARM ROLLER: Tool Used: Long nose plier Time Taken: approx. 13.) OPEN THE SPLIT PIN OF LOCKING ROLLER: Tool Used: Long nose plier Time Taken: approx. 8. 2 min. 2 min. 12.7.) OPEN THE CASTLE NUT OF LOCKING ROLLER: Tool Used: Ring spanner (size 18-19 mm) mm) D spanner (size 20-22 Page 63 NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA D spanner (size 20-22 Time Taken: approx. 5 min. Procedure: Clean the four dogs at the big sprocket of the carrier by removing the paint deposited with a scrapper.) OPEN THE SPLIT PIN OF ARM PIN: Tool Used: Long nose pliers Time Taken: approx.

) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL: Tool Used: 18-19 mm) mm) Ring spanner (size Ring spanner (size 16.15. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64 . Procedure: Support the castle nut from bottom using D-spanner and tighten it up using a ring spanner. 17. Procedure: Insert new split pins and cross them up. 5 min. 5 min.) OPEN THE CASTLE NUT OF ARM PIN: Tool Used: 18-19 mm) mm) Time Taken: approx. 5 min. 18.) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL: Tool Used: Long Nose Pliers D spanner (size 20-22 Time Taken: approx. Procedure: Straighten up the crossed pins and pull them out by using long nose pliers.) INSERT NEW SPLIT PINS: Tool Used: Long Nose Pliers Time Taken: approx. D spanner (size 20-22 Time Taken: approx. 2 min.

21.19.) INSERT NEW PIN: Tool Used: Hammer Time Taken: approx.) CLEAN THE SMALL SPROCKET: Tool Used: Scrapper Time Taken: approx. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65 . Procedure: The pin is first clamped to the fixture and then is rubbed by emery paper to clean the dirt sticking to it.) CHANGE PIVOTING DOG PIN: Tool Used: Punch and Hammer Time Taken: approx. 2 min. 22. Procedure: Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist. 2 min. 15 min.) CLEAN THE BACK TROLLEY: Tool Used: Scrapper Time Taken: approx. Procedure: Clean the paint sticking to front trolley from top first and then clean the whole trolley by lifting carrier with hoist. 24. 20. Procedure: Clean the small sprocket of the carrier by using a scrapper. 23. Procedure: Take out the old pin inserted in the pivoting dog of the front trolley by hammering with a punch. 10 min.) CLEAN THE ARM PIN: Tool Used: Amery Paper Time Taken: approx. 3 min. Procedure: Insert the new pin by hammering it with a hammer.) CLEAN THE FRONT TROLLEY: Tool Used: Scrapper Time Taken: approx. 10 min.

29.) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL: Tool Used: High Temp.25. 1 min. 26.) GREASE THE LARGE ROLLER: Tool Used: High Temp. Procedure: Grease the roller with high temperature grease. Grease Time Taken: approx. Procedure: Grease the roller with high temperature grease. Grease Time Taken: approx. Procedure: Rollers are fastened 30. Grease Time Taken: approx. Procedure: Grease the holes of arm with high temperature grease.) GREASE THE PIN HOLES OF ARM: Tool Used: High Temp. 1 min. Grease Time Taken: approx. 4 min. 28. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66 . Procedure: The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm. 27.) GREASE THE SMALL ROLLER: Tool Used: High Temp. 1 min. 10 min.) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS: Tool Used: Ring spanner (size 18-19 mm) mm) mm) D spanner (size 20-22 (size 30-32 Long nose pliers Time Taken: approx.) ASSEMBLE THE ARM ON THE SPINDLE SHAFT PLATE: Tool Used: Ring spanner (size 18-19 mm) D spanner (size 24-27 mm) Time Taken: approx. 1 min. Procedure: Grease the roller with high temperature grease.

35. 3 min.) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT: Tool Used: Time Taken: approx. Procedure: Grease the roller with high temperature grease. Procedure: Fasten the end plate back on the big sprocket using Allen wrench.) ATTACH THE END PLATE OF BIG SPROCKET: Tool Used: Allen Wrench Time Taken: approx.31. 32. Procedure: Put the big sprocket back on the spindle shaft and clean the excess grease coming out of the sides of hole. 1 min. 2 min. Grease Time Taken: approx. 33. Grease Time Taken: approx. 1 min. Procedure: Open the grub screw of the gear box to change the old lubricating oil present in gear box using Allen wrench. 36.) COLLECT THE OLD OIL IN A BIN: Tool Used: Time Taken: approx.) GREASE THE SPINDLE SHAFT: Tool Used: High Temp. Procedure: Grease the spindle shaft with high temperature grease. Procedure: Collect the old lubrication oil in a bin with proper handling.) OPEN THE GRUB SCREW OF GEAR BOX: Tool Used: Allen Wrench (size 6 mm) Time Taken: approx. 34. 1 min.) GREASE THE BIG SPROCKET HOLE: Tool Used: High Temp. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67 . 1 min.

37. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68 .1 min. 43. frame and gear box bracket. 38.) POUR NEW OIL IN GEAR BOX: Tool Used: Mug and Grade 220 oil Time Taken: approx. 44. 42. Procedure: The grub screw is 39.1 min. Procedure: Grease the bearing with high temperature grease. 2 min. Grease Time Taken: approx. Procedure: Lift the carrier with belt of hoist and attach the greasing gun rod with the bearing cap and push it inside.1 min. Procedure: Rewrite the number of carrier with permanent marker on the gear box. Procedure: Pour new lubrication oil in the gear box. 4 min.1 min. 41. Procedure: Grease the bearing with high temperature grease.) REASSEMBLE GRUB SCREW: Tool Used: Allen Wrench (size 6 mm) Time Taken: approx.) OPEN THE GEAR BOX OIL CAP: Tool Used: Time Taken: approx. Procedure: Grease the bearing with high temperature grease.1 min. Grease Time Taken: approx. Procedure: Open the gear box oil cap 40.) GREASE THE FLANGE BEARING OF SMALL SPROCKET: Tool Used: High Temp.) GREASE THE ROLLER BEARING: Tool Used: High Temp. 2 min.) GREASE THE TROLLEY BEARING: Tool Used: High Temp. Grease Time Taken: approx. Grease Time Taken: approx.) GREASE ROLLER BEARING OF GUIDE ROLLER: Tool Used: High Temp.) REWRITE THE NUMBER OF CARRIER: Tool Used: Marker Time Taken: approx.

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69 . To reduce this problem. The NG frame hole is repaired by welding a bush at the site of the hole which is a newly developed Kaizen. when it is suddenly stopped by the stopper.Problem Analysis Of Carrier Frame Hole NG: During the motion of the carrier. an anti back-up system is applied to reduce the vibrations. vibrations are produced in it and the pin inserted in the hole of the frame enlarges the size of the hole thereby causing the problem of frame hole NG.

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unbalancing of the carrier thereby causing improper motion at the carrier turns and revolutions and also resulting in the body parts falling in the oven.Problems Caused By Loading: Improper loading of the frame body on the carrier damages the insulator collar because an unbalanced force acts upon it and insulator collars being the non-metallic parts are severely affected. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 71 . R is the resultant vector This is a production problem which causes the bending of jigs.

Gear Box Failure: Gear box of the carrier also fails some time due to overloading or improper coupling. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 72 . Bending of Striker: Overloading at CTs and CRs causes the bending of the strikers which result in altered motion of the carrier.

hammering of the nut for the proper locking can also cause the breaking of nut. The stresses are developed in the post which leads to its breaking. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 73 . Moreover. Overloading: Overloading is the state when the load on a part of the carrier is higher than its tolerance value.Breaking of Post: The post of the carrier can be broken due to variable and unbalanced load acting on the carrier. chain is not able to move forward properly causing overloading of chain. Its causes are:  If any object interrupts the motion of chain.  Improper position of the jig may lead to unbalancing of the carrier and overload may occur.

 Bush between coupling is cut.  Swivel pipe bends -> Carrier wouldn’t be leveled.  Bearing sometimes disrupts system.  Spindle shaft bends -> Carrier wouldn’t be leveled. Guide pin may not properly interact with the arm which may lead to non-alignment.  Breaking of any of the carrier dogs will lead to improper revolution of the carrier. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 74 .  Chain of the carrier turn may not be in proper position leading to overload at CT.  Insulator sometimes fails to stop current  End plate threading wears.  Striker and arm also bends. Other Problems:  Cable breaks -> Current does not reach to body part  ED COLLECTER burns out -> It would not collect current  Threading of end–plate striker wear out -> Striker would not hit limit switch.

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As far as my project of study.Conclusion From my project of one month here in HMSI. The carrier being used in the paint shop is the best possible system for proper painting of parts. NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 76 . problems related to it can be solved. By knowing the various specifications. maintenance and breakdown analysis of carrier is concerned. I came to know that how work goes on in the organization. I came to know the importance of carrier in paint shop and the production problems caused by the carrier in the industry.

Virender Singh Mr.com References:      Mr. Rajender Dev Sources: Workshop of HMSI Frame Maintenance department of HMSI NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 77 .Honda2wheelersindia.Vishal Sharma Mr.Jagtar Singh Mr. Vivek Sharma Mr.BIBLIOGRAPHY Website: www.