INTERNSHIP REPORT

SUBMITTED BY
FASIH UR RASHEED
DATE OF SUBMISSION
27TH JUNE 2014

NED UNIVERSITY OF ENGINEERING

AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

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 ACKNOWLEDGEMENT
Alhamdulillah, First of all I would like to thank ALMIGHTY ALLAH as finally
completed my internship at ATLAS HONDA for which I am thankful to them as
well.

I would like to acknowledge the staff & management for their support and
assistance with this internship. I take this opportunity to express my profound
gratitude and deep regards to ATLAS HONDA staff for their exemplary guidance,
monitoring and constant encouragement throughout the course of this internship.
The blessing, help and guidance given by them from time to time shall carry me a
long way in the journey of life on which I am about to embark.

I am obliged to staff members of Atlas Honda, for the valuable information

provided by them in their respective fields. I would like to thank my beloved
friends as well that always stick together till the end of the internship and also
worked hard to produce a good assignment with responsibility.

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 Preface

The purpose of this report is to fulfill the internship requirement for the Bachelor
of Engineering degree in Mechanical Engineering. Basically this internship is an
integral part of the Industrial training which will enhance my technical knowledge,
skills development and gain experience for my professional career and will aid in
job-seeking. I hope that this report will be easier to understand, precise and will be
effective for those requiring an overview of ATLAS HONDA operations.

This report summarizes the purpose & importance of monitoring and discusses the
production and processes, data and conclusion of my internship.

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 Table of contents

1. Introduction

2. Production departments
 Maintenance Department
 Press Shop
 Die and Tool Room
 Welding
 Paint Shop
 Engine Assembly
 Frame Body Assembly
 Buffing Shop
 Drum Gear
 Hub and Panel

3. Conclusions

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 ATLAS HONDA
INTRODUCTION:
Honda Atlas Cars Pakistan Limited is a joint venture between Honda Motors
Company Limited, Japan and the Atlas Group of Companies, Pakistan.

Both these motorcycle manufacturing concerns were established by the Atlas

Group. In addition, a third concern, Atlas Epak Ltd. was taken over by the
Government of Bangladesh in 1971 after the fall of Dhaka. AHL manufactures and
markets Honda motorcycles in collaboration with Honda Motor Company. The
company was established on November 04, 1992.

The Company also manufactures various hi-tech components in-house in

collaboration with leading partners.

The company is listed in Karachi, Lahore and Islamabad Stock Exchanges.

Since the commencement of production in 1994, the company has produced and
sold more than 200,000 cars till July 2012.

Currently, the products available in the market are Honda Accord, Honda CR-V,
Honda Civic (four models) and Honda City (four models) with wide range of
colors and advanced technological features.

On April 01, 2013 Atlas Honda inaugurated the famous scheme having the
following slogan:

“You buy a Honda we plant a Tree”

Atlas Honda two wheel products include:

 CD 70
 CG 125
 CD Dream
 Deluxe
 Pridor

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Annual Production Capacity
 750,000 units

Authorized Capital
 1.50 Billion (PKR)

Paid Up Capital
 1,034.07 Million (PKR)

Karachi Plant
Company mother plant is based in the city of lights and provincial capital of Sindh,
The Karachi city. It is located at F-36, Estate Avenue, S.I.T.E. Karachi. Atlas Group
signed technical agreement with Honda in 1963 and plant started commercial
production subsequently. Plant spread over an area of 5 acres. In 1964, production
began with 7 motorcycles per day. Now plant production has reached up to 450
units per day. This plant manufactures Honda CD 70 models only.

Sheikhupura Plant
Another plant of Atlas Honda is situated in Sheikhupura city, Punjab. It is located
around 27 km on Lahore-Sheikhupura Road from Sheikhupura. The plant was built
in 1981 and spread over an area of 27 acres with the establishment of modern and
synchronized 500K plant in 2006. The plant manufactures all four models i.e. CD
70, Pridor, CG 125 and CG 125 Deluxe.

Export
 Bangladesh

Symbol of the Company

 ATLH

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Membership of Industry & Associations
 Pakistan Automotive Manufacturers Association.
 Marketing Association of Pakistan.
 Management Association of Pakistan.
 Lahore Chamber of Commerce & Industry.
 Sheikhupura Chamber of Commerce & Industry.
 Overseas Chamber of Commerce & Industry.
 Karachi Chamber of Commerce & Industry.

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MAINTENANCE DEPARTMENT

The maintenance department is responsible for the rectification of all types of

errors and malfunctioning that occur in the plant. The work request is sent to the
maintenance department by the department where problems occur and the
maintenance decides on which priority scale the request is to be completed.

The priority scale is as under:

 A1: Top priority; production stops and no alternatives are available. Work
time 24 hours.
 A2: when alternative is available and production does not stop.
 A3: not a matter of urgency; AC / water cooler.
 A4: Civil works
 B: building of a machine/project up to a year’s time.

Maintenance department is divided in to 5 sections

1) ERU (Electric Repair Unit)

2) MRU (Mechanical Repair Unit)
3) PSU (Plant Service Unit)
4) BMU (Building Maintenance Unit)
5) PMU (preventive maintenance unit)

ERU:
The ERU consist of engineers and technicians that are responsible for rectification
of electric and circuit problems encountered in the plant.

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MRU:
Mechanical repair unit is responsible to address and rectify the mechanical
problems and consists of qualified mechanical engineers and skilled technicians.

PSU:
The plant service unit consists of 1 Boiler, 5 Compressors and 5 Generators.

Boiler works on the principle of fire tube boiler and the heating surface is 2400 sq.
ft. having a pressure capacity of 10bar. It provides the steam required in paint shop
and buffing shop.

Two types of Compressors are installed; 3 (variable speed) and 2 (fixed speed).

Atlas CAPCO GA180, compressible air LS75

The compressed air is used in the pneumatic machines like paint spray gun,
different jigs and fixtures in the plant.

There are 5 different generators with different capacities; at the plant, power
generation capacity is around 4 Megawatts while the power consumption is around
2 Megawatts.

CIVIL WORKS AND BMU:

These types of works are sourced out and are totally performed by third parties on
contract basis.

There were a total of 52 personnel assigned for these works.

PMU:

The preventive maintenance unit also called as the time based maintenance is a
scheduled maintenance which is performed weekly or on monthly basis to prevent
parts from malfunctioning.
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PRESS SHOP
The press shop in Atlas Honda Karachi plant is bigger than that at SKP plant. It is
responsible for the production of 32 parts for which 18-20 tons of Mild steel is
daily consumed. Sheets are imported from Japan and range in thickness from 0.8
mm to 2.3 mm used in different amounts to produce different parts.

MACHINES & PRESSES:

 2 Hydraulic Press of 400tons and 200 tons

 5 Mechanical Press out of which 3 are of 200tons capacity and others

having 15tons and 50tons

 2 Shearing Mills

 3 Pneumatic Press of 150tons

 2 Lifters; one is 3.5 tons and other is of 4.5tons

PROCESSES PERFORMED:
The following mechanical processes are performed by the help of presses and
shearing machines.

 Shearing

 Notching

 Deep Drawing

 Piercing

 Blanking

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  Bending

DIES:
The following dies are used for the production

 White and Pink for CD-70cc

 Yellow for CG-125

 Blue for Pridor (100)

 Green for Deluxe(125)

MANUFACTURED PARTS:
The following parts are manufactured in the press shop.

 Fuel tanks and its components of all models

 Frame body and its components of all models

 Clutch plates of all models except Pridor

 Fender parts of CG-125

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DIE AND TOOL ROOM
The die and tool room is responsible for the maintenance and inspection of the dies
used in the press shop as well as responsible for the manufacturing of new jigs and
fixtures as per requirement. The die room has a vast used of pneumatics.

In die and tool room, various dies and tools are used. The different dies used
include:

1) Draw dies

2) Notching dies

3) Pressing dies

TYPES OF DIES:

1) Trimming die

2) Blank and Piercing die

3) Parting die

4) Bending die

Scope of Work:

In scope of work, there is preventive maintenance of all dies as well as the

corrective maintenance.

New dies and jigs machining is carried out as per requirement.

Tool Room:

The tool room consists of machines to carry out different mechanical operations.

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GRINDING:
Several grinding operations are performed in the tool room as per requirement.
They include:

 Surface grinding machine.

 Cylindrical grinding machine.

 Universal tool & cutter grinding machine.

 Offset grinding machine.

 Centerless grinding machine.

 External grinding machine.

 Step drill grinding machine.

 Drill sharper grinding machine.

TOOL MODIFICATION:
Magnetic plate is present for work piece holding and is responsible for truing and
dressing on the grinding wheel. The tool for clutch plate was firstly imported from
Japan but is now made locally reducing the cost.

Other machines include

 Shaper

 Leath machine

 Punch for clutch plate.

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WELDING SHOP
The welding shop is one of the largest shops in the whole plant. It consists of 3
lines

 The fuel tank line

 The frame body line

 The fender line

In welding shop, following welding types were used:

 Spot welding

 MIG welding

 TIG welding

 Argon welding

 Brazing (CO2)

 Robot welding

FUEL TANK LINE:

In fuel tank line there are total fifteen stations and sixteen workers are showing
their skills including one quality inspector. In this line fuel tank is completely
fabricated up till its water testing. Fuel tank line takes approximately four minutes
for completing the fuel tank. The processes that occur in the fuel tank line are as
follows:

 Robot welding to connect R/L fuel tank.

 Grinding.

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  Deburring (collar forming)

 Paper grinding.

 Rappel arc (MIG welding).

 Buffing.

 Fuel tank bottom sub assembly (spot).

 Fuel tank checking.

 Seam welding.

 Gas welding; brazing for fuel cork.

 Fuel tank side cover (MIG welding)

 Water coasting

 Edge grinding

 Final station

FRAME BODY LINE:

 The brackets 4 spot welding units which join different brackets and
stray covers for the frame body.

 TIG welding (for left and right panel joining).

 After this the part is sent to the inspection station where tolerances

and alignment of the frame body is checked.

FENDER LINE:
 The fenders are received from vendors and riveting is done here.

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PARTS:
The parts which are manufactured include:

 Fuel tank of CD-70

 Frame body of CD-70

 Rear fender of CD-70

 Front fender of CD-70

 Bracket of CG-125

 Front fender of CG-125

 Rear fender of CG-125

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PAINT SHOP:
The paint shop in the plant is responsible to paint all the metal parts such as Fuel
tanks, covers, fenders (front & rear), swing arm, number plate in case of export,
engine hangers and etc and also the ABS parts such as side covers, seat, hub front,
hub rear, panel front, panel rear for CD-70, CD-125 and some parts of CD-100 as
well. Parts from welding shop such as fuel tanks, fenders and frame body, parts
from CKD store such as side covers, seats, case head, from PP store such as front
fork, swing arm, rear fender and from buffing shop such as hub front and rear and
panel front arrive at paint shop to be painted.

The paint shop consist of two parts:

 Phosphating shop.

 Paint shop.

PHOSPHATING SHOP:
The phospating shop is further dived into two portions.

 Hub and panel:

The hub and panel parts from buffing shop are painted and a layer of
lacquer is coated on them.

 Phosphating shop:
The metallic parts are treated here. A hoist capable of holding 2 ton
load is used to lift the parts and dipped in metaclean for 15minutes at
70 degree centigrade for cleaning. After that it is passed to 2 hot water
tank. Further it is dipped in metaphos for 7 minutes for phosphating
for adhesion and resistance. It is then rinsed with tap water at 200
degree centigrade for 15 to 20 minutes.

It is finally baked in the oven to seize the chemical reactions.

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PAINT SHOP:
In the paint shop the frame body, fuel tank and plastic side covers are painted. The
process include brushing, mopping, then rubbing with emery paper and then
cleaning with air pressure. Then it is painted and sent to the oven. Finally a layer of
lacquer is coated. The process is same for the ABS parts.

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Engine Shop
In engine shop, the man power is around 25 personnel and 450 engines are
manufactured as per demand.

PROCESS:
 Sub assembly cover R crankcase oil seal, clutch, spindle kick
 Sub assembly cover R other parts assembly
 Gear assembly
 No punching

Engine shop is divided in two sections

 Main Assembly
 Sub Assembly

SUB ASSEMBLY:
In sub assembly there are a number of processes. The engine number is punched on
the case. After that studs are inserted followed by the placement of ratchet guide
plate, sprocket and spindle. The crankshaft is connected to the piston by the crank
pin. In the next station compression, support and oil rings are placed on the piston.
On the next station studs are inserted and gear shifter pin and oil pump is inserted.
On station 4 of subassembly line the clutch plate is assembled followed by the
insertion of push rod. After that cylinder head, rocker arm, cover head, spark plug,
gas kit and camshaft mechanism in inserted. On the final station generator is
assembled

MAIN ASSEMBLY:
In main assembly we assemble transmission and kick in R-crank case, drive
sprocket, drum bolt and crank case bolt, drum pin, spindle gear, shifter and primary
gear driver, collar bush, clutch and outer cover, oil through R cover gasket and R
cover, cap nut cylinder side bolt and valve timing adjustment, push rod, oil ring

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and ACG fitting, nut flange tappet adjustment and cap tappet cover, cover L
cylinder head and neutral switch. Air leak testing is done and oil is filled.

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FRAME ASSEMBLY:
Frame assembly shop is the place where the final product is obtained.
Approximately a motor bike is obtained every 56 seconds. It is divided into 2
sections

 Sub Assembly
 Main Assembly

SUB ASSEMBLY:
Here little parts are coupled together and converted into big parts as it takes more
time when we fit them individually on the bikes. There were 28 workers assigned
on the sub assembly line.

Parts that are assembled in sub assembly are:

 Frame Body
 Swing Arm
 Front Fender
 Rear Fender
 Step Bar
 Muffler
 Handle
 Fuel Tank
 Front Wheel
 Rear Wheel

MAIN ASSEMBLY:
The parts from sub assembly and store are brought to the main assembly where all
the parts are finally fitted. Around 20 workers were assigned to perform duties in
the Main Assembly area. The final product is obtained at the end of the main
assembly line after which it is tested for pickup, gear transmission, horn and other
things. This is the final inspection station of the plant. The motorbike after testing
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is marked as okay and sent for export or local sales. The vehicles with defectives
are rectified and then tested again before being certified as okay.

There was a total man power of around 60 personnel.

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BUFFING SHOP:

Buffing is the process makes the surface smooth producing a high luster and mirror
finish if desired. This is done with the use of buffing wheels and buffing
compounds. The buffing is done on the front parts of the vehicle where luster and
shiny surface is required. What you sell should look good or the customer won’t be
appealed to buy the product.

In buffing shop, two processes take place:

1) Buffing
2) Washing

BUFFING:
The parts where luster and shine is a must are buffed in the buffing shop. The
buffing material used here is known as cunning luster. The buffing is done before
being sent to the paint shop. The parts where luster is not compulsory are not
buffed instead they are washed then polished and then sent to pain shop for
lacquer. Different parts on CD 70, CG 125, CG dream and Pridor are washed and
buffed.

WASHING:
In Washing process, Right crank case and left crank case are washed as per the
following sequence:

 Degreasing: The chemical used is metaclean 2300, the part is dipped

for 1 minute at 50-60 degree Celsius.
 Rinsing: it is then rinsed in tap water for 30 seconds.
 Nitric Acid Tank: It is then dipped in nitric acid for 30 seconds.
 Allodine Tank: Metachromeis used as a chemical and the temperature
ranges about 40 to 55 degrees centigrade for 30 seconds
 Rinsing: It is then dipped in tap water for 30 seconds.

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  Hot Water: The temperature of water ranges about 50 to 60 degrees
centigrade for 1 minute

Rear parts are washed with metaclean 2300 while the front parts are washed
manually.

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Drum Gear Shop
The drum gear shift machine assembly assembles drum gears for CD-70, CD-125
and CD-100. The raw material i.e. the casted part is obtained from two different
vendors; Atlas Engineering and General Engineering. The casted part is processed
and treated here to get the final drum gear assemble. Here, the man power is
around 52 and 2600 parts per day are made.

Different phases of the drum gear assembly include:

1) Machining
2) Hardening
3) Grinding

MACHINES:
Following machines are used during the machining process:

1) Centered Drilling machine: it utilizes a carbide drill bit to produce 5 mm dia

holes on both sides.
2) Hydraulic Lathe
3) CNC Lathe (for CD70); OP 1: Step turning is performed on the half length
of work piece.
4) CNC Lathe (for CG125); OP 1: Step turning is performed on the half length
of work piece.
5) CNC Lathe for CD70; OP 2: Step turning is performed on the half length of
work piece.
6) CNC Lathe for CG125; OP 2: Step turning is performed on the half length of
work piece.
7) Chamfer: It is used to remove burs of the drilled holes.
8) Tapping: Used to create internal threads.
9) Drill Machines: Gang drill and multi head drills are used to produced
different holes in the piece.
10) CNC Milling: Used to cut grooves across the length of the part.

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Hardening:
The surface treatment process is completed in 3 stages. The part is hardened then
washed and finally tempered to obtain required specifications and hardness.

1) Furnace: the carburizing furnace is used to harden the part by increasing

the carbon % in the part upto about 0.6 %. The process in total takes 4 hours
to complete. First the part is put in the furnace for about 145 min at 880
degrees. Then by the help of conveyer it is dipped in oil and quenched at 100
degrees for 30 min.
2) Washing: All the parts are washed with Metaclean chemical. This process
takes time of around 1.25 hours. The parts were first washed with alkali
(Hilton 140) but using metaclean is less expensive. After metaclean is
sprayed the part goes through hot water spray then it is blown with hot air.
3) Tempering: After washing, all the parts are tempered at a unique
temperature(the temperature is around 170 degrees centigrade) with process
time of around 1.25 hours.

After every 200 parts hardness is checked by using universal hardness testing
machine.

GRINDING:

After surface treatment the part is sent for grinding operations. The purpose of
grinding is basically to improve the surface of the part. Following grinding
machines are used for this purpose.

1) CD70 Center less grinding machine.

2) CD70 Angular grinding machine.
3) CG125 Angular grinding machine.

A chemical named lublofolic is used in grinding operations instead of cutting oil.

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FINAL INSPECTION:
The final inspection area receives a part from the grinding area. The part is
checked thoroughly for its angles to be precise, its diameters to be accurate, its
depth of holes to be within the tolerances. Then the OK parts are dipped in antirust
and dispatched to the store.

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HUB AND PANEL:

The hub and panel assembly at the Atlas Honda Karachi plant assembles the panel
and hubs for the motorbikes under the banner of Honda. Almost 22 parts are
manufactured in the hub and panel assembly.

The manufactured parts include:

1) Front and Rear Panel of CD70

2) Front and Rear Panel of CG125
3) Front and Rear Panel of CD100
4) Front and Rear Panel of CG125 (Deluxe)
5) Front and Rear Hub of CD70
6) Front and Rear Hub of CG125
7) Front and Rear Hub of CD100
8) Front and Rear Hub of CG125 (Deluxe)

PANEL:
The panels assembled here undergo the following operations:

1) Pinion fitting: The pinion is fitted by the help of pneumatic jig.

2) Oil seal: An oil seal is fitted in the panel.
3) Anchor pin with greasing: Anchor pin is inserted.
4) Cam fitting
5) Apply grease: Grease is applied to the panel.
6) Gear receiver
7) Break shoe: Break shoe is fitted over the panel.
8) Oil dust seal is fitted.
9) Arm return spring is attached.
10) Indicators are inserted.
11) Arm is attached.

Same process is repeated for the Rear Panel.

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BREAK SHOE:
The casted break shoe is obtained from different vendors. The break shoe is then
sent to short blasting where it is blasted with small steel balls and sand to make the
surface rough so that it would be more adhesive. The break shoe is then sent for
Allodine and then Araldtie paste pasting is applied which has a drying time of 24
hours at room temperature. Later it is placed on the panel.

Same process goes for liner pasting and then bonding of liner and brake shoe.

HUB:
The hub consists of oil seal bearings and collar each of which is fitted using
pneumatic jigs.

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Conclusion:
The industrial training provided very good exposure and knowledge as well as
enhances the communication and problem solving skills of the student.
Furthermore, the students also learn to be adaptive to the working environment.

In real job environment, trainees experienced that, it is important to take

responsibility & accountability in all the given tasks and take care of attitude to
make sure it will produce a good first impression overall.

After the completion of internship, it proved that industrial training was successful
by achieving the desired objectives. Here, the knowledge that trainee gains did not
come only from books, but mainly comes from the skills and experience of the
technical/trained staff. Overall, the whole internship tenure for the trainee was a
fruitful experience including the practical skills and knowledge.

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