Industrial Safety and environment

FMECA OF NOISE HAZARD

Presenters: 2015-IM-09
2015-IM-10
2015-IM-11
2015-IM-12
2015-IM-13
2015-IM-14
2015-IM-15

Presented To: Dr. Sadaf Zahoor

 INTRO TO ATLAS HONDA
Atlas Honda Limited is a joint venture between the Atlas Group and Honda Motor Co., Japan. The
foundation of the Atlas Group was laid in 1962 with the establishment of Shirazi Investment(Pvt) Limited
with a capital of half a million rupees and three men doing business in trading shares and real estate.

The growth of the Atlas Group is the result of its focus on good corporate governance. Today Atlas is a
diversified group dealing in engineering, financial services and trading.

Atlas shareholders equity now stands over 25 billion rupees; assets have increased to over 60 billion
rupees; personnel strength is over 7000 and annual sales have crossed 60 billion rupees. The Group paid
taxes of Rs. 15 billion over 2% of the total government revenues.

With the annual production capacity of 1,000,000 the company has an authorized capital of 1.5 Billion
rupees and paid up capital of 1,034,066 million. The company also manufactures various hi-tech
components in-house in collaboration with leading parts manufacturers like Showa Atsumitech, Nippon
Denso and Toyo Denso. Honda Motorcycles are by far the largest selling motorcycles in the country with
an unmatched reputation for high quality, reliability and after-sales services.

AHL has two manufacturing setups, one in Karachi and the other in Sheikhupura. The Karachi plant is
spread over an area of 5 acres and produces 500 units. The Sheikhupura Plant is spread over an area of
23 acres and produce 2200 units per day. The Karachi Plant only manufacturers Cd-70 while the
Sheikhupura plant manufacturers all 6 models.

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 VISION:

Market leader in the motorcycle industry and emerging as a global competitive

center of production and exports.

MISSION:
A dynamic growth oriented company through market leadership, excellence in
quality and service and maximizing export, ensuring attractive returns to equity
holders, rewarding associates according to their ability and performance,
fostering a network of engineers and researchers ensuing unique contribution
to the development of the industry, customer satisfaction and protection of the
environment by producing emission friendly green products as a good
corporate citizen fulfilling its social responsibilities in all
respects.

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 COMPANY PROFILE
CEO Mr. Saquib H. Shirazi

Plants and Location Karachi and Sheikhupura

Regional Offices Lahore, Rawalpindi, Multan, RY Khan, Hyderabad, Faisalabad

Export Afghanistan, Bangladesh, Srilanka

Products D-70, CD Dream, PRIDOR, CG-125, CG-125 Deluxe, CG Dream

Annual Production
1,000,000 Units (Capacity Enhancement Project: 1,300,000)
Capacity

Man Power Strength Permanent: 2500, Contract: 2276 Total: 4776

CD 70 / CD Dream: 94%, CG125 / CG Dream:90%. Pridor 100 cc+CG 125

Indeginization Status
DELUX: 85%

Parts Suppliers Network 152

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 MARKET COMPETITORS
Competitors of AHL:

Market always creates competition because there is no restriction for any one, everyone

try to compete other AHL competitors are:

Dawood Yamaha Motor Company.

Sehgal & Company.

Suzuki Motorcycle.

Sohrab Motorcycle.

Chinese Brands:

Ravi,Sthalco , Super Power, Metro, Super Star, Habib, Pak Hero, Super Asia, New

Asia etc.
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 SAFETY PROGRAM IN ATLAS HONDA

AHL has generated its own Manual for Safety & Environment that explains everything in case of some
emergency.

Pakistan Institute of Quality Control is the safety training institute for AHL. This institute conducts fire
training sessions at AHL plant to make employees aware of the dangers not visible. FASTAC (Fire &
Security Training Center) offers First Aid Training Course which was attended by the relevant employees of
AHL.

Recently Rescue 1122 were invited to AHL Sheikhupura Plant to give some know how about First Aid to all
the employees. Not only AHL arrange such activities but also they have also ensured safety measures to get
ISO certification.

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Introduction to All departments:

1. Logistics Department

2. Human Resource Administration

3. Corporate Affairs Finance

4. Marketing

5. Supply Chain

6. Quality Assurance

7. Engineering & Projects Research

8. Development Information Technology

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TO DEVISE METHODS TO REDUCE
NOISE LEVEL IN WELDING SHOP.

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 1000K ASSEMBLY PLANT LAYOUT
Mess Engine Assembly

P Line P Line2
a a
FB 1 s
s
welding
s s
a a
g g
e e

Jig
MA

A
s As
S sy L
y. L I
ED paint i ne
n
Main e
oven

Passage

T
Passage

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1000K ASSEMBLY PLANT

1. Engine Assembly

2. Welding Shop

3. ED Painting

4. Frame Assembly

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 NOISE HAZARD AT WELDING SHOP

Noise level Measured at welding shop: 116 dBA

Standard Noise Levels at working place

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 Causes of Noise
Hammering Process

Transfer of Frame body from one station to

another on an iron sheet floor

Argon welding

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 FMEA WORKSHEET
Project Leader Mr. Irfan Rasool. (Assisstant Manager 1000k plant)
Support Member Mr. Kashif Mehmood
Project Team Group 8

Potential Potential Actions

PROCESS Current
noise noise SEV OCC DET RPN Recommen SEV OCC DET RPN
STEP Controls
causes effects ded

Hard
hearing
Hammerin Iron with Brass
9 10 2 180 5 10 2 100
g Hammer constant hammer
vibration in
body
Shifting Headache, Belt
Rattling
frame hearing conveyors
of Frame Ear plugs
body from loss and are
body with 8 8 2 are being 2 8 3 48
one distraction employed
iron sheet 128 used only.
station to for the for this
on floor
another workers purpose

Ear muffs
Headache
Argon Welding or Dampers
and hearing 8 10 2 160 4 10 3 120
Welding noise should be
loss
employed

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 FMEA WORKSHEET
Sev - Severity of the failure (what impact will it have on our process?)
Occ How likely is the event to occur (probability of occurrence)
Det How likely can the event be detected in time to do something about it
RPN Risk Priority Number (multiply Sev, Occ, and Det)

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Any Questions?