The finished part is visually inspected and buffing is done to ensure that no defect/dent reaches the weld area. The presses work in pair of two. One for drawing and second for shearing.
Then these parts are sent to the weld section where they are clamped in a jigand a robotic arm welds the two parts together. An operator then checks the weld done by the robot in order to ensure that there is no welding miss or spatter. These defects are rectified by manual welding or by buffing. The second part of the fender is welded using spot welding. The weld is then inspected again. Finally the brake wire harness is welded. Also the L stay and R stay are welded (Stay are the clips) which are used to hold the fender along with the fork assembly. A fiber tool is used to remove any seam from the external surface.The welded part is then sent for paint. Where it is painted and sent for Fork Assembly in AF-1 Press and Weld Operations for Front Fender (Scooter)
FRAME ASSEMBLY PROBLEMS:
- Swing arm pressing.
- Handle switch fitment.
- Reducing line stoppage.
- Race cone pressing.
KAIZEN Philosophy: -
KAIstands for “change” and ZEN stands for “improvement”.
So KAIZEN means, “Continual change for improvement”. This is the activity, which is open for all the employees, and all the employees take keen interest in this activity. “The more the number of Kaizens in a department, the more is the honor for the same” makes this event very much interesting.
Why to choose the PDCA Approach…….?
1. Being a closed loop, it helps in better control of the various steps.
2. Like a closed loop system it gives feed back and thus better control of the
various activities.
3. It helps in continual improvement of the methods.
4. It helps in pin-pointing the problem.
5. Better comparison between Planned and Actual Achievements and time.
6. Makes the things simpler and easier to understand as each step is self-explanatory.
7. Better understanding of the basic procedure being followed.
8. Helps in better and positive thinking.
9. Helps in achieving the results in a more systematic manner.
10. Helps in finding the root cause of the problem.
11.Continuous monitoring approach resulting in better achievements.
12.Development of new ideas.
13.Better and safe approach towards the problem.
14.Examination of the problems and their countermeasures is more systematic.
15.It is a systematic approach towards the problem.
RESEARCH METHODOLOGY
This methodology will explain how I went about doing my project. It is divided into two sections Sampling details & Data collection + analysis. In this there will be explanation of what kind of sample data I have taken for my project and the collection of that data.
SAMPLING AND DATA COLLECTION:
For the completion of my project I went through the random sampling of data. In which I have picked up some components randomly for the observation and did the analysis as required for the project. Photographs were taken and relevant readings were recorded for documentation & project report.
Data collection includes all the relevant and appropriate data required for the completion of the project. This is of two kinds, Primary data and Secondary data. Primary data includes all the data which I have collected from the crankcase line such as component flow path, dent prone areas on the cover & joint faces, dimensions of the cone plugs and actual dents on KSPG components during the trial PP1 before the mass production of this new model. Some data was collected from the metallurgical lab after hardness inspection of cone plugs and some data was collected from engine assembly.
Apart from this I have also used some data from the department itself as a secondary data. It includes the quotations from vendors, process sheets, PQCS-I & II, plug cone drawings, operation standards, defect flow sheets etc. This collection has been shown in the annexure attached ahead.
These all were the samples that I have taken for the study to complete my project in a better way. I decided to choose this study material from our company itself because this was best and comprehensive according to the executives and the line leaders who themselves have designed it so far. So it was very easy for them to teach me about that. Also it is very clear from the fact that the current documentation is better because the production target was getting achieved very well.
1) THE PDCA APPROACH: -
Among the most widely used tools for continuous improvement is a four-step quality model-the plan-do-check-act (PDCA) cycle, also known as Deming cycle or Shewhart cycle.
Plan- Identify an opportunity and plan for change.
Do- Implement the change on a small scale.
Check- Use data to analyze the results of the change and determine whether it made a
difference.
Act-If the change was successful, implement it on a wider scale and continuously assess
your results. If the change did not work, begin the cycle again.
this approach were incorporated while implementing the countermeasures. It helped in the uninterrupted
flow of project activities. It is a result oriented methodology with side by side analysis of the result. It helps as a perfect effectiveness and improvement monitor. It provides us with appropriate ideas and concrete steps to avoid failures. It is a complete
quality analysis + control package with minimum discrepancies. That is why it is sometimes referred to as root cause of all improvements.
As a whole the PDCA methodology was of immense help during my stint of seven months as an industrial project trainee.
Atomobile Domestic Sales Trends
Automobile Domestic Sales Trends | (In Nos) | ||||
Category | 2006-07 | 2007-08 | 2008-09 | 2009-10 | 2010-11 |
Total CVs | 467,765 | 490,494 | 384,194 | 532,721 | 676,408 |
Total Passenger Vehicles | 1,379,979 | 1,549,882 | 1,552,703 | 1,951,333 | 2,520,421 |
Total Two Wheelers | 7,872,334 | 7,249,278 | 7,437,619 | 9,370,957 | 11,790,305 |
Three Wheelers | 403,910 | 364,781 | 349,727 | 440,392 | 526,022 |
Grand Total | 10,123,988 | 9,654,435 | 9,724,243 | 12,295,397 | 15,513,156 |
Two-wheeler manufacturer Honda Motorcycle & Scooter India (HMSI) reported 2.09 per cent jump in its total sales for March at 1,47,301 units compared to 1,44,288 units in the same month of the previous year.
For the entire 2010-11 fiscal, the company's total sales increased by 30.31 per cent to 16,56,727 units from 12,71,377 units in the previous fiscal, HMSI said in a statement.
During March, motorcycle sales inched marginally to 65,899 units as against 65,888 units in March 2010, it added.
The company reported an increase of 3.83 per cent in scooter sales to 81,402 units last month from 78,400 units a year ago during the same month.
During 2010-11, the company's motorcycles sales rose by 44.06 per cent to 7,48,895 units from 5,19,832 units in the previous fiscal.
Scooters sales in the last fiscal stood at 9,07,832 units as against 7,51,545 units in 2009-10, up 20.80 per cent.
MARKET DETAILS OF AUTOMOBILE INDUSTRY:-
Automobile Industry is one of the few industries which have shown a continuous rapid growth since the industrial revolution in early 20th century. Also it has grown within itself, with the no. of manufacturing companies and types of vehicles increasing every year. Indian automobile industry is no exception with most of the major companies of the world investing in INDIA
The globalization of the Indian automobile industry continues, and their collaboration with foreign companies is flourishing. Gradual changes in the Indian economy and rising disposable income of the people is resulting in increased motorization. Global connections are seen as an effective way to respond to this trend, and will continue to multiply as the world’s automobile industries try to meet the increasing demands in a growing number of markets.
The main reasons for this exponential growth and revolution in Indian automobile industry (especially two-wheelers) are:-
- Government’s initiative on rural roads and better connectivity with major towns and cities.
- Improved agricultural performance.
- Upward trend of purchasing power in the hands of rural people.
- Better understanding between the world economies resulting in free and easy trade.
- Increasing trend of cooperation between world class companies in the field of automobile industry with an approach to reduce the costing.
HONDA PHILOSOPHY
· 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, present and future.
· It challenges the organization to strive for the realization of its vision
· It helps our organization to maintain its sense of uniqueness
HONDA PLANT FACILITIES :-
Few of the In-House Facilities
High Pressure Die Casting, Gravity Die Casting & Low Pressure Die Casting
Gravity Die-Casting & Low pressure Die Casting Sections are for manufacturing critical engine parts.
Welding Robots
Weld Shop has spot welding, seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels.
Paint Shop Robots
Paint Shop has a conveyor system, which is unique amongst all Honda Factories in the world. The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion, high gloss and superior paint finish. Robots are used in painting for improved paint finish.
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust. Each of the engines is then inspected for various parameters.
Honda Unicorn:-
After having conquered the racing circuits with its unparalleled technology, Honda presents the Unicorn. The Honda Unicorn is the First Motorcycle of HMSI. It is a tough & stylish 4-stroke 5 geared motorcycle incorporating the best of Honda’s worldwide technology standards.
· First Bike with Mono Suspension
· Sporty Design & Macho Looks
· 4-stroke 150 cc engine
· Best fuel efficiency in its class (60 km/l)
· Riding comfort even during multiple ride
| | PARTICULAR | DETAILS |
| ENGINE | Type | 4-Stroke,Single Cyl., Air Cooled, |
| Displacement | 149.1 CC | |
| Max Power | 13.3 bhp @ 8000 rpm | |
| Max torque | 12.8Nm @ 5500 rpm | |
| Transmission | 5 Speed Constant Mesh | |
| Ignition | Digital (Multi Mapping) | |
| FEATURES | Suspension | Mono Suspension |
| Safety | Multi reflector Head Lamp | |
| Gear Mechanism | 1 Down – 4 Up | |
| Brakes | Front – Disc Rear – Drum | |
| BODY | Body | Steel |
Honda Dio :-
Honda Dio was launched in September, 2002. Dio is
| PARTICULAR | DETAILS | |
| ENGINE | Type | 4-Stroke,Single Cyl., Air Cooled, |
| Displacement | 102 CC | |
| Max Power | 7 bhp @ 7000 rpm | |
| Max torque | 0.8 Kg-m @ 5500 rpm | |
| Transmission | V-Matic | |
| Ignition | Self & Kick | |
| FEATURES | Technology | Tuff up Tube |
| Safety | Multi reflector Head Lamp | |
| Easy Maintenance | Clic Mechanism | |
| Others | Under Seat Box | |
| BODY | Body | Plastic |
