In Guidance Of:
Subm Submiitted By:
Mr. vimal Raina Raina
SUDH SUDHIIR JAIN JAIN
Depart Department ment Head Head
1571483608
Manufact Manufacturi uring ng
Mechanical Mechanical and Aut Automati omation on Engineer Engineering ing
ACKNOWLEDGEMENT
I take take imme immense nse pleasure in expressing our heartfel heartfeltt indebtedness indebtedness to the manage manageme ment nt of Yamaha India Yamaha India for giving me kind permission for doing my summer internship at their Surajpur plant. I am equally indebted to my project guide, Mr. Bijender Kaushik to whom I accord our sincere gratitude and profound thankfulness for his perpetual guidance, insightful opinion, and constructive criticism to encourse our fervent endeavor. I also wish to extend my my profound gratefulness to all the working staf stafff and operat operator or of the plant for their invaluable support, thoughtful vision and productive suggestion. Last but not the least, we are forever, indebted to the omnipotent and to our parents, for their cheerful encouragement, unfailing patience and consistence support, without which, we would have been lost in the dark. Thank you all.
Summer Project Certificate
This is to certify that Mr. SUDHIR JAIN JAIN has successful completed summer internship for a period of 45 days starting from 1st of june to 15th of july at INDIA YA YAMAHA MO MOTOR PVT. LTD. in partial partial fulfi fulfillmen llmentt of the requireme requirement nt for his his B.Tech B.Tech Degree. This is his original work to the best of my knowledge.
(PROJECT GUIDE) Date: - __________
METHODOLOGY
This canbe termed as method used to undergo at a parti particular proj project. This was not as research project that that canbecompleted tedbyusingthemetho ethodof questionnaires. t is an experience experience based project and here methodology regarding thi this proj project can betermed asthetrai training undergone in Indi India Yamaha Motor Pvt. Ltd. Ltd. I tr tried to contact every employee from top top to bottom ttom level management, who helped elped me lot. And the knowledge given there, there, regardi regarding ng export procedure and documentati entationwhichwasonly nlypossiblebyundergoingtrai training. Although true pictureof the export procedure, documentation and marketing in foreign country can be only obtai tained by visitinga parti articular ular relevant country. But as thi this was not possible best effort effort have been madeto collect all all relevant informati formation on within constraints.
The methodology of data collection is based on primary as well as secondary data.
Primary Primary Data: Personal interaction with Internship Site Supervisor. Discussion with other officials.
Secondary Secondary Data: Company’s Website, Company’s Magazines, Past year data and other available records & reports.
COMPANY PROFILE
HISTORY : "If you're going to do something, be the best." "If you are going to make it, make it the very best there is."
Genichi Kawakami fourth-generation President in 1950 at the young age of 38. With these words as their motto, the development team poured all their energies into building the first prototype, and ten months later in August of 1954 the first model was complete. It was the Yam Yamaha aha YA-1. YA-1. The bike was powered powered by an air air-cooled, 2-stroke, 2-stroke, single cylinder 125cc engine. Once finished, it was put through an unprecedented 10,000 km endurance test to ensure that its quality was top-class. This was destined to be the first crystallization of what has now become a long tradition of Yamaha creativity and an inexhaustible spirit of challenge. Yamaha Motor Co. Ltd. was founded on July 1, 1955. Staffed by 274 enthusiastic employees, the new motorcycle manufacturer built about 200 units per month. By 1956, a second model was ready for production. This was the YC1, a 175cc single cylinder two-stroke. In 1957 Yamaha began production of its first 250cc, two-stroke twin, the YD1. Then in 1960, Yamaha International Corporation began selling motorcycles in the USA through dealers. dealers. The first irst watercraf watercraftt model was was the CAT-21, CAT-21, followed followed by the RU RUN13 and the P-7 123cc outboard motor. Yamaha DT-1. The world's first true off-road motorcycle debuted in 1968. Genichi Kawakami set the stage for Yamaha Motor Company's success with his vision and philosophies. Total honesty towards the customer and making products that hold their own enables the company that serves people in thirty-three countries, to provide an improved lifestyle through exceptional quality, high performance products.
Major Products And Services Manufacture and sales of motorcycles, scooters, electro-hybrid bicycles, boats, sail boats, Water Vehicles, pools, utility boats, fishing boats, outboard motors, diesel engines, 4-wheel ATVs, side-by-side vehicles, racing karts, golf cars, multi-purpose engines, generators, water pumps, snowmobiles, small-sized snow throwers, automotive engines, intelligent machinery, industrial-use remote control helicopters, electrical power units for wheelchairs, helmets. Biotechnological production, processing and sales of agricult agricultural ural and mari marine ne product products s and microorganisms. Imp Import ort and sales of various types of products, development of tourist businesses and management of leisure, recreational facilities and related services.
It started its manufacturing in India with local partner Escorts in 1996. It acquired 100% ownership in 2001. YAMAHA is currently operating in Indian market with various models viz. CRUX (100cc), ALBA (106cc) and GLADIATOR (125cc).YAMAHA have launched YRF R-15, 150 cc, 6-speed bike in Indian market recently. Now it has two manufact manufacturi uring ng unit units s at Faridabad in Hary Haryana ana and and Surajpur in Ut Uttar Pradesh. The Surajpur plant has two main assembly lines having a capacity of producing maximum of 677 bikes per 8 hour shift. Since last few years years YAMA YAMAHA HA is not doing well in India, India, so YAMA YAMAHA HA MOTO MOTOR R CO. CO., LTD. came with 70-30 partnership with MITSUI & CO., LTD. and it became INDIA YAMAHA MOTOR PRIVATE LIMITED from 17 October, 2007. After this agreement Yamaha aims at increasing its target sales from 120,000 units (2007) to 650,000 units (2010). The YAMAHA plant is ISO 9001, 14001 and 18001 certified. The first certification is for quality management where as the second and third one are for environmental and safety standards and health respectively.
CORPORATE PHILOSOPHY For society, for the world … Yamaha amaha works to t o realize\ our corporate cor porate mission missi on of creating Kando…
Yamaha Motor is a company that has worked ever since its founding to build products defined by the concepts of “high-quality “high-quality and high-performance” high-performance” and “light weight and compactness” as we we have have continued to develop new technologies in the areas of small engine technology and FRP processing technology as well as control and component technologies.It can also be said that our corporate history has taken a path where “people” are the fundamental fundamental element and our product creation and other corporate activities have always been aimed at touching people’s hearts. Our goal has always has always been to provide products that empower each and every customer and make their lives more fulfilling by offering greater speed, greater mobility and Greater potential. Said in another way, our aim is to bring people greater joy, happiness and create Kando* in their lives. As a company that makes the world its field and offers products for the land, the water, the snowfields and the sky, Yamaha Motor strives to be a company that “offers new excitement and a more fulfilling life for people all over the world” and to use our ingenuity and passion to realize peoples’ dreams and always be the ones they look to for “the next Kando.” Kando.”
YA YAMAHA AND MITSUI ENTER INT INTO A JOINT VENTURE IN INDIA Yamaha Motor Co., Ltd. (Headquarters: Shingai, Iwata, Shizuoka Pref.; President: Takashi Kajikawa) (hereafter YMC) and Mitsui & Co., Ltd. (Headquarters: Otemachi, Chiyoda-ku, Tokyo; President: Shoei Utsuda) (hereafter Mitsui) announced the agreement that Mitsui will become a joint investor in the new motorcycle manufacturing company company India Yama Yamaha ha Motor Motor Private Private Limited (I (IYM) YM) established established by YMC YMC in October 17, 2007.YMC and Mitsui have reviewed the possibilities for Mitsui's participation in various areas of YMC's business activities with the aim of strengthening its overseas business and cooperative ventures in other areas of business. The decision announced today is a result of these these review reviews s and repeated repeated discussions discussions with with a focus on a "comprehensive "comprehensive joint business venture in India." YMC started manufacturing of motorcycles in India by establishing a joint venture company with local partner Escorts in 1996. In 2001, YMI became a 100% owned subsidiary of YMC. Then in 2005, a separate sales company, India Yamaha Motors Private Limited, was established, after which the Yamaha motorcycle business in India was conducted by two companies specializing in manufacturing and marketing respectively.With the stable growth of the Indian economy as a whole, the Indian motorcycle market has grown to 7.3 million units in 2007, making it the world's second largest market in terms of demand. The aims for the future are for YMC to aggressively introduce new high value-added models and promote a sales network strategy that includes expanding the establishments of directly-run showroom/dealerships and for Mitsui to use its strengths in logistics and dealer network development to achieve a synergistic effect that will stimulate a growth in sales of Yamaha motorcycles from 120,000 units (domestic only exclusive of exports: 60,000 units) annually in 2007 to 650,000 units (domestic only exclusive of exports: 90,000 units) annually in 2010 while improving the brand's presence in the fiercely competitive Indian Economy.
1.4 INDIA INDIA YAM YAMAHA MOTOR PVT. LTD. (IYM) (IYM) Head Office: Office:
A-3 Suraj Surajpur pur Industrial ndustrial Area, Noida-Dadri Road, Surajpur - 201306, Distt. Gautam Budh Nagar, U.P., India
Foundati Foundation: on:
Oct. 17, 2007
Start of operat operation: ion:
April 1, 2008, 2008,
Headed eaded by:
Mr. Tsutomu Mabuchi, Mabuchi, Managing Director and Chief Executive Officer
Capital:
1.5 billion rupee (as of Mar. 5, 2008), 2008), with ith plans to event eventually
increase capital to 5.6 billion rupee (approx. 16 billion yen) Capital apital ratio: ratio:
70% by Yamaha Yamaha Mot Motor Co., Ltd. 30% by Mitsui & Co., Ltd.
Number umber of employees: employees: 2000 (approx.) (approx.) Are Area as of bu business:
Development, manufac facture ture and sales of mo motorc torcy ycles, sp spare parts & accessories. Export of locally assembled motorcycles and parts.
Scale of operations: operations:
First year year (nine (nine mon months beginning Apr. Apr. 2008) 2008) projected projected sales of 10 billion rupee (approx. 30 billion yen)
INDI INDIA A YAMAHA YAMAHA MOTOR MOTOR INAUGUR INAUGURATED ATED NEW PLANT PLANT AT SURAJPUR The new Surajpur plant has been inaugurated by Mr. T.Kazikawa C.E.O & MD Yamaha Global on 6th July 2009, which has capacity to produce 6 lakh motorcycles annually including Fazer followed by FZ-16, FZ-S, YZF-R15 and other models. The plant capacity can be augmented up to 1 million units. This fully integrated assembly plant plant is built on the lines of Yamaha’s globally tried, tested and successfully implemented standards and meets the global quality benchmarks. At the core are the 5-S and TPM activities that fuel its Manufacturing Processes. The plant has 3 vehicle assembly lines and 4 engine assembly lines including one dedicated for export engines. The engine and vehicle assembly lines are synchronized and incorporate concepts of Unit Assurance i.e. Complete Product As Assuran rance, Pa Parts rts As Assuran rance th throu rough 10 100% kit sup supply on on lilines and sy synchron ronizatio tion of of parts storage, supply and production. The innovative production processes along with high tech final assurance processes are aimed to achieve Zero Claims at our dealers and thus, a highly satisfied customer base.
1.2 INDUSTRY PROFILE The two-wheeler industry in India has been in existence since 1955. It consists of three segments scooters, motorcycles and mopeds. These are very popular as a mode of transport due to their fuel efficiency and ease of use in congested traffic. The number of two wheelers sold is several times that of cars. According to a recent survey by SIAM (Society of Indian Automobile Manufacturers) the no. of two wheelers sold in the fiscal year ended in march,2008 is 7.25 million units as compared to 1.5 million units of corresponding 4 wheelers ( passenger cars, SUVs etc.). The two-wheeler market in India is the biggest contributor to the automobile industry
with a size of Rs.100000 million. Foreign collaborations have been playing a major role in the growth of the Indian two-wheeler market, and most of them are Japanese firms. Au Auto segment in in Ind India is widely leade aded by two two wheeler manufac facture turerr as we can see seen in the graph. So there is a lot of opportunity for two wheeler manufacturers. 3.9
4.03
13.44
Pessanger essanger Vehicle Commercial Vehicle
Three Wheeler Two Wheeler Wheeler
78.6
AUTO SEGMENT IN INDIA The total two-wheeler sales of the Indian industry accounted for around 77.5% of the total vehicles sold in the period mentioned. Among the 3 segments of the Indian two wheeler market, major growth trends have been seen in the motorcycle segment over the last four to five years. One good reason for such increase in demand for motorcycles is due to its resistance and balance even on bad road conditions. Most of the rural areas in India do not have decent roads and hence the need for good, shockresistant, and steady two-wheelers such as motorcycles had been felt. However, the two-wheeler market in India is a fast growing market due to its technological advancements in product manufacturing and emphasis on design innovation.
The major two wheeler manufacturing companies in India are Hero Honda, Bajaj, TVS motors, YAMAHA, Honda etc. Recently Yamaha comes in list after Hero Honda, Bajaj and TVS Motors as per current yearly sales.
Segmen egmental tal Growth of the Indian Indian Two Wheele Wheelerr Indust Industry ry (FY2000-2004) 50 40 30 20
MOTORCYCLE SCOOTER MOPEDS
10 0 F Y2000
F Y2001
F Y2002
F Y2003
F Y2004
-10 -20
The two-wheeler sales declined marginally in FY2001. This was followed by a revival in sales growth for the industry in FY2002. Although, the overall two-wheeler sales increased in FY2002, the scooter and moped segments faced de-growth. FY2003 also witnessed a healthy growth in overall two-wheeler sales led by higher growth in motorcycles even as the sales of scooters and mopeds continued to decline. Healthy growth in two-wheeler sales during FY2004 was led by growth in motorcycles even as the scooters segment posted healthy growth while the mopeds continued to decline. Figure 1 presents the variations across various product sub-segments of the twowheeler industry between FY1995 and FY2004. The major two wheeler manufacturing companies companies in India India are are Hero Hero Honda, onda, Bajaj, TVS mot motors, YAMA YAMAH HA, Honda Honda etc. etc. Recently Yama Yamaha ha comes comes in list list aft after Hero Hero Honda, Bajaj and TVS Mot Motors as per current current yearly yearly sales. In two-wheelers, two-wheelers, hero Honda Motors Ltd., India’s largest bike seller, managed to sustain sales, while rivals Bajaj Auto Ltd. and TVS Motor Co. Ltd. saw double-digit declines in fiscal 2008. Hero Honda sold more than 3.24 million vehicles in the year. Its sales in March were up 15% to 308,052 units.
In two-wheelers, two-wheelers, hero Honda Motors Ltd., India’s largest bike seller, managed to sustain sales, while rivals Bajaj Auto Ltd. and TVS Motor Co. Ltd. saw double-digit declines in fiscal 2008. Hero Honda sold more than 3.24 million vehicles in the year. Its sales in March were up 15% to 308,052 units. Meanwhile, Bajaj Auto’s sales in the year dropped 20% after it sold about 1.68 million 1.68 million units. Its sales in March, too, were dismal at 114,436 units, down 20% over the same month last year. Sales at TVS Motor during the year slid 19% to 1.15 million units, while its March sales stood at 103,975 units, a decline over the same month a year ago.
Al Almost al all the the two two-wh -wheelers lers companies excep cept YA YAMAHA Motors tors have launched scooter ter version in India. Although currently Bajaj Auto is not manufacturing any scooters previously Bajaj was market leader of two wheelers in India due to varieties of scooter models. Recently Recently Hero Honda Honda is producing producing a scooter scooter model PLEASUR PLEASURE, E, TVS Motors Motors is producing SCOOTY, HMSI is manufacturing various scooters like ACTIVA, ETERNO etc. But YAMAHA has limited itself to bike manufacturing only.
3.8
5.8
8.5
Hero Honda
39.8
Bajaj TVS
17.7
Honda YAMAHA
24.4
Others
% OF MARK MARKET ET SHARE IN IN TWO WHEELE WHEELE IND INDUSTERY USTERY 2006 2006
MANUFACTURING PROCESS IYM's manufacturing facilities comprises of 2 state-of-the-art Plants at - Faridabad (Haryana) and Surajpur (Uttar Pradesh). Currently 10 models roll out of the two Yamaha Plants. The infrastructure at both the plants supports production of motorcycles and its parts for the domestic as well as oversees market. At the core are the 5-S and TPM activities that fuel fuel our agile Manufacturi Manufacturing ng Processes. rocesses. It It has In-house In-house facilit facility y for Machin Machining, ing, Welding processes as well as finishing processes of Electroplating and Painting till the assembly line..The stringent Quality Assurance norms ensure that our motorcycles meet the reputed International standards of excellence in every sphere. As As an En Environ ronmental tally sensitiv tive org organizati zatio on we we ha have the the con concept of "Environ ronmentfriendly technology" ingrained in our Corporate Philosophy. The Company boasts of effluent Treatment plant, Rain water - Harvesting mechanism, a motivated forestation drive. The IS0-14001 certification is on the anvil - early next year. All our endeavors give us reason to believe that sustainable development for Yamaha will not remain merely an idea in pipeline.It believes in taking care of not only our Motoring Needs but also the needs of Future Generations to come. The various types of shops used in IYM are given below: 1. Welding Shop Shop 2. Pressing Shop Shop 3. Electro lectro Plating lating Shop Shop 4. Steel Painti Painting ng Shop 5. Plastic lastic Painti Painting ng Shop 6. Engine Engine Assembly Assembly 7. Body Body Assembly Assembly
Flow Chart of the fulfillment of the component requirement:
B.O.P
Vendor
Forming/Generating Process
Transported to company
Inspected
Arr Arra anged
Supplied to the worker
FRAME LINE PROCESS
Frame Line: Frame is also main part of any vehicle, which supports the other accessories over it such is fuel tank, seat, mudguards, engine, muffler and etc. Frame is made of steel pipe or rods. Steel pipe/rods are used in manufacturing of frame as a row material. It is manufactured in the frame line. The manufacturing of frame in INDIA YAMAHA MOTOR PVT. LTD. is done in two welding lines; one is the manual welding in which all welding tasks performed by the workers and other is the robotic welding in which all wending tasks performed by robotic welding machine. The robotic welding line takes 3 - 4 minutes in the completion of manufacturing of a frame while the manual welding line takes 2 - 3 minutes in the completion of a frame. Frame Welding: MIG (Manual) Robot Arc Welding. Frame consists of some parts, those are known as the particular names are given below; a. Head pipe b. Main Main pipe c. Down own tube d. Seat rail
e. Engine Engine bracket f. Stopper g. Cross tube The manufacturing processes of frame of a motorcycle are given below: Head Pipe & Main Pipe - MIG Welding Main Pipe Sub Main pipe & Engine Brkt. - MIG Welding Down Tube Sub Welding Down Tube & Head Pipe - Welding Front Frame Component 1 Front Frame Component 2 Main Pipe Sub & Seat Rail Sub - Welding Seat Rail Sub & Brkt. Stop Switch - Welding Seat Rail Sub & Brkt. Helmet Hanger - Welding Inspection Al Alignment Fine Boring of Welded Frame Starting with the three initial stages as manual welding stages where the work is done on the dandum and the main main pipe, diff different brackets are are welded welded manua manualllly. y. Set Setup: 15sec.
Welding: 45sec
The second stage involves the welding for Ignition Coil fitment and the fuel tank brackets: Set Setup: 10sec
Welding: 45sec
The back seat: Set Setup: 15sec
Welding: 30sec
Head pipe & Main Pipe - MIG Welding: In this this process process head head pipe is welded w witith h the the main main pipe by MI MIG welding machine. machine. Machine used
:
400 AMPS AMPS MIG weldi welding ng set
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
4.1. 4.1.2 2 Main Pipe Sub: Sub: In this process some parts such is cross pin for tube bracket, pad for the main pipe, side plate for muffler, plate for clamp, cover plate for clamp and clamper are jointed or welded with the main pipe by the MIG welding machine. Machine used
:
400 AMPS AMPS MIG welding set
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
4.1. 4.1.3 3 Main pi pipe & Engi Engine Brkt. - MI MIG Wel Welding: In this process the engine bracket is welded to the main pipe. It is performed on the MIG welding machine. Machine used
:
400 AMPS AMPS MIG welding set
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
4.1. 4.1.4 4 Down Down Tube Sub Sub Welding: elding: In this process the sub welding is being done over the down tube by sub welding set. Cross tube tube 1, 1, bracket FR upper 1 & 2, bracket bracket FR under under 1 & 2, cross cross tube tube 2 and wir wire e holder L/R are the parts that are welded to the down tube in this process. Machine used
:
400
AMPS AMPS
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
MIG welding set
4.1. 4.1.5 5 Down Down Tube & Head Pipe - Wel Weldi ding: ng: In this process the head pipe and down tube are welded together by MIG welding machine Machine used
:
400 AMPS AMPS MIG weldi welding ng set
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
Gas Gas flow flow
:
12 - 15 Ltr/min.
4.1. 4.1.6 6 Front Frame Com Component ponent 1: In this process the front components is welded to the frame which consists main pipe sub 3 and down tube sub 2; these components are also welded by MIG welding machine. Machine used
:
400 AMPS AMPS MIG weldi welding ng set
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
Gas Gas flow flow
:
12 - 15 Ltr/min.
4.1. 4.1.7 7 Front Frame Com Component ponent 2: In this process the front components is welded to the frame which consists gusset head pipe1 and gusset head pipe 2; these components are also welded by MIG welding machine. Machine used
:
400 AMPS AMPS MIG weldi welding ng set
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
4.2. 4.2.8 8 Main Pi Pipe Sub & Seat Rai Raill Sub Sub - Wel Welding: In this process seat rail sub and back stay sub left and right are welded to the main pipe sub by the welding machine. Machine used
:
400 AMPS AMPS MIG weldi welding ng set
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
4.2. 4.2.9 9 Seat Rail Sub & Brkt. Stop Swit Switch ch – Welding: Afte Afterr the the welding of se seat ra rail sub to the the main pipe, the the stop top brea reaking brac racket is is welded to the seat rail sub. Machine used
:
400 AMPS AMPS MIG weldi welding ng set
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
Gas Gas flow flow
:
12 - 15 Ltr/min.
4.1. 4.1.10 10 Seat Rai Raill Sub & Brkt. Helm Helmet Hanger Hanger - Wel Welding: Afte Afterr the the we welding ing of of seat rai rail sub sub an and the the sto stop p bre brea akin king bra brac cket, the the he helmet hanger bracket is welded to the seat rail sub. Machine used
:
400 AMPS AMPS MIG weldi welding ng set
Wire ire diamet diameter
:
1.2 mm
Volt Voltage age
:
18 - 20 V
Current urrent
:
150 - 180 A
Gas Gas flow flow
:
12 - 15 Ltr/min.
4.1.11 Inspection: Afte Afterr the the completio tion of al all welding proc rocesses, th the inspectio tion proc rocess is being done. Th The inspection is performed to check any defect in the frame. The worker should have to check the frame by as per given standard specifications.
4.1.12 Alignment: Afte Afterr the the completio tion of in inspection tion proc rocess, th the alignment of of th the fra frame is being che check. It It should be proper alignment of frame.
4.1.13 Fine Boring of Welded Frame: In the last step of manufacturing the frame, a fine boring is done welded frame. To perform this process WIDIA 2 spindle fine boring machine is used. Machine Machine used
:
WIDIA 2 spindle fine boring Machine Machine
Pressure
:
10 - 12 Kg/ Kg/cm2
System pressure pressure
:
25 - 30 Kg/ Kg/cm2
Slide pressure pressure LH/ LH/RH
:
5 Kg/ Kg/cm2
Some Welding Defects: Weld Hole (Burn)
Porosity Incomplete Welding Non-uniform Welding Spatter
Some Error Incurred During the observation: Jig Error – Error – No No Servo (Feedback) Mechanism Robot Problems 1. Bush Bush Broken – Broken – 100’ 2. Teaching – Teaching – 60’ 3. Pin Destroyed/Cha estroyed/Changed nged – (30 – (30-90)’ 90)’ Torch problem. WRC - Wire Change Man Power Less Power Out. Component Not Available: 1. Bracket Tank Tank Fitting Fitting – – 75’ 2. Main Main Pipe – Pipe – 15’ 3. Bracket Side Stand
FUEL TANK LINE
PROCESS: BLANKING MACHINE: MECH PRESS M/C
OPERATION OPERATION & REMARK REMARK 1) Set the slide adjuster to the Die height limit pad. 2) Roll the sheet on slide rollers & butt against the locators. 3) Press the double hand switch by both hands. 4) Check scrap going down smoothly. 5) Take the blank out. NOTE-1) Apply oil to the guide post every 50 shots. 2) Apply oil to the cutting edges at start of shift & every 50 shot 3) Wipe off the Die after 100 shots. ACCESSORIES: 1) Leather gloves 2) Apron 3) Old dhoti
PROCESS: PROCESS: DRAW DRAWIING M/C NAME: Hyd. press m/c
OPERATION OPERATION & REMARKS REMARKS 1) Blank sheet shall be cleaned .No dust & burr (max 0.5) allowed on the sheet. 2) Set the blank sheet on the blank holder according pins. 3) Push the operating switch. 4) After pressing appearance shall be checked by visually. 5) Stanch properly after Draw operation to avoid dents (soft pressure). NOTE: 1) Apply oil to the guidepost every 50 shots. 2) Adjust D/Cushion pressure based on lot material properties. 3) Die polishing after 50 shots. ACCESSORIES :Oil stone (5 PC’s)
.Magnet agnet floater
Cotton otton gloves
.Old dhoti
.Emery Emery paper#400
.Apron Apron
.Emery .Emery paper#60 paper#600 0
.Lubri Lubrication cation oil
DIE/JIG/TOOL: . Drawing mould xxxxxxxxx . Point micrometer.
MUFFLER LINE FLOW CHART CHART STEP 1 TAKE A MS SHEET/BODY 1-1 COMING FROM PRESS SHOP
STEP 2 FOLD IT IT IN IN THE FORM FORM OF CONE CONE OR CYLIND CYLINDER ER AS REQUI REQUIRED OF MODEL/ROLLING OF BODY 1-1.
STEP 3 JOIN ITS ENDS BY TIG ARC WELDING/TIG WELDING OF BODY 1-1
STEP 4 TAB CUTTING OF BIG END &SMALL END OF BODY1-1
STEP 5: Forming of Big End & Small End Of Body 1-1
STEP 6 Tack Welding of Body1-1 + Partition 1-1
STEP 7 Circular Welding of Body 1-1 Sub + Body Pipe Sub
STEP 8 Press Fitting & Tack Welding of body1-5 Sub & Body Sub
STEP 9 Body 1-2 Sub + Body 1-3 Sub Circular Welding
STEP10 Muffler Sub + Brkt 2-1 + Stopper -1 MIG Welding
STEP 11 Body 1-1 Sub + Body 1-2 Sub Circular Welding
STEP12 Muffler Sub + Nut Welding
STEP13 Leakage testing & Repair
STEP 14 Chipping & Finishing
STEP14 Trolley Loaded For Buffing & Plating
STEP 15 FINALLY CHECKED BY Q.E
PAINT SHOP Paint shop procedures are: STEP 1: The parts are fed to the paint shop in a hanging line. STEP 2: Those parts initially pass through a closed chamber where they are treated with special type of liquid at 60 degree centigrade temperature to wash dusts and other particles from the body surface. surface. This is is known as as PRETR PRETREA EATM TMENT ENT.. STEP 3: Subsequently a person checks these parts whether all the dusts are removed or not. Then the body is dried by hot air in a chamber, which is maintained at 75 degree centigrade. STEP 4: Next to this, first coat of paint is done manually using paint spray. STEP 5: Afte Afterr 5-10 -10 minutes tes the the second coat is is applied to the the body. Fi Finally one more coat is applied for finishing touch. The complete paint spray is done manually. STEP 6: These painted parts are moved through a heat chamber (maintained at 75 degree centigrade) for the paint to be settled and dried fully. STEP 7: This complete cycle takes around 3 hours. In this process paint utilization is only 40% and almost 60% of paint goes waste. The painted parts are checked for defects and the data analysis shows
Stage wise dust analysis o
Checking of visual sources of dust dust
o
Collecti ollection on of dust samples samples
o
Analyzi Analyzing ng type of dust dust by microscope
Dust analysis by microscope o
Magnificat Magnification ion of dust dust analysis analysis
o
Magnificat Magnification ion of rust analysis analysis
o
Magnificat Magnification ion of t/c t/c over spray spray
o
Magnificat Magnification ion of b/ b/c over spray
Type of dust
Source Source of dust o
B/C booth booth str.
o
B/C booth booth ceiling filter ilter
o
Hangers & hanger hanger trolley rolley
o
T/C boot booth str.
o
T/C booth entry entry wall
o
T/C booth exhaust system
o
Passage Passage aft after washing
Afte Afterr checking if the there is minute dust pa partic ticles in the the painted ted body parts rts tho those dusts are removed by a process called as BUFFING. In this process a chemical is applied to the affected part and the dust is sucked by application of air. After buffing parts are sent to GRAPHICS shop for pasting stickers if necessary. But if there are large particles existing in the body part then those parts are again sent for reworking in the same shop. Above procedure are followed for plastic parts but there are another electric paint shop for MS parts which is automated.
ELECTROPLATING SHOP It is a technique of painting in which we didn’t directly apply the paint on the body parts but we sealed it with some rusting free metals or alloy like chromium or zinc. And give it good appearance. All process is done on dc supply. STEP 1: SHOK CLEANING: In this step we do soak cleaning in which we deep the w/p into the solution of sodium hydroxide & hot water, so that the grease or other oil material gets cleaned. STEP 2: WATER WASH: Water wash in this process we wash the w/p twice in the hot water for better cleaning purpose. STEP 3: AN ANODE CLEANING ING: It is a process of electro plating in which w/p is made as cathode and m/s plate is as anode &when the current pass through it. Then deposition of metal from w/p to the m/s sheet takes place so we say that it is ultra cleaning process.
STEP 4: WATER WASH: STEP 5 AN ANODE CLEANING ING STEP 6 WATER WASH (TWICE):
STEP 7 NEUTRALIZATION PROCESS In this process we deep the w/p into a get a neutral w/p.solution of sulphuric acid to neutralized the effect of base. After this we STEP 8: NICKEL DEPOSITION (SEMI BRIGHT PROCESS): In this process we mix distilled water, nickel sulphate , nickel chloride & boric acid in proportional amount. It is also an eloctroplating process in which deposition of nickel on the w/p takes place. To remove the impurities present in the nickel powder we place it in bags (cotton).
STEP 9: CHROME COATING (FULL BRIGHT) High density golden color liquid gets stick on it .After washing it again & again it comes to its original color. STEP 10: AIR AIR BLOWION IONG: Finally we dry it with blowing hot air through it & when it become dry then we send it to assembly shop. CAUSE OF DEFECT 1. Dust in w/p 2. Rust in w/p 3. Grease Grease or other impurit impurities ies 4. Improper Improper handling handling
ENGINE ASSEMBLY DEFNITION:Engine is a combination of different links that convert chemical energy into mechanical energy. Due to which we get desired output by specified input. It is generally of two types Internal combustion engine External combustion engine
TO STUDY OF VARIOUS SUB-ASSEMBLY STAGE 1.Axle Drive rive Assy.
2.Axle Main Main Assy.
WASHER CIRCLE
1 GEAR
2 GEAR
1 Crank assembly assembly
4.Balancer 4.Balancer Assy. Assy. CRANK
5.Co 5.Cover ver Crank CaseCase-3 3 Assy. Assy.
7.Ca 7.Cam m Shaft Assy. Assy.
9.AIS Pipe Fitting Assy.
6.Piston 6.Piston Ring Assy. Assy.
8.Hea 8.Head d Cyl Cylinder
10.Cover CC1 CC1 Assy. Assy.
11.stat 11.stator or assy.
13.Kick shaft Assy.
SPRING
kaasai KICKSHAFT
KICK GEAR
WASHER
CLIP
16.Rotor Assy.
ENGINE ASSEMBLY ASSEMBLY FLOW ON MAI MAIN LINE LINE STEP 1: Place the bearings in the cc-1 & cc-2 (axel drive bearing, axel main bearing, balancer bearing, crank shaft bearing).
STEP 2: Code punching: In this stage a 14 digit number is punched on the engine.
STEP 3: Ap Apply the the cran rank shaft, ft, ax axel main, axel driv rive& balancer into it.
STEP 4: Then we place other parts like gears, fuel oil pump& ffinally we closed it by placing adeshive& gasket between them.
STEP 4: Then we place the piston with cylinder head, air cooler (fins) & finally close it with cc covers.
STEP 6: We fill it with oil and send for engine tsting where its performance is chacked.
Toke
Oil
The summa summary ry of the whole whole process is is given given below Balancer Ba lancer
Balancer Ba lancer pin
Crankag rankage e1
Crankage Cran kage 2
Number Punching
Oil pump
Bond m/c
Gear attached
Conveyor belt start
Bearing press
Kick Shaft
Clutch assembly
Cover 2 attached
Self star motor
Body cylinder piston
Cylinder head
Spark Sp ark plug
Timing gear
Rotor
Oiling
Ap A ppearanc nce e check
Oil enters
L:ine code
Body Assembly Body Assembly is the process of assembling the actual motorcycle while receiving different parts from different shops or vendors. An assembly line is a manufacturing process in which parts (usually interchangeable parts) parts) are added to a product in a sequential manner using optimally planned logistics to create a finished product much faster than with handcrafti handcrafting-type ng-type methods
In IYM there three assembly lines present, each is assigned what to produce by the production planning and control department.
The procedure followed in assembling a motorcycle is given below.
Pressing of ball
Rear fender
Number punching
Tail light
Breakshoe
Chains, shockers
Main frame,footrest
TFF,mudguard
Engine
Rear tyre
Horn,stick
meter
Battery Batt ery box
Chain cover
Brakes on tyr tyre e
bracket
Tailcover
Headlight
Brake,clutch lever
Fuel tank
Inspection
Battery
seat
4 M ANALYSIS FOUR M’S STANDS FOR MEN MACHINE METHOD MATERIAL
The basic characteristics of four M are for optimum production.
Men: The The men force should be trained well. The men should have right attitude for work. The appropriate part of total work force should be multi skilled.
Machine The proper machine and tool kit should be allocated at workplace. Stand by machines and tool kit option should be there in case of critical parts. Periodical review of of machines machines and tool kit by experts. experts.
Method Method should be well explained to the responsible worker. Improve that method which doesn’t fulfill the requirement of production. Method should be time saving, space saving, cost saving.
Material Material should be the as per standard given by company. Timely availability of material by vendor. Vender should be responsible for all incurred cost of company, in case of any material defect.
CONCLUSION The The summ summer trai training ning at the Yamaha Yamaha india motors otors ltd. ltd. Surajpur was was a learning curve and a joyous experience in my engineering studies. It was a pool of knowledge and I sincerely hope that it will be useful in my career besides learning the technical aspects I also learned the methodology of working of such a reputed and productive organization. I would sincerely like to thank my institute and also Yamaha India for this venture.
