Indsutrial Training in Hero MotoCorp Ltd.

Copyright2013-2014
Hero MotoCorp Ltd.
Gurgaon Plant
Aaditya Nagpal
401107001
Mr. Supreet Bhullar
(Asst. Professor, Thapar University)
Faculty Coordinator
Mr. Sanjeev Mittal
(Asst. General Manager, Hero MotoCorp Ltd.)
Industry Coordinator

Copyright2013-2014
HERO MOTOCORP LTD.
• Started in 1984 as a joint venture
• Largest two wheeler company in India
• In 2010, Honda moved out of venture
• Splendor is company’s most successful model
• 17 different products across 100cc, 125cc, 150cc, 225cc and scooter
category
• 3 plants with combined capacity of 6.35 million units
• 6,106 employees all over in India
Wednesday, August 6, 2014THAPAR UNIVERSITY, PATIALA 2

Copyright2013-2014
THE GURGAON PLANT
• 2nd plant of company
• Produces 7000 bikes per day (18 sec for each
bike)
• Most of the new bikes are produced
• Important models: Glamour, Passion (new),
Karizma, Ignitor, Pleasure, maestro

Copyright2013-2014
THE WELD SHOP
• In Gurgaon plant, it consist of 2 sections
• 1)Weld Shop I (old) & 2) Weld Shop II (new)
• Fuel tanks (3 lines) & frame body (3 lines)
• Important processes: MIG welding, Grinding,
Boring, MFF welding, Sanding, Spot welding,
Buffing, Seam welding, Brazing, Leak testing

Copyright2013-2014
PROJECT 1
“ Optimization of Usage of
Consumables in the Weld Shop”

Copyright2013-2014
PROCESS FLOW IN FUEL TANK LINE
Body R/L MIG
weldng
Bead grinding Burring
Denting and
belt sanding
MFF MIG
Welding
SandingBuffing
Body R/L and
bottom tacking
Seam welding
Cock drain and
pipe brazing
Final inspecion Leak testing
Rear numper
plate spot
welding

Copyright2013-2014
THE EIGHT COMPONENTS
TACKING
ROBOTIC WELDING
MANUAL WELDING
FINE BORING
QC & INSPECTION
IN PROCESS INVENTORY
PAINT SHOP
PROCESS FLOW IN
FRAME BODY LINE

Copyright2013-2014
CONSUMABLES IN THE WELD
SHOP
• Consumables can be defined as the components of an end product
that are used up or permanently altered in the process of
manufacturing
• These are categorized into three classes
• ‘A’ class consumables are those consumables that are used on the
very important part of the bike from the point of view of beauty and
safety
• Costs around Rs. 25 per vehicle
• Excessive consumption is a major problem which is caused by
worker mistakes or material

Copyright2013-2014
OBJECTIVE OF THE PROJECT
• Consumption of the consumables:
– Observe the processes where the consumables are used and
also to measure the consumption of them in these processes
– Define an optimum number for their consumption
• Ways to reduce the consumption:
– Make changes in the process to make optimum utilization
– Make changes in the material (consumables)

Copyright2013-2014
DELIVERABLES
• The project would be helpful to estimate the
cost of various consumables per vehicle for
different models
• If the suggested changes are done it will
reduce the consumption of consumables as
well as increase the quality of the vehicle

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SANDING DISC
• A heavy paper with abrasive material attached to its surface
• Sandpaper is part of the "coated abrasives" family of
abrasive products
• It is used to remove small amounts
of material from surfaces, either to
make them smoother (painting and
wood finishing), to remove a layer
of material (e.g. old paint), or
sometimes to make the surface smoother

Copyright2013-2014
• used mainly in weld shop for fuel tank line
• mainly to remove the small defects on the
tank, to make surface smoother
• four sanding stations on each line, three
rework stations and one final inspection point
• grit size 120, but at rework it is 100

Copyright2013-2014
CONSUMPTION PATTERN
The following figures indicate the sanding paper and cost
needed per tank to do sanding operation. First the number of
tanks per sanding paper was calculated. Based on that these
figures are obtained. Value of 1 sanding paper is Rs 29
MODEL NO. OF TANKS SANDING DISC/ TANK COST / TANK
(Rs.)
KARIZMA 21 0.095 2.76
ZMR 22 0.091 2.64
GLAMOUR 31 0.065 1.89
GLAMOUR FI 30 0.066 1.91
PASSION 41 0.049 1.42
X PRO 36 0.056 1.62
IGNITOR 32 0.063 1.83
CBX 33 0.061 1.77

Copyright2013-2014
CAUSE AND EFFECT DIAGRAM
WASTAGE OF
SANDING
DISC
MATERIAL LARGE
BACKUP
PADS
SIZESHAPE OF
PAPER
HUMAN
ERROR
EXCESSIVE
CUTTING
REWORK
USES MORE
PAPER
QUALITY

Copyright2013-2014
PROBLEMS AND SOLUTIONS
• Larger backup pads in new weld shop- reduce backup
pad size in both sections
• Cutting should be same in both weld shops
• Rework fuel tanks consume more amount of paper,
reduce defects MFF welding & body R/L welding
• Polygon sized paper manufactured by vendors directly

Copyright2013-2014
MISCELLANEOUS OBSERVATION
• Two different types of sanding discs were being
used :
1.) “CE code” 2.) “YC code”
• “CE code” disc predominantly used
• Few operators in Weld Shop II were using “YC
code disc”
• Output of “YC” disc nearly half.
• The use of it immediately stopped and it was sent
to the concerned personnel to find out the causes
and costing of the same.

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GRINDING WHEEL
• Grinding is an abrasive machining
process that uses a grinding wheel as the
cutting tool.
• Grinding practice is a large and diverse
area of manufacturing and tool making.
• In mass production contexts it can rough
out large volumes of metal quite rapidly.
• It is usually better suited to the
machining
of very hard materials than is "regular"
machining

Copyright2013-2014
• Grinding wheel is only used in fuel tank
lines
• Grinding wheel used has specifications
100*6*15; max speed limit is 72 m/s
• In old weld shop one station for grinding
just after R/L body robot welding and two
station for
• In new weld shop one station for grinding
after R/L
body welding and one for rework
• Grinding wheel is also used at seam
welding
electrodes for wheel dressing.

Copyright2013-2014
CONSUMPTION PATTERN
A different technique was used to calculate the
consumption of grinding wheel. All the figures
were obtained with skilled operator and number
of fuel tanks per grinding wheel is calculated. As
the readings were obtained on production line,
the readings were obtained as a combined of two
models. Glamour was the only model which can
be observed for long time. So, assuming it as a
base we calculated the number of fuel tanks for
grinding wheel. Similarly Passion was also studied
for long time in the line and was taken as
standard. Cost of 1 grinding wheel is Rs. 110/-

Copyright2013-2014
CONSUMPTION PATTERN
MODEL 1 MODEL 2 NO. OF
COMPONENT
S PER
GRINDING
WHEEL
NO. OF
COMPONENT
S OF MODEL
1/WHEEL
NO. OF
COMPONENT
S OF MODEL
2/WHEEL
PASSION XPRO 160+65 250 180
GLAMOUR KARIZMA 130+39 210 102
GLAMOUR IGNITOR 150+37 210 127
GLAMOUR HUNK 171+19 210 100
GLAMOUR CBX 90+62 210 108

Copyright2013-2014
CONSUMPTION PATTERN
MODEL NO. OF
COMPONENTS
PER
GRINDING
WHEEL
GRINDING
WHEEL
PORTION
USED PER
COMPONENT
COST OF 1
GRINDING
WHEEL
(Rs.)
COST OF
GRINDING
WHEEL PER
COMPONENT
(Rs.)
PASSION 250 0.0040 110 0.44
XPRO 180 0.0056 110 0.62
GLAMOUR 210 0.0048 110 0.53
KARIZMA 102 0.0098 110 1.08
IGNITOR 127 0.0079 110 0.87
HUNK 100 0.0100 110 1.10
CBX 108 0.0093 110 1.02

Copyright2013-2014
• Pneumatic Grinder Neck damage -
worker awareness can solve this issue
• Sharp edges of new grinding wheel -
Company should order wheels having
less sharpness at edges
• Way of rework at MFF – smaller
diameter & higher thickness wheels
should be used
• Use of grind wheel for seam welding
dressing - harder grinding wheel
specially designed for wheel dressing
should be used

Copyright2013-2014
BRAZING ROD
• Brazing is a metal-joining process whereby a
filler metal is heated above melting point and
distributed between two or more close-fitting
parts by capillary action
• Filler metal used in brazing is in the shape of
rod and it is called brazing rod and made of
Bronze Alloy ( in Hero motocorp)

Copyright2013-2014
• Used in fuel tank line only for cock, drain pipe, breather
pipe brazing & in rework
• Two stations on each line for cock & drain pipe brazing, and
two rework stations
• Rework is done at two stations one is just after MFF
welding and one is at final inspection
• Cock is small pipe through which the fuel flows to the
engine

Copyright2013-2014
Model
Fuel Cock
Brazing
Drain Pipe
Brazing
Total Value Of
Brazing Rod
(Rs)
Brazing Rod /
Comp
(Kg.)
Brazing Rod /
Comp
(Kg.)
Glamour 0.0146 0.0093 13.27
Ignitor 0.0243 0.0026 14.93
X Pro 0.0215 0.0102 17.62
CBX 0.0255 0.0102 19.86
Karizma 0.0196 0.0116 17.36
Karizma Fi N/A 0.0121 6.76
Glamour Fi N/A 0.01 5.56
Passion 0.0218 N/A 12.15

Copyright2013-2014
CONSUMPTION PATTERN

Copyright2013-2014
MIG WELDING WIRE 1mm
• MIG welding is a Fusion welding process in
which the inert gas is used as a shielding gas
• Gas metal arc welding (GMAW) is an AW
process in which the electrode is a consumable
bare metal wire, and shielding is accomplished by
flooding the arc with gas
• Copper coated mild steel wire

Copyright2013-2014
• wire of 1 mm is used in Tack welding of
components
• It is also used in all manual welding stations
just after robotic welding
• Tack welding is a process of joining all the
major components of the frame body together
by a temporary welding joint

Copyright2013-2014
CONSUMPTION PATTERN
MODEL BEFORE
WEIGHT
(KG)
AFTER
WEIGHT
(KG)
WIRE
USED
(KG)
NO. OF
COMPONENT
S
WIRE /
COMPONEN
T (KG)
COST /
COMPONEN
T (Rs.)
PASSION 13.30 12.80 0.50 10 0.050 3.30
GLAMOUR 13.10 12.00 1.10 20 0.055 3.63
GLAMOUR
FI
13.26 12.20 1.06 20 0.053 3.50
KARIZMA 13.30 12.65 0.65 10 0.065 4.29
The figures shown below are done with skilled operator. The initial
weight was calculated and then from final weight and number of
tanks, the figures were obtained.
Cost of 1 KG wire is Rs. 66

Copyright2013-2014
EXCESSIVE
USE OF 1 mm
wire
MATERIAL
OILED PARTS
HUMAN
ERROR
WASTAGE
IN TRASH
DURING
CHANGING
DEFECTS
DURING
ROBOTIC
WELDING
QUALITY
IMPROPER
CLEANING
AND
STORAGE OF
WIRE ROLLS
HIGH
CURRENT
AND VOLTAGEPROCESS

Copyright2013-2014
• Higher current & voltage used at stations – worker awareness can
solve this issue
• Improper cleaning & storage of wire rolls – suggested a storage
facility as well as packaged shipping of rolls, glass covers on the
rolls
• Oil problem: oiled parts cause several
defects in welding. They must be
cleaned before welding
• While changing of wire rolls lot
of wire is thrown in trash
• Defects in robotic welding
cause consumption of wire
in manual stations

Copyright2013-2014
MIG WELDING WIRE 1.2mm
• MIG welding wire of 1.2 mm is used for higher strength
joints
• Used in gantry robotic welding in the frame body line
• Gantry robot is a pneumatically controlled programmable
robot with two welding arms
• The temporary joints in the tack welding are made
permanent in this process.
• Two robotic arms use separate wire rolls

Copyright2013-2014
CONSUMPTION PATTERN
The figures were obtained based on the robot working at standard
working conditions. This process does not involve any manual
operations. The data was obtained by observing the final and initial
weight of the wire rolls. (Cost of MIG welding wire of 1.2 mm = 63.20 INR
per kg)
MODEL BEFORE
WEIGHT
(kg)
AFTER
WEIGHT
(kg)
WIRE
USED
(kg)
NO. OF
COMPONENTS
WIRE /
COMPONENT
COST /
COMPONENT
(Rs.)
GLAMOUR 13.16
13.28
12.62
12.72
1.1 26 0.042 2.67
GLAMOUR
FI
13.16
13.28
12.62
12.72
1.1 26 0.042 2.67
PASSION
PRO
13.26
13.18
12.82
12.60
1.12 26 0.043 2.70
SCOOTER 12.72
12.62
12.48
12.46
0.4 10 0.040 2.52

Copyright2013-2014
• Similar problems as in wire roll of 1 mm like
improper cleaning, storage and high voltage
current, oil problem
• Defects in tack welding can lead to defects in
robotic welding which increases the
consumption in manual welding stations

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WELDING WIRE 0.8mm
• Used only in the fuel tank line
• Body R/L welding, MFF MIG welding, Base fuel pump
welding in form of wire rolls; all of these are robotic
welding processes
• Body R/L welding: It involves the welding of the two parts
of upper body parts of the fuel tank with to form a upper
body
• MFF MIG welding: MFF, Metal Fuel Filler is a small
components used in the fuel tank of each vehicle. This acts
as the gate to fuel intake in to the tank.
• Base fuel pump: the fuel pump which controls the fuel flow
to the engine (used in Glamour-FI only)

Copyright2013-2014
CONSUMPTION PATTERN
Model
Body R/L Welding
WIRE / COMP (Kg) COST/COMP (Rs.)
GLAMOUR 0.015 0.991
IGNITOR 0.016 1.075
X PRO 0.010 0.672
CBX 0.012 0.806
PASSION 0.013 0.851
KARIZMA 0.024 1.613
KARIZMA FI 0.024 1.613
GLAMOUR FI 0.015 0.991
The initial and final weight of the wire roll was recorded. Based on
that the consumption of wire roll per fuel tank was obtained. Cost
of one wire roll= 67.20 Rs.

Copyright2013-2014
TRIAL OF BHH MAKE
• Usha Martin wire rolls used
• Trial on BHH conducted
• Trial passed

Copyright2013-2014
• Oil problem- cleaning of parts is needed to solve this problem
• Proper cleaning of wire rolls & storage facility is needed
• Robots in overdrive mode cause higher consumption – proper
operating parameters can solve this problem
• Improper placement of MFF & bypass lock- assure the proper
clamping of both the parts
• Near MFF, welding in body R/L can be avoided to reduce wire
consumption

Copyright2013-2014
ARGON GAS
• Produced industrially by the fractional
distillation of liquid air
• Mostly used as an inert shielding gas in
welding
• In other high-temperature industrial processes
where ordinarily non-reactive substances
become reactive

Copyright2013-2014
• Used at body R/L robot and MFF robot welding
• Used in the fuel tank line as a mixture with
carbon dioxide mixture contains 20% carbon
dioxide and 80% Argon gas.
• Both of these gases act as a shielding gas to avoid
the oxidation of the welding bead.
• These gases are fed to the faying surfaces using
Gas Metal Arc Welding process.
• Use of an inert gas helps to get a better control in
welding

Copyright2013-2014
CONSUMPTION PATTERN
The flow meters were attached with each of the welding robot.
By recording the time of welding for each fuel tank, the gas
flow in liters can be estimated. Cost of air per LTR is Rs. 30.
MODEL
TOTAL CONS. Of
AIR (LTR)
Ar (M3)
1 LTR = 10-3 M3
COST OF
ARGON/TANK (10-3
*Rs.)80%
IGNITOR 13.83 0.011 0.332
XPRO 5.06 0.004 0.122
KARIZMA FI 6.60 0.005 0.158
GLAMOUR FI 7.00 0.006 0.168
GLAMOUR FI 13.87 0.011 0.333
KARIZMA 6.49 0.005 0.156
PASSION 9.36 0.007 0.225
CBX 13.47 0.011 0.323
Body R/L robot

Copyright2013-2014
MODEL
TOTAL CONS. OF
AIR USED (LTR)
ARGON (M3)
1 LTR = 10-3 M3 COST OFARGON/COMP
(10-3 * Rs.)
80%
IGNITOR 13.95 0.011 0.332
XPRO 11.78 0.004 0.122
KARIZMA FI 13.09 0.005 0.158
GLAMOUR 14.39 0.006 0.168
GLAMOUR FI 14.39 0.011 0.333
KARIZMA 13.09 0.005 0.156
PASSION 10.66 0.007 0.225
ACHIEVER 11.20 0.009 0.269
CBX 21.84 0.011 0.323
MFF MIG welding:

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WASTAGE OF
ARGON GAS
MATERIAL LARGE
BACKUP
PADS
SIZEOILY PARTS
HUMAN
ERROR
IMPROPER
PLACEMENT
OF MFF
EXCESSIVE
FLOW OF
GASES
METHOD

Copyright2013-2014
• Excess flow of gases – Regula gas savers
should be used properly
• Oily parts – proper cleaning is needed
• Improper placement of the MFF - proper
clamping of the MFF & bypass lock should
used

Copyright2013-2014
CARBON DIOXIDE
• Most widely used gas in the welding
department.
• when consumed, a semi-inert gas that is an
acceptable shielding gas for welding steel.

Copyright2013-2014
• Used in both sections of the weld shop, In fuel
tank line it is used as a mixture with Argon gas &
in frame body it is used as the only one gas.
• In fuel tank line it is used at the Body R/L
welding, MFF welding and Base fuel pump
welding.
• In frame body line it is used at all the welding
stations.

Copyright2013-2014
CONSUMPTION PATTERN
The gas flow meters were attached with each of the welding stations showing
the flow rate for the gas. Gas flow of Carbon dioxide in kg was calculated.
Then, by knowing the density of the gas, the gas required for each fuel tank in
Kg was calculated. BODY R/L
MODEL
TOTAL CONS. OF
GAS USED (LTR)
CO2 (KG)
1 LTR = 0.000616 KG
COST OF
CO2/COMP
(10-3 * Rs.)
20%
IGNITOR 13.95 0.0017 0.0086
XPRO 11.78 0.0015 0.0073
KARIZMA FI 13.09 0.0016 0.0081
GLAMOUR 14.39 0.0018 0.0089
GLAMOUR FI 14.39 0.0018 0.0089
KARIZMA 13.09 0.0016 0.0081
PASSION 10.66 0.0013 0.0066
ACHIEVER 11.20 0.0014 0.0069
CBX 21.84 0.0027 0.0135

Copyright2013-2014
MFF
In case of the frame body line, the direct value of gas flow in
liters can be obtained by noting the welding time. It was then
converted to Kg by conversion factor
MODEL TOTAL CONS. (LTR)
CO2 (KG)
1 LTR = 0.000616 KG
COST OF CO2/TANK
(10-3 *Rs.)
20%
IGNITOR 13.83 0.0017 0.0085
XPRO 5.06 0.0006 0.0031
KARIZMA FI 6.60 0.0008 0.0041
GLAMOUR FI 7.00 0.0009 0.0043
GLAMOUR FI 13.87 0.0017 0.0085
KARIZMA 6.49 0.0008 0.0040
PASSION 9.36 0.0012 0.0058
CBX 13.47 0.0017 0.0083

Copyright2013-2014
Frame Body Stations
Frame Body Stations
Model Operations Total Cons. (Ltr)
Co2 (Kg)
1 Ltr = 0.000616
Kg
Cost Of Co2/
Comp
(10-3 *Rs)
Glamour
Tacking 1 4.8 0.003 0.0152
Tacking 2 3.75 0.003 0.0149
Robot 1 8.59 0.005 0.0265
Robot 2 7.87 0.005 0.0242
Full Welding 1 7.90 0.005 0.0243
Full Welding 2 8.70 0.005 0.0268
Full Welding 3 1.48 0.001 0.0045
Full Welding 4 2.72 0.002 0.0084
Total Gas Used 0.028 0.1325
Passion
Tacking 1 3.9 0.0024 0.0125
Tacking 2 2.52 0.0016 0.0113
Robot 1 10.42 0.006 0.0321
Robot 2 15.00 0.009 0.0462
Full Welding 1 15.00 0.009 0.0462
Full Welding 2 15.00 0.009 0.0462
Full Welding 3 3.75 0.002 0.0116
Total Gas Used 0.038 0.1896

Copyright2013-2014
Model Operations
Total Cons.
(LTR)
Co2 (Kg)
1 Ltr = 0.000616 Kg
Cost Of Co2/
Comp
(10-3 *Rs)
Scooter
(Manual Line)
Tacking 1 3.02 0.002 0.0093
Tacking 2 3.41 0.002 0.0105
Tacking 1 3.97 0.002 0.0122
Tacking 2 3.97 0.002 0.0122
Tacking 1 3.66 0.002 0.0113
Tacking 2 4.07 0.003 0.0125
Full Welding 1 7.65 0.005 0.0236
Full Welding 2 7.45 0.005 0.0229
Full Welding 3 7.10 0.004 0.0219
Total Gas used 0.027 0.1365

Copyright2013-2014
• Excess flow – fixed flow regulators can be
used
• Spattering – proper welding
• Proper current and voltage should used
• Other same as Argon gas

Copyright2013-2014
OXYGEN AND DISSOLVED
ACETYLENE
• Used in brazing operations in fuel tank line of the weld
shop.
• The brazing is done to fit the cock, drain pipe and
breather pipe at the base of the fuel tank.
• Used as a mixture with Dissolved acetylene gas which
is used as a fuel gas in brazing.
• The proportion of two gases depends on the operator
working on the station.
• The two gases are fed separately from cylinders kept
outside the weld shop area.
• These gases can be controlled for their flow using flow
controllers on brazing torch.

Copyright2013-2014
CONSUMPTION PATTERN
It is not possible to estimate the gas flow at a
station from there, as cylinder supplies the gas
to every brazing station in the weld shop. Also,
there are no flow meters on the gas pipes. Only
operating parameter mentioned there is the
pressure

Copyright2013-2014
• Excess pressure that produced excess flow
• Excess flow - this increases the gas
consumption
• Fix pressure regulator can be used

Copyright2013-2014
PROJECT - 2
“Elimination of Defects in Weld
Shop in fuel tank line”

Copyright2013-2014
OBJECTIVE OF THE PROJECT
To eliminate or reduce defects in welding. It
was proposed to make line-1 of fuel tank
welding a zero defect line .Once this is done, It
would be compared with other lines and then
the required steps would be taken on the
other lines also.

Copyright2013-2014
METHODOLOGY
• To make line -1 a zero defect line, we need to eliminate
the defects generated in this line, apart from that we
need to reduce the material and time loss in the line.
• First step was to identify the defects generated on the
parts during welding operation and also other
operations. Once that was done data was collected for
over a period of 7 days in both shifts. Once that was
done the data was analysed to find the reasons for the
defects and finally necessary proposals were provided.

Copyright2013-2014
LEAK TESTING EXCEL

Copyright2013-2014
LEAK TESTING OBSERVATIONS
MODEL Passion X Pro Glamour Achiever Karizma R Ignitor Xtreme
TOTAL INSPECTED 245 150 170 80 80 100 140
R/L DEFECTS 25 16 19 11 4 8 3
(%) 10.2040816 10.6666667 11.1764706 13.75 5 8 2.14285714
SEAM DEFECTS 19 11 21 4 5 3 5
(%) 7.75510204 7.33333333 12.3529412 5 6.25 3 3.57142857
MFF DEFECTS 12 5 8 2 3 20 9
(%) 4.89795918 3.33333333 4.70588235 2.5 3.75 20 6.42857143
CORK DEFECTS 3 0 2 0 0 3 15
(%) 1.2244898 0 1.17647059 0 0 3 10.7142857
MASKING DEFECTS 4 2 1 0 0 0 0
(%) 1.63265306 1.33333333 0.58823529 0 0 0 0
PIPE DEFECTS 0 2 5 0 5 2 22
(%) 0 1.33333333 2.94117647 0 6.25 2 15.7142857
SHROUD DEFECTS 0 0 0 0 1 0 0
(%) 0 0 0 0 1.25 0 0
TOTAL DEFECTS 63 36 56 17 18 36 54
(%) 25.7142857 24 32.9411765 21.25 22.5 36 38.5714286
NO OF DEFECTED PIECES 55 33 51 17 18 32 48
(%) 22.4489796 22 30 21.25 22.5 32 34.2857143
QUALITY (%) 77.5510204 78 70 78.75 77.5 68 65.7142857

Copyright2013-2014
OBSERVATIONS
• Maximum no. of defects are Seam defects,
Body R/L defects and MFF defects
• Pareto Principle holds true here. Nearly 80%
defects are caused by very few causes.
• Maximum quality is achieved in Achiever,
while maximum no. of problems are
encountered in CBZ extreme.

Copyright2013-2014
MIG WELDING
MIGBODYR/LWELDING
ROBOTNO.9300049 ROBOTNO.9300050 ROBOTNO.9300051
puncture pinhole Gasprob undercut OK puncture pinhole Gasprob undercut OK puncture pinhole Gasprob undercut OK
SHIFT A B A B A B A B A B A B A B A B A B A B A B A B A B A B A B
DAY-1 13 13 8 4 0 0 0 0 10 8 25 20 7 3 1 1 0 0 5 3 12 2 0 0 0 0 0 0 14 23
DAY-2 10 5 8 1 0 0 0 0 12 19 13 8 9 3 0 0 0 0 13 14 11 3 5 0 0 0 0 0 9 22
DAY-3 14 3 0 0 0 0 1 0 10 22 14 10 0 0 0 0 0 0 11 15 0 2 0 0 0 0 0 0 25 23
DAY-4 6 16 7 7 0 0 1 0 11 12 13 16 4 6 0 1 0 0 9 11 3 6 1 3 0 0 0 0 21 20
DAY-5 9 11 8 2 0 0 1 1 11 11 18 14 4 3 0 1 0 1 7 7 1 5 1 1 0 0 0 0 23 19
DAY-6 2 2 0 6 0 0 0 0 23 16 12 10 13 3 0 0 0 0 6 12 2 2 0 4 0 0 0 0 23 19
DAY-7 4 0 0 0 21 16 0 0 0 9 1 0 0 0 24

Copyright2013-2014
Robot no. 9300049
0
5
10
15
20
25
1 2 3 4 5 6 7
days
quantity
punchure
pinholes
undercut
gasproblem
ok
Robot no. 9300049
0
5
10
15
20
25
1 2 3 4 5 6
days
quantity
punchure
pinholes
undercut
gasproblem
ok
SHIFT A SHIFT B

Copyright2013-2014
0
5
10
15
20
25
30
1 2 3 4 5 6 7
quantity
days
Robot no. 9300050
punchure
pinholes
undercut
gasproblem
ok
SHIFT A SHIFT B
Robot no.9300050
0
5
10
15
20
25
1 2 3 4 5 6
days
quantity
punchure
pinholes
undercut
gasproblem
ok

Copyright2013-2014
Robot no. 9300051
0
5
10
15
20
25
30
1 2 3 4 5 6 7 8
days
quantity
punchure
pinholes
undercut
gasproblem
ok
SHIFT A SHIFT B
Robot no. 9300051
0
5
10
15
20
25
1 2 3 4 5 6
daysquantity
punchure
pinholes
undercut
gasproblem
ok

Copyright2013-2014
This process uses 3 robots. Work involved is
both automated and manual. However
inspection is done visually. From the data it
average ok parts were calculated
Robot no OK parts average
shift A Shift B
9300049 12.42 14.66 14
9300050 8.57 10.33 9
9300051 19.85 21 20

Copyright2013-2014
DEFECTS
Puncture:
It is caused when the gap between the parts exceeds 0.8mm.thus causing
a gap more than the diameter of the feed wire and these results in the
formation of bigger hole due to melting of sheet adjacent to the flame of
welding rod.
The gaps can be caused due to
• Denting of surface causing deformation of welding profile.
• Direct deformation of the welding profile due to mishandle and over
stacking of the parts.
• Spatters from the weld in adjacent region results in improper welding.
environment
human
method
PUNCTURE

Copyright2013-2014
REMEDIES PROPOSED
• Proper handling of parts. Avoid placing parts
on floor.
• Proper cleaning of the parts.
• Gap between the parts should be less than 0.8
mm.
• Over stacking to be reduced in trolley.

Copyright2013-2014
Pinholes: It is caused when a region remains unwelded or welding is not
done in the welding profile.
Reasons:
• Unclean surface like presence of oil may cause welding trouble.
• Improper feeding of wire.
• Dust in feeding tube and wire.
• Improper alignment of the parts.
• Defect in die.
• Programming error
• Play in the axis of robot arm
PINHOLES
ENVIRONMENT
HUMAN
ERROR
EQUIPMENT
ERROR
METHOD

Copyright2013-2014
REMEDIES PROPOSED
• Proper cleaning of feed rod after ever 50 parts
produced.
• Inspection of dies and robotic arms on a
regular basis.
• Mishandling of parts to be avoided.
• Laser inspection can be installed to check the
alignment of the parts

Copyright2013-2014
• Gas Problem: This is mainly caused due to entrapment
of shielding gas in the welding zone.
• Reasons:
• Pressure of the argon gas must be optimum or else it
results in defect.
• Problems in tube.
• Remedies proposed
• Worker should be able to check correct pressure of the
gas. Sensor can be installed in the robot for pressure
check and warning.
• Proper cleaning should be done.

Copyright2013-2014
Undercut: It is a long cut which occurs rarely and
has same reasons as that of puncture. As visible
in the data it is scarce so it is clear that it is
caused due to human error which may be
alignment problem or the reason may be the
voltage and current fluctuation.
As far as remedies are concerned human errors
are to be reduced. Although laser inspection will
help to even further reduce it.

Copyright2013-2014
MFF MIG WELDING
Robot no 9300084
0
5
10
15
20
25
30
1 2 3 4 5 6 7
days
quantity
punchure
gas
undercut
ok
SHIFT A SHIFT B
Robot no 9300084
0
5
10
15
20
25
30
1 2 3 4 5 6
daysquantity
punchure
gas
undercut
ok

Copyright2013-2014
Robot no 9300087
0
5
10
15
20
25
30
1 2 3 4 5 6 7
days
quantity
punchure
gas
undercut
ok
SHIFT A SHIFT B
Robot no 9300087
0
5
10
15
20
25
30
1 2 3 4 5 6
daysquantity
punchure
gas
undercut
ok

Copyright2013-2014
Robot no 9300305
0
5
10
15
20
25
30
1 2 3 4 5 6 7
days
quantity
punchure
gas
undercut
ok
Robot no 9300305
0
5
10
15
20
25
30
1 2 3 4 5 6
days
quantity
punchure
gas
undercut
ok
SHIFT A SHIFT B

Copyright2013-2014
Robotno OKparts average
shiftA ShiftB
9300084 24.5 23.2 24
9300087 24 23.8 24
9300305 23.14 23.2 23
The defects are minimum because :
• welding profile is a circle
• there is no movement in the robotic arm during
welding
• Instead the tank rotates about the axis of the
profile circle to be welded

Copyright2013-2014
DEFECTS
• The defects generated in this process is same as
that of the MIG body R/L welding like puncture
,gas problem undercut. Since the welding profile
is not complex pinholes are not generated.
• The basic cause for the defects are same but the
reasons to these defects is slightly different due
to change in the procedure of welding. In MFF
welding the welding tip remains stationary and
the MFF is placed over the r/l body and the body
rotates. The parts are held in position by the
clamper.

Copyright2013-2014
REMEDIES PROPOSED
• Clamper to be provided.
• Welding tip cleaning to prevent gas problem.
• Gas flow should be optimum to prevent gas problem.
• Buffing (remove coating to ensure welding is properly done) on
MFF component should be done properly.
• Gap between Body R/L and MFF should be minimum.
• Automatic air supply system after every stroke on hydraulic press to
prevent cut at MFF welding area.
• Play in jig rotating bearing.
• Play in axis motor to be reduced.
• Wire roll should be of good quality.
• Worn out brass locators to be replaced and schedule to be made for
the same.
• Cleaning of MFF locator after every 50 component.

Copyright2013-2014
LEAKAGE IN WELDING
0
5
10
15
20
25
1 2 3 4 5 6 7
quantity
days
leakage in fuel tanks
"9300027":
"9300046"
"9300060"
"9300417"
SHIFT A

Copyright2013-2014
SHIFT B
0
5
10
15
20
25
1 2 3 4 5 6
quantity
days
leakage in fuel tanks
"9300027":
"9300046"
"9300060"
"9300417"

Copyright2013-2014
• Leakage is caused due to defect in the welding of the parts. The
tank is tested for leakage by filling it with pressurized gas and then
placing it in clear water, bubbles indicates the presence of leakage
and if the leakage is present it is sent for brazing where it is
rectified.
• The method of testing is effective however as the parts are
continuously dipped in water the water becomes dirty and
inspection becomes tough. So to increase the efficiency of the
testing water must be changed on a regular basis.
• The types of leakage that occurs are
• Body R/L Leakage
• MFF Leakage
• Seam Leakage
• Spot Leakage
• Cock Leakage

Copyright2013-2014
Of the entire leakage problem, Body R/L Leakage
occurs in majority. The reason being simple that the
majority of the defects are generated in Body R/L
Welding. From the data collected it was inferred that
almost 10 out of every 20 tanks were having leakage.
The data for body R/L Leakage suggests it is a major
problem
Mean number of defected parts in
A Shift B Shift Mean
7.63 4.79 6
Thus to reduce the leakage problem the defects in the
Body R/L welding are to be reduced

Copyright2013-2014
CONCLUSION
The project on elimination of defects is
basically a step to increase the productivity by
reducing time and money on rework and
rejection. Under this project we have come up
with ideas to prevent these defects and if the
ideas can be successfully implemented it can
result in increase in productivity.

Copyright2013-2014
PROJECT – 3 (Miscellaneous)
“Study of the plant, industry and organization
from an Industrial Engineering and
Entrepreneurial Perspective”

Copyright2013-2014
Why Hero is no 1?
• First company to make motor cycles popular in
India
• Technological advantage because of JV with
Honda from Japan
• Great marketing campaigns
• Understanding the needs of the customer
• Huge product variety and range across all
segments as opposed to competition
• Strong dealer network and service network

Copyright2013-2014
VENDOR DEVELOPMENT
• Strong and old supplier base and vendors
• Vendors have grown with the company
• Huge investments are required
• Mostly friends and relatives of the promoters
• Difficult to match the economies of scale
• Huge penalty if there is a delay
• Every vendor is a vendor for a specialised product
only
• Final price is determined by Hero
• Rising inputs and material costs

Indsutrial Training in Hero MotoCorp Ltd.

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