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  1. 1. INDUSTRIAL TRAINING PROJECT REPORT On Press Trolley Management HONDA MOTORCYCLE & SCOOTER INDIA PVT. LTD. MANESAR, DISTT. GURGAON SUBMITTED BY: SUBMITTED TO:- Angel Bajaj Er. Nishish Andleigh ROLL NO. 1243289 Leader of Press Dept. B.TECH (ME) (Quality and Check) Global Institutes of H.M.S.I. Management and Technology Amritsar
  2. 2. ACKNOWLEDGEMENT A summer project is a golden opportunity for learning and self-development. I consider myself very lucky and honored to have so manywonderful people lead me through in completion of this project. I wish to express my indebted gratitude and special thanks to Er. Rajnish Mittal, Senior at H.M.S.I. , who in spite of being extraordinarily busy with his duties, took out time to hear, guide and keep me on the correct path and allowing me to carry out my industrialproject work at this esteemed organization and extending during the training. A humble ‘Thank you’ Sir. I also express my deepest thanks to Er. Nishish Andleigh,leader in press dept.(quality) atHMSI, for giving necessary advices and guidance throughout the project work. Place: Manesar Angel bajaj
  3. 3. CERTIFICATE OF APPROVAL HONDA MOTORCYCLE & SCOOTER INDIA PVT. LTD. MANESAR, DISTT. GURGAON This is to certify that Mr. Angel Bajaj has completed the 6 week Industrial Training during the period from 16 June 2014 to 31 July 2014 in our Organization as a Partial Fulfillment of Degree of Bachelor of Technology Mechanical Engineering. During training he successfully completed his project on Press trolley Management in the maintenance engine department of scooter plant. Er. Nishish Andleigh,leader Leader of press dept.(quality) HMSI, Manesar, Distt. Gurgaon
  4. 4. TABLE OF CONTENTS TOPICS: PAGE.NO  CERTIFICATE OF COMPLETION.............................................................................02.  ACKNOWLEDGEMENT.............................................................................................03. 1. INTRODUCTION:...................................................................................................(04 - 30)  Brief profile of student.................................................................................................04.  Brief profile of organization.........................................................................................06.  HONDA Products……................................................................................................07.  History of HMSI……………………………………………………………………….......08.  Plant Overview/ Layout…………………………………………………………………..11.  Flow Chart of Production……………………………………………………………..…14.  Company Vision and Work Culture…………………………………………………..16-30 2. Raw material……………………………………………………………………………….40 3. Press shop…………………………………………………………………………………….41 4. Weld shop………………………………………………………………………………….45 5. Paint shop………………………………………………………………………………………46 6. Project………………………………………………………………………………………………49
  5. 5. INTRODUCTION:  Brief profile of student: I am Angel Bajaj, and I am a resident of Amritsar, Punjab. My father Mr. Deep Kumar Bajaj is a Serviceman and my mother Mrs. Dolly Bajaj, is a house wife. Currently I am pursuing B.tech in Mechanical at Global Institutes of Management and Technology. I always take a keen part in all the college activities.. I have done my Schooling from St. Sai Sr. Sec. School Amritsar. I am a keen worker who likes surfing internet, playing sports, reading Novels. I have participated and played many outdoor games in my graduation level at my college and presently I am working as an intern in Honda Motorcycle and Scooter India Pvt. Ltd. for 2 months.  Brief profile of project mentor at Honda My project mentor is Er. Nishish Andleigh, leader of press dept.(quality) HMSI, Manesar, Distt. Gurgaon Brief profile of organization HONDA, one of the biggest brand names in the automobile world today was founded by Soichiro Honda at Hamamatsu, Japan, in 1948. Since then, the company has been
  6. 6. growing by leaps and bounds satisfying customers all over the world with its comfortable world class products having most advanced technology. Honda Global Network : Six Regional Head Quarters WITH 6 OPERATINGREGIONS  North/ Central America  South America  Afro-Europe  Asia & Oceania  Japan  China PRODUCT CATEGORIES:- Scooters Motorcycles Automobiles Power Products Robots (ASIMO) Jet Engines(In developing stage) Honda Motor Company, Japan with its headquarters in Tokyo, has manufacturing operations in 32 countries with 109 production bases. It has 3 business divisions namely 2- wheelers, 4-wheelers and Power Products. Apart from HMSI that manufactures 2- wheelers, the other business divisions in India include Honda Siel Cars India Limited (HSCI) and Honda Siel Power Limited (HSPLThe company principal of Honda Worldwide is dedication to supplying products of the highest quality at a reasonable price for worldwide customer satisfaction. The various group companies of Honda in India are:  Honda Motorcycle and Scooter India Private Ltd. (HMSI)  Honda Siel CarsIndia Limited (HSCI)  Honda Siel Power Products Limited (HSPP)
  7. 7.  Honda R & D (India) Pvt. Ltd Honda's Products around the World JET ENGINE
  8. 8. HONDA MOTORCYCLES AND SCOOTERS INDIA PVT. LTD. (H.M.S.I)
  9. 9. Honda Motorcycle & Scooter India Pvt. Ltd. (HMSI), a wholly owned subsidiary of Honda Motor Company Ltd. was incorporated on 20th August 1999 to manufacture two wheelers in India. It’s Symbol “Wings” is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in the lifestyle of the people of India. It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards. Honda’s commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions. Ever since its establishment in 1999, HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people. In a short span of Eight years, HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India. While endeavoring to meet and exceed the expectations of the customers, the critical importance of providing the product, technology and service that not only benefits the customer but also the society in areas such as environment preservation and riding
  10. 10. safety is also realized. It is believed at HMSI that by meeting these expectations, HMSI will enhance the quality of life through products and services that reflect the spirit of today. Bringing joy to people and contributing to social development will continue to be the principles that will guide HMSI in future. It came into mass production with Honda Activa in 2001. Since then, the company has continued to grow in the Indian market along with regularly providing world class, advanced and technically sound products. Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality, HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Eterno, Dio, Unicorn and Shine. Apart from outstanding sales, Honda also caters its customers with excellent service and spare parts support. The HMSI factory is spread over 52 acres, with a covered area of about 85,815 square meters at Manesar, Gurgaon district of Haryana. The foundation stone for the factory was laid on 14th December 1999 and the factory was completed in January 2001. The initial installed capacity was 100,000 scooters per year, which has reached 6, 00,000 scooters by the year 2007 and motorcycle capacity shall be 4,00,000 per annum. The total investment outlay for the initial capacity was Rs. 215 crores and now the accumulated investment is 800 crores. HMSI mainly deals with:-  Manufacturing and sales of two wheelers.  Manufacturing and sales of two wheeler engines.
  11. 11.  Service and sales of spare parts and accessories.  Export of Honda products (CBU, Engine & Parts). PLANT OVERVIEW FACTORY ( 52 ACRES ) LAND AREA – 210540sq mtr COVERED AREA – 85815sq mtr
  12. 12. PLANT LAYOUT HMSI deals with the both the products in the two-wheeler segment. In this plant there are two sections one is scooter plant and other is motorcycle plant. In scooter plant all the models Activa, Dio, Eterno, Lead and Beat are being made. In Motorcycle plant Unicorn , Shine and Stunner, Aviator are being made.
  13. 13. FLOW CHART PRODUCTS:
  14. 14. 2001 Started with mass production of 1st scooter, Activa. ‘Scooter of the year award’for Activa. ISO-9001-2000 Certification by TUV, Germany 2002 Launched new motor scooter, Dio. ISO-14000 Certification by TUV, Germany. BBC WheelAward for Dio. Exportstarted to Latin America 2003 Launched geared scooter Eterno. Achieved status of No. 1 Scooter manufacturing company in domestic Market. Achieved status of no 1. Exporter in scooter segment Certification by ARAI for emission lab 2004 Scooter of the year award for Eterno. HMSIestablished new motorcycle plant. Launched 1st 150 cc motorbike, Unicorn. CKD exportto Latin America. Bike of the year award to Unicorn
  15. 15. 2005 ISO-14001:2004 Certification by TUV, Germany. Unicorn Tops in TNS Consumer Satisfaction Survey in “Premium Motorcycle” category Activa achieved landmark sales target of 1 million units 2006 HMSIlaunched its 2nd Motorcycle model, SHINE a 125ccsegment Motorcycle. HMSIsuccessfully launched LEAD in Australian Market.HMSIlaunched new variantACTIVA & BEATCKD 2007 Launch of new scooter AVIATOR. It is a E-class scooter 2008 Hondalaunched a new bike, Stunner a 125ccbike with a sporty look. 2009 HMSIlaunched its 4th Motorcycle, TWISTER a 110ccbike which was the first bike in Indiawith lower engine capacity and high style. 2010 HMSIlaunched a new modelof Unicorn with the name Unicorn Dazzler, 150 cc bike.
  16. 16. 2011 HMSIwowed Indian customerswith its latest offering – CBR 250R 2012 HMSIintroduced seven new bikes &scooters. CBR 150R, DIO, DREAMYUGA, CB SHINE, VT1300CX, CBR1000RR FIREBLADE & CBR 250R (Red, Blue& White). COMPANY VISION:-  Maintaining a globalviewpoint, they are dedicatedto supplying products of the highest quality yet at a reasonable pricefor worldwide customer satisfaction.
  17. 17. WORK CULTURE:- It providesevery Honda associate around the world with a vision. 1. It tells us the values of our business. 2. It bonds everyone togethertowards a commonmission. 3. It provides a constantstandard for correct action and ethical behavior.
  18. 18. 4. It shows the link betweenthe company’spast,presentand future. 5. It challenges the organizationto strive for the realizationof its vision. 6. It helps our organizationto maintain its sense of uniqueness. HMSI being a company of Japanese origin, I also got acquainted with the Japanese principles of manufacturing like  JIT (Just in Time)  TQM (Total Quality Management) Cause & effect analysis  PDCA (Plan Do Check Act) cycle HONDA PHILOSOPHY HONDA PHILOSOPHY MANAGEMENT POLICIES Compan y Principl e TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT THE THREE JOYS TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT RESPECT FOR THE INDIVIDUAL
  19. 19.  5-S rule: Seiri = Organization Seiton = Neatness Seiso = Cleaning Seiketsu = Standardization Shitsuke = Self-discipline  3-G principle: Gemba = Go to actual place Genbutsu = See actual problem Genjitsu = Take realistic solution  3-K principle: Kiken = Dangerous Kitanai = Dirty Kitsui = Inconvenient Our fundamental beliefs (Company’s Mission):-  Respect for the individual
  20. 20.  The three joys RESPECT FOR INDIVIUAL: The Human Being is born as a free and unique individual with the capacity to think reason and create -- and the ability to dream. "Respect for the individual" calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners. Respect for the Individual recognizes the following core concepts: Initiative Respect For the Individual TrustEquality
  21. 21. Initiative: Initiative means not to be bound by preconceived ideas, but think creatively and act on your own initiative and judgment, while understanding that you must take responsibility for the results of those actions. Equality: Equality means to recognize and respect individual differences in one another and treat each other fairly. Our company is committed to this principle and creating equal opportunities for each individual. Trust: The relationship among associates at Honda should be based on mutual trust.Trust is created by recognizing each other as individuals, helping out where others are deficient, accepting help where we are deficient, sharing our knowledge, and making a sincere effort to fulfill our responsibilities. Honda is comprised of individuals working together for a common purpose. Each individual, acting appropriately within his or her role, must translate the philosophy into actions. It is this contribution from each associate that contributes to the company’s success. And every associate should be honored for these efforts.
  22. 22. THE THREE JOYS: Our goal is to provide Joy through our business:for those who buy our products ("The Joy of Buying"), engage in selling our products and services ("The Joy of Selling"), and are involved in business of creating our products ("The Joy of Creating").  The Joy of Buying is achieved through providing product and services that exceed the needs and expectations of each customer.The Joy of Buying is essentially the establishmentof a relationship with the customer,initiated through the products and continued through the sales and service experience. Importantly, the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer .  The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a customerbased on mutual trust. Through this relationship, Honda associates,dealers and distributors experience pride and joy in satisfying the customerand in representing Honda to the customer.  The Joy of Creating occurs when Honda associates and suppliers involved in the design, development,engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers. Formerlyknown as the "Joy of Producing," the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done.
  23. 23. The Joy of Selling The Joy of Creating The Joy of Buying
  24. 24. HONDA MANAGEMENT POLICIES:- 1. Proceed always with ambition and youthfulness. 2. Respectsound theories,develop fresh ideas and make the effective use of time. 3. Enjoy your work and encourage opencommunications. 4. Strive constantly for a harmonious flow of work. 5. Be evermindful of the value of researchand endeavor. HONDA CORPERATE CULTURE:- 1. Free thinking & openmindedness. 2. Challenging spirit 3. Sincerity & Integrity Co-evolution
  25. 25. JAPANESE WORK CULTURE:- 1. A typical Japanese office is an open space with an over-crowding of desks or very little private work space. 2. An Employee for Life. 3. Other-centered,work centered long term relationships. 4. How work is done often matters more than what is accomplished. (Patient thoroughness,especially in preparation,is valued overspeed or creativity,Thorough documentationallows contextto speak) Working Preference:- 1. Safety:- Man,Machine, Environment. 2. Quality:-Component,Product,vehicle. 3. Quantity:- Daily Productiontarget.
  26. 26. HONDA PRODUCTS 1. HONDA ACTIVA 2. HONDA DIO 3. Activa125
  27. 27. 4. ACTIVA i 5. AVIATOR
  28. 28. 6. HONDA UNICORN 7. HONDA SHINE
  29. 29. 8. CD 110 9. CBR250 10. CBR1250
  30. 30. 11. TRIGGER Raw Material 1. ScooterRaw Material:- 1. KVT CRCEDD 0.7*515*540 2 KWP CRCEDD 0.8*650*745 3 K24 CRCEDD 0.7*545*550
  31. 31. 2.Motorcycle Ram Material:- S no. Model RH/LH Plate Bottom 1. KSP 0.8*510*800 0.8*565*690 2. KWF 0.8*530*750 0.8*500*680 3. KYJ/KPPR 0.8*540*720 0.8*500*610 4. K21 0.8*550*805 0.8*610*690 5. K23 0.8*515*760 0.8*590*690 For Motorcycle model EGIF (JNC270E) Grade material used for all tanks EG (Electro Galvanized) IF (Interstitials Free) Single side coated (Zn+Ni) Coating mass standard 20MG/m2 CRCA:-cold Rolled Closed Annealing Press Section Classification of presses:- 1. Mechanical press:- In this press, the load generation thro motor, flywheel, gear, transmission through connecting rod. High productionrate. 2. Hydraulic press:- Load generation thro motor driven hydraulic pumps and transmission through hydraulic cylinders. Generally, low production rate.
  32. 32. There are 4 mechanical presses:- Scooter Parts MotorcycleParts P1, P2, P3 & P4 are the mechanicalpresses. They are used because of their high productive rate. There is also a hydraulic press which is used for the die maintenance. The productive rate of this press is less than that of mechanicalpress. That’s why, mainly mechanicalpresses is used for the press operations in the industries. Note:-
  33. 33. The P2 is used for drawing operation and P1 is used for Trimming, Piercing and bending. The reason is that because the P2 press machine has double pads and cushions which absorb the force exerted by the die. Whereas, in the P1 only Trimming, Piercing and bending which occurs at the principle on the cam and the followerthat’s why we don’t do the drawing operation on the P1 Press. Press PPE’s:- 1. Helmet 4. Hand gloves 2. Arm guard 5. Safety shoes 3. Ear gloves 6. Goggles Press Operation 1. Scooter line:- Blank sheet  Draw Part  Trim & Piercing Hemming  Side Bending  Front bending Rework  Supply to Paint
  34. 34. 2. Motorcycle line:- R/M sheet  Draw Operation  Trimming Rework  Quality Guide Inspection Rework Quality Guide Inspection MaterialMovement to Weld Defects in Press operation:- 1.Dent:- Due to presence of foreign substancein die. 2.Crack:- Due to high pressureand tight pins. 3.Wrinkle:- Due to tight feed.
  35. 35. 4.Thinning:- Decreasingin the thickness of the product due to stretchingand uneven pressure. 5.Overlap:- Overlappingof the sheet on itself. 6.Burr:- Occur at the piercing. 7. Turn up:- Bending at the corners. Rework Operation Random tool Rotary tool
  36. 36. Hammer Producer:- 1.Firstly, the dent is removed with the help of hammer. 2.Then, with the rotary tool, which rotate at 18000rpm is usedfor cutting. 3.At the last, with random tool, which rotate at 12000rpm is usedfor finishingof the rework material. Note: - The Rotary tool and random tool work on the principleof the compressed gas. Standardization:- All the components that are manufactured are HMSI has to go through the test of three standards:- 1.ISO-9001:- Belong to quality standard 2.ISO-14001:- Belong to environment/ safety 3.ISO-27000:- Belong to containingsecrecy
  37. 37. Weld Shop There are 4 types of welding done in HMSI:- 1. MIG welding 2. TIG welding 3. Spot welding 4. Seam welding The filler metal used in the welding is mild steel coated with copper metal for the preventing it from corrosion.
  38. 38. Robots are used for doing MIG welding and in the rework it is done manually. Then this all frames are checked at the inspection shop. The fame is manufactured in the weld shop. Defects:- 1.Cracks 2.Beats 3.Blow holes 4.Coricity 5.Holes 6.Less penetration Paint Shop After then, the frames are put in the carrier on the conveyer for the painting. Before painting, the fames are washedin the ionizedwater then dried in the oven at 500 temperatures. Then ED coating (electrode deposition)is done on them. Then, at paint booth the base coating and top coating is done by the robots.
  39. 39. But for finishingand parts which are not painted is done manually. Then, these frames are allowed to enter at the oven for drying of the paint. The ED coating will get depositand the paint will got attached metal. Then, this paint coated is checked at the inspectionbooth. The defected frame are sent to the manually paint shop. Then, all the OK frames are sendingto the assembly line for the manufacturing of the product. Note:- There are 4 conveyer line with different temperatures and components. The metallic frames are kept at 1700 temperature where as fiber frames are kept at 800 temperatures The heat is generated in the conveyer by C.N.G and steam is also usedto create the heat for the drying of the paint on components.
  40. 40. Project Report:- Press Trolley Management Plate Bottom:- Trolley no. Wheel Cup Broken Mesh Hook Hole 1 2 3 4
  41. 41. 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
  42. 42. 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 Result
  43. 43. No. of ok trolleys =36 No. of mesh broken trolleys =10 No. of cup broken trolleys =1 Half Outer RH/LH Bin:- Trolley no. Wheel Cup Broken Mesh Hook Hole 1 2 3 4 5 6 7
  44. 44. 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
  45. 45. 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
  46. 46. 52 53 Result No. of ok trolleys =30 No of mesh broken trolleys =23 FENDER (SMALL SIZE) BINS:- Trolley no. Wheel Cup Broken Mesh Hook Hole 1 2 3 4 5
  47. 47. 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
  48. 48. 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Result No. of ok trolleys =29 No. of mesh broken trolleys =6 No. of cup broken trolleys =6 No. of NG- hole trolleys =1
  49. 49. Total Result Total no. of OK trolleys =36+30+29=>95 Total no. of mesh broken trolleys =10+23+6=>39 Total no. of cup broken trolleys =1+6=> 7 Causes & Prevention:- 1.Maintenance of the trolleys periodically. 2.Maintaininga suitablegap between the trolleys at the storage area.
  50. 50. 3.Lubricationof the hook and the wheels after every period of time. 4.Keep the trolleys in the queue. 5.Painting or Coating of the trolleys for their prevention from rust.

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