2. Group no - 01 2 M.haroon afzal bsme-01113017 Akmal hafeez
bsme-01113011 Waqas gul bsme-01113066 Rashid munir
bsme-01113015
3. Atlas Honda
4. m. Haroon Afzal BSME-01113017 4
5. Overview 5
6. Introduction 6 Atlas Honda Limited is a joint venture
between the Atlas Group and Honda Motor Co., Japan. Both these
motorcycle manufacturing concerns were established by the Atlas
Group. Atlas Honda Limited manufactures and markets Honda
motorcycles in collaboration with Honda Motor Company.
7. Plant Departments 7 Atlas Honda follows Process Layout. They
have different sections of different operations some of which are:
Casting Plant Paint Shop HR Department Finance & Accounts IT
Department Logistics Vendor Procurement Maintenance Store QC
Department Manufacturing Plant Assembly Plant Engine Plant
8. 8
9. Management 9 It is a skill of personal will and humility
towards the profession through which a person can lead any
institute or organization with well organized manner.
10. Management system 10 In Honda Atlas the Management Style is
Benevolent autocracy, Which means the employs are expected to be
loyal and co-operative in production. The behavior of top
management with the employs is decent and kind but decision making
is centralized.
11. Organization?? 11 An Organization is firm which born when a
group of persons work on a common goal. Honda is a Private Limited
Company. Two or more person can form this type of company and Govt.
does not interference the working of the system.
12. Atlas Honda Plants Location 12 Atlas Honda have two main
plants in Pakistan. One is in Karachi and the other one on
Sheikhupura Road They manufacture Only CD70 in Karachi, while in
Sheikhupura Plant they manufacture all of their models i.e. CD70,
CD100, CD125, and CD125 Deluxe.
13. Plant Locations RESONS 13 Further more the reason of there
more production in Shiekhupura Road. They could also have made
there plant in other place then this, but another reason is that
they have the most demand in Punjab all over Pakistan. Most of
there Vendors & Sub Contractors are also from Lahore and
Shiekhupura so there availability also counts a lot.
14. Plant Locations RESONS 14 The reason of manufacturing only
One model in Karachi is the plant location as well the demand in
Karachi. As we all know that street crimes and car snatching are
very common in Karachi. So they prefer to have the cheapest of the
motorcycles.
15. Effect of Location 15 Human resources Infra Structure
Industrial Culture Material Resources Energy
16. 16
17. AKMAL Hafeez BSME-01113011 17
18. Process layout 18 In process layout the machines are
grouped on the bases of function in atlas Honda process layout has
used
19. Process Layout . 19 PROCESS NO. OPTION OPERATION
DESCRIPTION 1 Cutting & Molding Die cutting of metal sheets
& shaping of cut parts 2 Die Casting Casting of aluminum parts
3 Welding & Grinding Joining of sheet Metal Parts &
Grinding of welds & seams. 4 Machining Finishing of Site Cast
& supplied parts 5 Cleaning & Preparation Spraying with
Rust inhibiting Compound. 6 Phosphating Surface cleaning &
preparation of Mild steel parts 7 Dipping Surface coating in a
paint dip tank 8 Anodizing Surface preparation of Cast and Machined
Aluminum parts 9 Degreasing Surface cleaning of circular Aluminum
parts 10 Drying after Phosphating Oven Drying 11 Drying after
Dipping Oven Drying to cure Dip Tank coating 12 Air Drying Drying
by Compressed Air 13 Spray Painting Surface Finishing by Air/ Paint
spray 14 Buffing Mechanical cleaning of circular Aluminum parts 15
Drying after painting Oven Drying to cure Spray paint coating 16
Engine Assembly Assembly of Engine from parts 17 Final Assembly of
Complete Motorcycle
20. Total productive maintenance Application 20 They have:
Proper Material Movement Space for the Operator Space for repair
& Maintenance Space for temporary storage Space for Loading
Unloading Maximization of the use of workspace All the utilities
are provided in the proper manner. Proper Safety Rules
21. STORES 21 Stores dept. at AHL performs following functions.
Manages the receiving, stacking & issuance of parts &
materials to the shop. Ensures the provision & dispatches of
required parts to SKP & KHI plant, spares part division &
vendors. Handles the rejections & damages from all shops
Handles the scraps & wastes generated in the factory
22. Division of stores 22 Stores dept. at AHL has been divided
into a no of small stores according to the type of material being
stored and functions/services provided by the store. The division
is shown as follows At AHL, following handling techniques are used:
a) For handling from shop to shop especially designed trolleys, and
pallets are used. b) Imported motorcycle components are received in
steel & wooden cases &pallets. c) Local vendor parts are
received from receiving section in standard carton boxes.
23. Material Handling 23 For in plant material handling, they
have Fork Lifters, Trucks, Pick-ups etc. They have Belt conveyor on
their assembly line which moves automatically and can be paused if
required.
24. Material Handling 24 They also use suspension conveyors on
the assembly line to bring the chassis from the paint ED Paint shop
onto the assembly line. In their Engine Div. they use Idler roller
conveyors to forward the work piece from one machine to
another.
25. 25
26. PRODUCTION PLANNING 26 PPC deals with managing the details
of what & how many products to produce and when, and obtaining
the raw materials, parts, and resources to produce those items. PPC
does this by managing information. For this purpose PPC has to keep
strong interactions in terms of coordination, communication &
cooperation with 4 major sections of Production and service
departments like. QA, Logistics Maintenance DCC/ Stores PPC Karachi
as well.
27. Waqas gul BSME-01113066 27
28. Planning 28 Production planning is done to ensure the
budgeted production targets of AHL. The planning is majorly done at
AHL, the company sets its production targets. On the basis of these
targets following type of planning is done. Aggregate planning
Master production schedule
29. Aggregate planning 29 On the basis of forecasting, a
schedule from SAP, according to the production capacities &
companys strategies, is generated which includes the planning of
whole year. It includes the production breakup of motorcycles for
whole year into model wise, plant wise & month wise
breakups.
30. Master production schedule 30 In Honda Master Production
Schedule represent Quantities of individual products Considering
demand for cast current inventory and back log. On the basis of
aggregate planning, such a monthly schedule is made which includes
day wise (2- shift wise), model & color wise breakups.
31. VENDORs 200+ vendors are actively engaged with the company.
Apart from the local vendors there is one main foreign supplier for
imported components/ parts i.e. Honda Motor company JAPAN which
accounts for 30% of its purchases. Trading reputation of the
company is excellent since the company is known for its fair
dealing and timely payments record to all creditors
32. VENDOR PROCUREMENT The main responsibility if this dept. is
ensuring part availability in right quantity & in right time.
This department is for local vendors in Pakistan. Purchase orders:-
The purpose is to inform developed vendors (in the start of the new
year)that during this new year, AHL will buy the parts in such
quantities and at such rate. This basically helps vendor to do his
aggregate & capacity planning. Trading reputation of the
company is excellent since the company is known for its fair
dealing and timely payments record to all creditors
33. Batch Production 33 Atlas Honda manufactures motorcycles in
Batches. In 2012 they manufactured 6,44,000 Bikes and had a target
of 7,50,000 bikes last year. They manufacture bikes on the order of
PPC (Production and Planning Control). PPC receives orders from
their dealers.
34. Batch Production 34 PPC is the most important department
throughout the plant, so as it has to make decisions according to
the demand that on which day how many bikes will be manufactured of
each model further more of which color, and in what time. And they
make it sure that there desired production rate is fulfilled
completely. Atlas Honda manufactures 1815 bikes per day on an
average.
35. Batch Production 35 There total Lead time on the assembly
line is 28sec for One bike. They have only one assembly line, on
which they make modifications according to the model to be
assembled. Similarly, they do not have different
departments(welding, painting, etc.) of every model, they rather
just change the jigs accordingly and start to manufacture the next
model. There casting plant is Ranked on 1st position in Asia. They
have a very good environment over there and very good facilities
for the workers too.
36. Production capacity in Pakistan 36
37. Rashid munir BSME-01113015 37
38. Variety Control 38 Planning is nothing without control.
PPC(Production planning and control) control ensures & arranges
the necessary resources for implementation of production plan. For
this purpose PPC has an eye on the in-house, vendor, import items
&ensures that all the material for the next day production are
available. if there is any shortage, then they collaborate with
vendor procurement to ensure availability of part in time. The
other function of PPC is that if there are deficiencies in the
resources available for production due to any reason, they work to
save the company from production loss.
39. Process of Variety Control 39 Honda Atlas Variety Control
process is based on Following. Simplification:- Honda Atlas
Reducing The Number of type of product. Standardization:- Honda
Atlas make the Qualitative values of Significant Product.
Specialization:- Honda Atlas Effort on a limited variety of
product.
40. QUALITY ASSURANCE 40 QA dept. administers Quality
management & quality control functions. QA dept. identifies
quality related problems in vendor & in-house parts & takes
preventive action for their re-occurrence.
41. WARRANTY & FINALINSPECTION 41 Warranty Claim Data
Collection Final inspection Stages of final inspection a) Test
bench b) Visual check c) Functional check
42. 42 Visual check: At the second stage visual check is
performed. In this test, inspectors check the bike visually
according to the criteria & inspection points provided to them.
Functional check: It includes the Co & HC emission test &
head light testing. Final inspection dept. generates the straight
pass of the motorcycles which shows the no of O.K parts as compared
to total no of production.
43. Final inspection 43 This section of QA is located in final
section of 500K plant. This section is formed for the final
analysis of the complete motorcycle that comes out of the frame
assy.
44. HR Department 44 In Honda Altus HR is fundamentally an
expression of this organization to belief on employee element on
the organization success. The current Chief Executive Officer:
Saquib H. Shirazi HR is Mr. Razi ur Rehman General Manager
Engineering and Projects: Muhammad Noman Khan
45. Human Resources and Succession Plan 45 Honda Atlas Human
Resources Policy is to hire young, fresh, energetic and active
associates to meet the existing and future workforce requirements
and providing its associates maximum opportunities for internal
mobility through personal training and development to enable them
to take higher positions.
46. HR Philosophy 46 In Honda Altas HR philosophies are
following: Respect for Individuals People of organization create
its success: Apply Integrity Professionalism Feeling for others
Primary job is to provide quality service. They have 3245 employees
currently working in their plant in 3 shifts.
47. Atlas Culture 47 Sincerity & Loyalty Time is money Be
self assured Dont expect others Members to be helpful Live
economically Do charity 3R Respect, recognition, reward Be overall
happy, healthy & wealthy Education, experience, expertise &
application
48. Recruitment & Separation Policy 48 Minimum
Qualification Written Test Primary Interview Final Interview
Pre-Employment Medical Test Offer Letter Joining Report Induction
Plan Probationary Period Confirmation Letter
49. Training Programs 49 They also arrange several training
programs and In house seminars with different institutions like:
IBA Karachi LUMS Lahore CMD Lahore PIM Karachi , Lahore PIQC Lahore
, Karachi PITAC Lahore NUST Islamabad CNDC