GET TRAINING EVALUATION(VEHICLE QUALITY

SC)

TRAINING SCHEDULE

S.No Activity

SEP'10 OCT'10

27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1 Introduction                                                      

2 VQ On                                                    

3 Conveyor Inspection                                                    

4 Re- Inspection & PDI                                                      

5 BOP Repair                                                      

6 Dismantling of Frame                                                    

7 Dismantling of Engine                                                    

8 Presentation                                                      

HMSI VEHICLE QUALITY SC

Shop Floor Layout

BRAKE TEST

SPEEDOMETER

ACCELERATIONTEST

VQ ON

BRAKE TEST

SPEEDOMETER

ACCELERATIONTEST

L1

R1 R2

L2

R3

L3

R4

L4

L1

R1 R2

L2

R3

L3

R4

L4

LOGISTIC

VQ OFF

PDI

REPAIR

REST AREA IPP VEHICLE

CARD MISS VEHICLE

HMSI VEHICLE QUALITY SC

VQ

ON

Verification ofEngine number

Verification of Frame number

Checking of Brake & Throttle Free play

Connecting bothPositive & Negativeterminals of battery

Measuring front andrear brake forces

Speedometer Test tocheck speedometer

error & needle vibration

Vmax & accelerationtest for checkingmaximum speed

HMSI VEHICLE QUALITY SC

Checking of Engine Noise

1. All ways first connect the positive terminal of battery to the vehicle.

2. Self start should be checked with both brakes.

3. Needle vibration should be in limit.

4. Headlight should be within high and low limit.

5. Choke lever must be closed while doing the Vmax test.

HMSI VEHICLE QUALITY SC

Learnt the procedure of Initial Inspection being performed to check the vehicle for brake force, speedometer and acceleration. Achievement of the cycle time, and the target of 80 vehicles per day. Learnt about the different types of Engine Noise.

HMSI VEHICLE QUALITY SC

DATE

TARGET

If we tight the nut of front Brake by 15mm and each front and rear combi brake by 10mm, then there will not be a problem of Brake Free play in 90% of vehicle.

HMSI VEHICLE QUALITY SC

HMSI VEHICLE QUALITY SC

R1

L1

R2

L2

R3

L3

R4

L4

• Electical • IGN offset• Handle lock op

• FHC,•Winker App• Frt Fork • Pivot Cover• FC, FCC

• L- Hook• BDC, CC, Mole• BDC sticker• BDC- RCC gap

• Color verification• Main stand pin & Washer• Muffler , RR wheel Nut

• L Box Bolts • Rear Grip• BDC Sticker• Mole

HMSI VEHICLE QUALITY SC

• Pillion step Cover• L-Cover• Kick Arm

• FC & FCC, Grommet• Frt Fork Arm , FLP• Frt Cable Routing

• Fork Play• Frt wheel Heavy• Chk all stn stamp • Unloading

1. Associate find difficulty to put vehicle on stand over conveyor.

2. Fixture does not provide tight grip to the vehicle.

Changes in the design of conveyor fixture.

HMSI VEHICLE QUALITY SC

HMSI VEHICLE QUALITY SC

S.No Defects Possible Solution

1. Head Light N/W

1. Check switch assembly.2. Check the bulb.3. Check the ACG Connection.4. Check the tail light bulb some times it get

shortened and break the fuse.

2. Winker not working 1. Change the bulb2. Change the winker cum relay

3. Self Start N/W

1. Check Self switch connection.2. Check Bulb should not be Short.3. Check Starter motor connection .4. Check ACG connection.

4. Self Start Continue 1. Check Starter relay2. Check connection of key set coupler.

HMSI VEHICLE QUALITY SC

DISMANTLING OF FRAME

DISMANTLEBDC

DISMANTLEFLP

DISMANTLEFCC & FC

DISMANTLEIC

DISMANTLEFHC & RHC

DISMANTLEBATTERY BOX

DISMANTLEFORK

DISMANTLEFT

•REMOVE ALL THE ELECTRICAL COUPLERS WHILE DISMANTLING & REMOVE THE HANGER BOLT TO REMOVE ENGINE FROM FRAME.•ASSEMBLED BACK THE VEHICLE IN REVERSE ORDER.

HMSI VEHICLE QUALITY SC

HMSI VEHICLE QUALITY SC

Ensure that Upper race cone and Lock nut should be tightened carefully with a torque wrench of 600 kgf-m.

If it is loose it will result in fork play.

If it is tight it will make the handle too hard to rotate.

Ensure that there must be

• 26 balls in upper race Cone• 19 balls in lower race cone

DISMANTLING OF ENGINE

REMOVE WIREHARNESS

SEPARATE FRAME AND ENGINE

DISMANTLE MUFFLER DISMANTLE SELF MOTOR & CARBURETOR

DISMANTLE FAN & ACGDISMANTLE L CASE COVERDISMANTLE CLUTCH & BELTDISMANTLE HEAD CVR,HEAD AND BLOCK

DISMANTLE L CASE DISMANTLE MISSION CASE DISMANTLE MISSION GEARS

HMSI VEHICLE QUALITY SC

HMSI VEHICLE QUALITY SC

HMSI VEHICLE QUALITY SC

HMSI VEHICLE QUALITY SC