Project

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 1

CERTIFICATE

This is to certify that the project entitled ldquoStudy of various parts of

Carrier and functions and its problem analysisrdquo is submitted by Mr

RAMNEESH SINGLA of the NATIONAL INSTITUTE OF KURUKSHETRA

(HARYANA) for the award of the degree in B Tech (Mechanical

Engineering) is a bona fide record of work carried out by him under my

supervision The contents of these theses in full or in parts have not

been submitted to any other institute or university for award of any

degree

Mr Vivek Sharma Ms Shelly Juneja

Executive HR Department

Frame Maintenance HMSI

HMSI

ACKNOWLEDEMENT

I Ramneesh Singla a student of mechanical 2nd year National Institute of Technology Kurukshetra(Haryana) would like to give my heartiest thanks to all under whom I completed my summer training I would like to express my deep gratitude to Ms Shelly Juneja amp Ms Kavita Pandey who gave me opportunity to do training at Honda Motorcycle and Scooter India Limited

I feel highly obliged and my heartiest thanks to Mr K K Chauhan Manager of Maintenance department who give wonderful project to do and a department which has provided me an immense learning and practicalities of actual problems faced at the strategic and functional level

I would like to thanks my project guide Mr Vivek Sharma amp Mr Virender Singh who showed me the way throughout My sincere thanks to Mr Vishal Sharma Mr Jagtar Singh Mr Rajender Dev they actually explained me the system flow and made me well versed with the intricacies of the project and were always available to solve my queries however trifle they may be

The acknowledgement would be incomplete if contribution of whole manufacturing division is not applauded as a whole I sincerely thank all of them for their cooperation and guidance during my tenure at HMSI

[RAMNEESH SINGLA]

EXECUTIVE SUMMARY Honda Motorcycles and Scooters India (Pvt) Ltd (HMSI) - The name speaks for itself and needs no introduction in the field of two-wheelers This esteemed organization has a name in the field of motorcycles and motor-scooters After being established in 1999 in a short span of time it has developed a reputation of providing world-class products with a technology to suit Indian conditions HMSI has always striven to provide the highest quality products in accordance with ISO 9001 for worldwide customer satisfaction No doubt the policies and procedures followed by HMSI are of world standard but with the growing competition and to cut cost in this price competitive market scope of improvement is always there and welcomed HMSI is always known for its quality and I feel very proud to be a part of such an esteemed organization In this span of my summer training I was deputed in the frame maintenance section (Scooter Plant) I was assigned projects which were of utmost importance to the frame maintenance section ie ldquoTo study the various parts and functions of a carrier and its problem analysisrdquo I came to know about the working of the maintenance department various parts of a carrier its motion its functions reasons for the breakdown of a carrier and countermeasures and the preventive maintenance of the carrier

During this project I learned a lot of things about the 5-S rule cause amp effect analysis the 3G approach section performance analysis amp counter measure TQM (Total Quality Management) etc which was very important from the industrial point of view I also got the opportunity to visit various other departments in the motorcycle and scooter plant of the company to know amp understand how the final vehicle was taking shape I visited press weld paint machining shops vehicle quality area engine and frame assembly

Contents

Company Introduction

Introduction to HMSI

Plant Overview

Flow Chart

Products

Honda Philosophy

Organizational Structure

Introduction to Maintenance Department

Project

Bibliography

1COMPANY

INTRODUCTION

11 HONDA HISTORY

FOUNDER - SOICHIRO HONDA ESTABLISHED AT - HAMAMATSU (JAPAN) ON 24 TH SEP 1948

MR HONDA helliphelliphellip A MAN AND HIS DREAM

He dreamed of providing people everywhere in the world an economical means of transportation He thought of better ways of making piston rings and found a company amp began production Then his company started producing small motorcycles including one built in 1949 called D-type dream

Then he thought of making high capacity motorcycles and taking them to racing So his company made bigger and faster machines two- four- five- and six-cylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle class)

He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co in Los Angeles Also Honda began manufacturing motorcycles at its Suzuka factory in 1960 Honda launched its first sports car the S500 in Japan and entered Formula-1 in 1964

In 1989 Soichiro Honda became the first Asian to be inducted into US Automotive Hall of Fame In 1990 Honda wins its fifth consecutive 1st ranking in the JD Power Consumer Satisfaction Index In 1993 founder Soichiro Honda passed away He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful amp fun to ride SOICHIRO HONDArsquoS dreams changed the world of motorcycling

Time Line of Honda and Its

History

And This Decadehelliphelliphelliphellip

200

1

500 World Grand Prix Victories

200

2

Race Debut of New 4 Stroke 5 Cylinder

Motorcycle (Called RC211V)

200

3

Mazda RX First Hydrogen Engine Car Unveiled At

Tokyo Car Show

Honda Enters Indy Car Series

Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race

Market feasibility Study For Air Craft Engine Begins

200

5

Asimo Inducted Into Hall of Fame

12 Hondarsquos Products Around The World

Jet Engine

Honda ndash At a Glance-

1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)

1048708 26th on global most admired

1048708 Capital - yen86 Billion (as of March31 2007)

1048708 Sales (Results of fiscal 2007)

1048708 Consolidated yen11087140 million

1048708 Unconsolidated yen4030881 million

1048708 405 subsidiaries (as of March31 2007)

1048708 Employees HONDA worldwide ndash

1048708 Consolidated 167231 (as of March31 2007)

1048708 Unconsolidated 26652 (as of March31 2007)

Honda Global Network

Six Regional Headquarters

North Central America South America

Afro-Europe

Asia amp Oceania

Japan

China

2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)

Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo 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 Hondarsquos 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 benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow

process in plant 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 Twister Dio Aviator Unicorn Shine Dazzler and Stunner 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 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores

HMSI mainly deals with-

Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)

Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -

1 Registered office Plot No 1 Sector 3 IMT Manesar

Distt ndash Gurgaon

2 Incorporation August 20th 1999

3 Equity capital Rs 300crores (Approx7500 million yen)

4 Area Land area 210000 sq m

Covered area 85815 sq m (41 )

5 Employees 3821 Associates ndash Japanese 15

6 Product Scooters ndash Activa Dio Aviator

Motorcycle- Unicorn Shine Stunner Twister Dazzler

7 Plant capacity 1000000 CBUrsquos per annum

SC ndash 600000 MC ndash400000

8 Logo WINGS

9 Directors Mr Shinji Aoyama President amp CEO

Mr H Nagata ( SrVP ) Mr Y Mizutani (Dir)

Mr H Iwakami ( Dir ) Mr M Kato ( Dir )

Mr T Oyama ( ASH ) Mr MTakedagawa

(HSCI) Mr K Nakazono ( HM-J )

Special features-

1048708 ISO 9001 2000 and 14001 Certified

1048708 ARAI Emission Lab Pune Certified

Society Friendly Organization

1048708 Worldrsquos No1 in Engine designing

3 PLANT OVERVIEW

Area 210000 sq m

Production155 million unitsyear

Location IMT Manesar

Incorporation 1999

Employees 6500

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 Aviator Lead and

Beat are being made In Motorcycle plant Unicorn

Shine and Stunner Aviator are being made

4 FLOW CHART

5 PRODUCTS-

2001

Started with mass production of 1st scooter Activa

lsquoScooter of the year awardrsquo for Activa

ISO-9001-2000 Certification by TUV Germany

2002

Launched new motor scooter Dio

ISO-14000 Certification by TUV Germany

BBC Wheel Award for Dio

Export started 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

HMSI established new motorcycle plant

Launched 1st 150 cc motorbike Unicorn

CKD export to Latin America

Bike of the year award to Unicorn

2005

SO-140012004 Certification by TUV Germany

Unicorn Tops in TNS Consumer Satisfaction Survey in ldquoPremium Motorcyclerdquo category

Activa achieved landmark sales target of 1 million units

2006

HMSI launched its 2nd Motorcycle model SHINE a 125cc segment Motorcycle

HMSI successfully launched LEAD in Australian Market

HMSI launched new variant ACTIVA amp BEAT CKD for Mexican Market

2007 Launch of new scooter AVIATOR It is a E-class scooter of 102cc

With Disc brake

2008 HMSI launched its 3rd Motorcycle STUNNER a 125cc bike with a sporty look

2009 HMSI launched its 4th Motorcycle TWISTER a 110cc bike which was the first bike in India with lower engine capacity and high style

2010 HMSI launched a new model of Unicorn with the name Unicorn Dazzler 150 cc bike

6 HONDA PHILOSPHY

It provides every Honda associate around the world with a vision It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision

Company

Principle

Company

Principle

THE THREE JOYSTHE THREE JOYS

HONDA PHILOSOPHY

Management Policies

RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL

It helps our organization to maintain its sense of uniqueness

COMPANY VISION-

Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction

OUR FUNDAMENTAL BELIEFS-

Respect for the individual The three joys

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 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 An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities

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 companyrsquos success And every associate should be honored for these efforts

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 products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of 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 customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and 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 Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done

THE HONDA COMPANY PRINCIPLE-

Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction

HONDA MANAGEMENT POLICIES-

Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the

effective use of time

Enjoy your work and encourage open communications

Strive constantly for a harmonious flow of work

Be ever mindful of the value of research and endeavor

HONDArsquoS CORPORATE CULTURE-

Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution

JAPANESE WORK CULTURE

A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life Other-centered work centered long term relationships

How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth

ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON

PHILOSPHY WITHOUT ACTION IS WORTHLESS

SOICHORO HONDA

HMSI Plant Facilities

Few of the In-House Facilities

High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting

Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts

Welding Robots

Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels

Paint Shop Robots

Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish

Engine Assembly

Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters

Frame Assembly

Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch

7ORGANISATION STRUCTURE

President and CEO

Sr VP

PurchaseGeneral Affairs

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop Weld Shop Paint Shop

MaintenanceUtility

K K CHAUHAN

8 Introduction to Maintenance Department

Introduction The maintenance department is one of the most important departments of the organization where the organization has its own production Maintenance department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the breakdowns which occur in the machines or where there is any production loss so when to overcome the problem of production loss maintenance team has to work efficiently so that there is no mistake committed by them by which production loss occurs

Some important definitions used by maintenance

Maintenance Action necessary for retaining or restoring an equipment machine or system to the specified operable condition to achieve its maximum useful life It includes planned and preventive maintenance

Planned Maintenance Preventive maintenance carried out according to a fixed plan is called planned maintenance

Preventive Maintenance Systematic inspection detection correction and prevention of incipient failures before they become actual or major failures is called as preventive maintenance

Breakdown Maintenance Repair or replacements performed after a machine has failed to return to its functional state following a malfunction or shutdown is called as breakdown maintenance

Predictive Maintenance Type of preventive maintenance performed continuously or at interval according to the requirement to diagnose and

monitor a condition or system also called condition based maintenance is called as predictive maintenance

Mean Time To Repair (MTTR) Basic measure of maintainability of repairable items it represents the average mean time required to repair a failed component or device is defined as mean time to repair

Mean Time Between Failures (MTBF) Basic measure of the reliability of repairable items it represents the average number of a life units during which all parts of a device or system perform within their specified limits under specified conditions are called as mean time between failures

Down Time Period during which an equipment or machine is not functional or cannot work It may be due to technical failures mechanical adjustments maintenance or non availability of inputs such as materials labor and power etc is called as down time

Frame Maintenance In this department there are three sections

1 Press Section

2 Weld Section

Maintenance Department

Engine Maintenance Frame Maintenance

3 Paint Section

PRESS SECTION Press section has mainly four machines

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done

Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation

Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes

CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame

WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers

1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer

2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up

3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter

4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter

5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters

6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it

When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay

PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone

Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism

Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed

Electro-Deposition In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on

the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven

ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth

Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat

In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven

Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection zone

Inspection Zone In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area

Unloading In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line

9 ProjectProject Definition

To study the various parts of the carrier being used in the paint shop and its problem analysis

Project Introduction

Carrier is defined as a thing which supports or holds up a part during its movement It is used to carry parts to the paint shop where various processes can be performed Carrier forms the basis of the Paint Shop because the movement of the parts from one point to another in the paint shop takes place only due to carrier The parts are loaded on the carrier with the help of a jig and then the motion takes place

Paint shop carrier is the most important moving part in the paint process Most problems and the breakdowns in the paint shop occur due to the carrier only It causes loss to the net production Bends or breaks due to load of body part applied on carrier causes distortions which ultimately results in the breakdown

Carrier is a part of the conveyer system being used in the paint shop The other components of the conveyer system are the prime mover drive (works as the input motion source for chain) chain and chain track carrier carrier turn (for turning the carrier) carrier

revolution (for revolving the carrier) stopper (it temporarily stops the carrier on line) carrier locks auto feeder cylinders and drop lifters which support the motion of carrier

Part Description Of Carrier

Rail

Rail can be of two types ie pre rail and power rail Pre rail is used to drive trolley of the carrier Power rail is used to drive the conveyer system

Gear Box

Gear Box acts as a Speed Reducer It consists of a worm and worm-wheel arrangement which turns the axis of rotation by 90deg and reduces the speed of the parts The gear box is coupled with the small sprocket Gear transmits power to small sprocket which helps for carrier turn this is also called as reduction gear The relation between the torque and diameter of worm shaft is given by

T (Kg-m) = π16dsup3τ

where τ is the twisting moment

Velocity Ratio = 160

Tensile Strength of Material = 60 Kgmmsup2

Trolley

There are two trolleys present in a carrier namely Front and the Rear Trolley Front Trolley stops the carrier at a specified position by the actuation of stopper while Rear Trolley stops the next carrier by engaging with the Front trolley of next carrier Trolley Wheel contains ball bearings The outer race serves as a wheel A grease fitting is installed as a greasing port Guide Roller is installed to reduce friction against free rail Pivoting Dog is lifted by the own weight The chain pusher engages to the Pivoting dog for transport To stop the carrier the stopper (installed on the line) pushes down the Pivoting Dog to release the engagement with the pusher

Swivel Pipe

Swivel pipe is used to drive carrier during carrier revolution Swivel pipe is connected to the shaft of worm gear thus it also gets its power from the gear box

Big Sprocket

It comes in contact with the chain of the carrier turn and is responsible for rotation of the carrier It is mounted on the spindle on which the pan cover is fixed Four carrier dogs are attached to it which control the rotation of the carrier Big sprocket is attached to the spindle shaft plate

Small Sprocket

It is attached to the shaft connected to gear box It comes in contact with the chain of carrier revolution and is responsible for the revolution of the carrier

Tension Spring

Spring is used to lock turning plate thus stopping carrier revolution It happens when there is no load on the spring But when the load is applied turning plate opens and hence carrier revolution occurs

Insulator Collar

It provides insulation to the carrier in ED process so that there is no current in the frame To avoid the flow of current in the rail of the conveyer system and to avoid damage to the whole system insulator collars are provided

Post

It is mounted on the pan cover and holds the jig by locking it at its position Post mainly has three parts post cover post spacer and post spacer

Coupling

Bush Coupling transfers the motion from small sprocket shaft to input shaft To avoid overloading at the gear box bush coupling is provided

Guide Pin Arm

It locks the turning of the Big Sprocket by elongating the spring connected to it It has three contact points one is the spring one touches the guide pin of the carrier turn and third is for the engagement and disengagement of big sprocket

ED Collector

ED collector is used to collect current during ED process and transmits it through the cables to the body parts

End Striker amp Turn Striker

They are used to control the turning and revolution of the carrier respectively While end striker controls the revolution of the carrier turn striker controls the rotation of the carrier

Pan Cover

It is a cover which protects the carrier from paint and ED It acts as a shield for carrier It is 480480 mm

Pan Cover

Preventive Maintenance of Carrier

Preventive Maintenance can be described as maintenance of equipment or systems before fault occurs Preventive Maintenance for the case of carriers is done semi-annually Maintenance of 28 carriers is done in a month Preventive maintenance is the systematic inspection detection correction and prevention of incipient failures before they become actual or major failures

Preventive Maintenance Procedure

1) OPEN RAIL OF CONVEYER LINE

Tool Used D Spanner (size 18-19 mm)

Time Taken approx 2 min

Procedure Open the nuts of the rail bracket by using the spanner of the above mentioned size

2) TIE CARRIER WITH THE HOIST

Tool Used Hoist

Procedure Fix the first attachment with the gearbox bracket small hook in the frame above the front trolley and big hook in the shaft pipe which is attached to the small sprocket

3) LIFT AND TAKE OUT THE CARRIER FROM THE LINE

Tool Used Hoist

Procedure Lift the carrier with the hook of the hoist and remove it from the line Then put it on the rail where preventive maintenance is to be done

4) DISASSEMBLE THE POST

Tool Used Ring Spanner (size 16-17 mm)

Procedure Open the bolts with the specified tool which fasten the post with the big sprocket

5) CLEAN THE ARM

Tool Used Scrapper

Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper

6) CLEAN THE BIG SPROCKET

Tool Used Scrapper

Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper

7) CLEAN THE BIG SPROCKET DOGS

Tool Used Scrapper

Procedure Clean the four dogs at the big sprocket of the carrier by removing the paint deposited with a scrapper

8) OPEN THE END PLATE OF THE BIG SPROCKET

Tool Used Allen Wrench (size 4 amp 6 mm)

Procedure Insert the Allen wrench and rotate them to open up the Allen bolts which fasten the end plate to big sprocket

9) REMOVAL OF BIG SPROCKET FROM THE CARRIER

Tool Used

Procedure Lift the big sprocket from spindle shaft panel

10) OPEN THE SPLIT PIN OF ARM ROLLER

Tool Used Long nose plier

Procedure Straighten up the fixed pin and pull them out of the castle nut of the roller using a long nose pliers

11) OPEN THE SPLIT PIN OF LOCKING ROLLER

Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using a long nose plier

12) OPEN THE SPLIT PIN OF ARM PIN

Tool Used Long nose pliers

Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers

17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL

Tool Used Ring spanner (size 18-19 mm)

D spanner (size 20-22 mm)

Procedure Support the castle nut from bottom using D-spanner and tighten it up using a ring spanner

18) INSERT NEW SPLIT PINS

Tool Used Long Nose Pliers

Procedure Insert new split pins and cross them up

13) OPEN THE CASTLE NUT OF ARM ROLLER

Procedure Open the castle nut by giving support from the D spanner

14) OPEN THE CASTLE NUT OF LOCKING ROLLER

15) OPEN THE CASTLE NUT OF ARM PIN

16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL

Procedure Straighten up the crossed pins and pull them out by using long nose pliers

21) CLEAN THE FRONT TROLLEY

Tool Used Scrapper

Procedure Clean the paint sticking to front trolley from top first and then clean the whole trolley by lifting carrier with hoist

22) CHANGE PIVOTING DOG PIN

Tool Used Punch and Hammer

Procedure Take out the old pin inserted in the pivoting dog of the front trolley by hammering with a punch

23) INSERT NEW PIN

Tool Used Hammer

Procedure Insert the new pin by hammering it with a hammer

24) CLEAN THE ARM PIN

Tool Used Amery Paper

Procedure The pin is first clamped to the fixture and then is rubbed by emery paper to clean the dirt sticking to it

19) CLEAN THE SMALL SPROCKET

Tool Used Scrapper

Procedure Clean the small sprocket of the carrier by using a scrapper

20) CLEAN THE BACK TROLLEY

Tool Used Scrapper

Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist

25) GREASE THE LARGE ROLLER

Tool Used High Temp Grease

Procedure Grease the roller with high temperature grease

26) GREASE THE SMALL ROLLER

27) GREASE THE PIN HOLES OF ARM

Procedure Grease the holes of arm with high temperature grease

28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL

29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS

(size 30-32 mm)

Long nose pliers

Procedure Rollers are fastened up back to the arm with castle nuts and the new split pins are inserted in the castle nuts

30) ASSEMBLE THE ARM ON THE SPINDLE SHAFT PLATE

Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm

31) GREASE THE SPINDLE SHAFT

Procedure Grease the spindle shaft with high temperature grease

32) GREASE THE BIG SPROCKET HOLE

33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT

Tool Used

Procedure Put the big sprocket back on the spindle shaft and clean the excess grease coming out of the sides of hole

34) ATTACH THE END PLATE OF BIG SPROCKET

Tool Used Allen Wrench

Procedure Fasten the end plate back on the big sprocket using Allen wrench

35) OPEN THE GRUB SCREW OF GEAR BOX

Tool Used Allen Wrench (size 6 mm)

Procedure Open the grub screw of the gear box to change the old lubricating oil present in gear box using Allen wrench

36) COLLECT THE OLD OIL IN A BIN

Tool Used

Procedure Collect the old lubrication oil in a bin with proper handling

37) REASSEMBLE GRUB SCREW

Procedure The grub screw is fitted back in the gear box using Allen wrench

38) OPEN THE GEAR BOX OIL CAP

Tool Used

Procedure Open the gear box oil cap

39) POUR NEW OIL IN GEAR BOX

Tool Used Mug and Grade 220 oil

Procedure Pour new lubrication oil in the gear box

40) GREASE THE FLANGE BEARING OF SMALL SPROCKET

Time Taken approx1 min

Procedure Grease the bearing with high temperature grease

41) GREASE ROLLER BEARING OF GUIDE ROLLER

42) GREASE THE TROLLEY BEARING

43) GREASE THE ROLLER BEARING

Procedure Lift the carrier with belt of hoist and attach the greasing gun rod with the bearing cap and push it inside

44) REWRITE THE NUMBER OF CARRIER

Tool Used Marker

Procedure Rewrite the number of carrier with permanent marker on the gear box frame and gear box bracket

Problem Analysis Of Carrier

Frame Hole NG

During the motion of the carrier when it is suddenly stopped by the stopper vibrations are produced in it and the pin inserted in the hole of the frame enlarges the size of the hole thereby causing the problem of frame hole NG

To reduce this problem an anti back-up system is applied to reduce the vibrations The NG frame hole is repaired by welding a bush at the site of the hole which is a newly developed Kaizen

Problems Caused By Loading

Improper loading of the frame body on the carrier damages the insulator collar because an unbalanced force acts upon it and insulator collars being the non-metallic parts are severely affected

R is the resultant vector

This is a production problem which causes the bending of jigs unbalancing of the carrier thereby causing improper motion at the carrier turns and revolutions and also resulting in the body parts falling in the oven

Gear Box Failure

Gear box of the carrier also fails some time due to overloading or improper coupling

Bending of Striker

Overloading at CTs and CRs causes the bending of the strikers which result in altered motion of the carrier

Breaking of Post

The post of the carrier can be broken due to variable and unbalanced load acting on the carrier The stresses are developed in the post which leads to its breaking Moreover hammering of the nut for the proper locking can also cause the breaking of nut

Overloading

Overloading is the state when the load on a part of the carrier is higher than its tolerance value Its causes are

If any object interrupts the motion of chain chain is not able to move forward properly causing overloading of chain

Improper position of the jig may lead to unbalancing of the carrier and overload may occur

Guide pin may not properly interact with the arm which may lead to non-alignment

Chain of the carrier turn may not be in proper position leading to overload at CT

Breaking of any of the carrier dogs will lead to improper revolution of the carrier

Other Problems

Cable breaks -gt Current does not reach to body part

ED COLLECTER burns out -gt It would not collect current

Threading of endndashplate striker wear out -gt Striker would not hit limit switch

Bush between coupling is cut

Bearing sometimes disrupts system

Swivel pipe bends -gt Carrier wouldnrsquot be leveled

Insulator sometimes fails to stop current

End plate threading wears

Spindle shaft bends -gt Carrier wouldnrsquot be leveled

Striker and arm also bends

Conclusion

From my project of one month here in HMSI I came to know that how

work goes on in the organization As far as my project of study

maintenance and breakdown analysis of carrier is concerned I came to

know the importance of carrier in paint shop and the production

problems caused by the carrier in the industry The carrier being used in

the paint shop is the best possible system for proper painting of parts

By knowing the various specifications problems related to it can be

solved

BIBLIOGRAPHY

Website

wwwHonda2wheelersindiacom

References

MrVirender Singh Mr Vivek Sharma MrVishal Sharma MrJagtar Singh Mr Rajender Dev

Sources

Workshop of HMSI

Frame Maintenance department of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

CERTIFICATE

This is to certify that the project entitled ldquoStudy of various parts of

Carrier and functions and its problem analysisrdquo is submitted by Mr

RAMNEESH SINGLA of the NATIONAL INSTITUTE OF KURUKSHETRA

(HARYANA) for the award of the degree in B Tech (Mechanical

Engineering) is a bona fide record of work carried out by him under my

supervision The contents of these theses in full or in parts have not

been submitted to any other institute or university for award of any

degree

Mr Vivek Sharma Ms Shelly Juneja

Executive HR Department

Frame Maintenance HMSI

HMSI

ACKNOWLEDEMENT

[RAMNEESH SINGLA]

Contents

Plant Overview

Flow Chart

Products

Honda Philosophy

Project

Bibliography

1COMPANY

INTRODUCTION

11 HONDA HISTORY

History

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

ACKNOWLEDEMENT

[RAMNEESH SINGLA]

Contents

Plant Overview

Flow Chart

Products

Honda Philosophy

Project

Bibliography

1COMPANY

INTRODUCTION

11 HONDA HISTORY

History

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Contents

Plant Overview

Flow Chart

Products

Honda Philosophy

Project

Bibliography

1COMPANY

INTRODUCTION

11 HONDA HISTORY

History

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Contents

Plant Overview

Flow Chart

Products

Honda Philosophy

Project

Bibliography

1COMPANY

INTRODUCTION

11 HONDA HISTORY

History

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

1COMPANY

INTRODUCTION

11 HONDA HISTORY

History

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

History

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

History

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

200

1

200

2

200

3

Tokyo Car Show

200

5

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Jet Engine

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Afro-Europe

Asia amp Oceania

Japan

China

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Distt ndash Gurgaon

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

8 Logo WINGS

Special features-

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

3 PLANT OVERVIEW

Area 210000 sq m

Incorporation 1999

Employees 6500

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

PLANT LAYOUT

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

4 FLOW CHART

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

5 PRODUCTS-

2001

2002

2003

2004

2005

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

2006

With Disc brake

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

6 HONDA PHILOSPHY

Company

Principle

Company

Principle

HONDA PHILOSOPHY

Management Policies

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

COMPANY VISION-

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

THE THREE JOYS

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

SOICHORO HONDA

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Welding Robots

Paint Shop Robots

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Engine Assembly

Frame Assembly

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

President and CEO

Sr VP

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

MaintenanceUtility

K K CHAUHAN

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

1 Press Section

2 Weld Section

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

3 Paint Section

Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading

PAINT PROCESS FLOW

1 Sanding Zone

2 Under Coat

3 Top Coat

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Rail

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Gear Box

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Trolley

Swivel Pipe

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Big Sprocket

Small Sprocket

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tension Spring

Insulator Collar

Post

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Coupling

Guide Pin Arm

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

ED Collector

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Pan Cover

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tool Used Hoist

5) CLEAN THE ARM

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tool Used Scrapper

Tool Used

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tool Used Scrapper

23) INSERT NEW PIN

Tool Used Hammer

Tool Used Scrapper

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

(size 30-32 mm)

Long nose pliers

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Tool Used

Tool Used Marker

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Frame Hole NG

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Gear Box Failure

Bending of Striker

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Breaking of Post

Overloading

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Other Problems

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Conclusion

solved

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

BIBLIOGRAPHY

Website

References

Sources

Workshop of HMSI

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Utility
K K CHAUHAN
EXECUTIVE SUMMARY

Date post:	28-Nov-2014
Category:	Documents
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