balancing sheet

8/6/2019 Balancing Sheet

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DISCOVER-100 LINE BAL

Sr. No. Stage

1 Number punching

2 Bar code scanning

3 Frame loading on conveyor

4 Flag loading



5 Fairing insertion

6 Engine insertion

7

Engine fr. Bkt. Matching

8 Fr. Fender tightening

9 Chain slackness



10 Chaincase Fitment

11 Chaincase Tightening

12 Silencer gaskit fitment

13 Stem nut tightening

14 Thermal sensor connection

15 Handle bar fitment



16 Battery connection

17 Seat cowl fitment

18 GSL fitment

19

20 LH. Bellow insertion

21 CDI fitment

Handle bar routing& Coupler connection



22 Petrol tank fitment

23 Fr. No. platefitment

24 LH Side Panel Fitment

25

Fr.Brake connection

26

On Line Inspection

27

Scanning

1



2

Rear wheel fitment

3Rr. Br. Connection

4

Fork fitment

5

Fr. Fender Fitment

6

Engine insertion



7

Engine Fr. Bkt. Matching

8

Fr. Wheel fitment

9Engine Tightening

10

Focus

11

Rider step

12

Rr. Wheel alignment

13

Silencer fitment



14

RH fender tightening

15

Carburator Tightening

16

Cable routing

17

Coupler connection RH.

18

Throttel connection

19

Throttel cap prefitment



20

Starter motor connection

21Seat cowl tightening

22

Grab handle fitment

23

Clutch connection

24

Kick fitment

25

On Line inspection



NCING at 7.7 m/min CONVEYOR SPEED

Activity Time (in sec)

LH 1 2 3 4

Frame unloading and move towards m/c 6.4 8.3 8.8 3.1

Bearing race collection 1.9 2.8 3 3.2

Race on m/c and clamp and cycle start 3 1.1 4.6 2.6

A.C. box polybeg remove 5.3 5.3 4.6 5.2

Move back to trolley 4.5 4 2.3 3.2

TOTAL TIME 21.1 21.5 23.3 21.4

Move towards conveyor

Unload kitbin empty

bar code scan & puton p v card

Move towards m/c

PV card on veh

Rubber band removal

Declamp frame and unload frame

7.7 10.6 9.9 7.6Move towards conveyor

Open main stand and matching with rear wheel

Rear axle from kitbin5.4 4.8 5.7 4.8

Chain removal from sprocket and rear axle insertion

Remove tackle and move back 5.1 5.8 5.7 5.4

TOTAL TIME 18.2 21.2 21.3 17.8

Tackle on flag and flag on conveyor 4.1 4.8 6 5.5

Ball cage on head pipe

Paint application on number punched 2.4 4.8 3.9 6.6

Fitment of battery acid drain pipe 5.9 6.7 6.7 4.5



Move back 4.3 4.1 4.1 3.4

TOTAL TIME 18.6 20.4 20.7 20

Pick fairing from trolley 6.5 6.3 11.2 6.9

Stem nut and washer prefit 5.6 8.1 2.2 5.9

Placing battery pad 3.1 2.6 2.8 3.5

Move back 3 3 3 3.3

TOTAL TIME 18.2 20 19.2 19.6

Engine 14 mm Rr. 2 bolt insertion 7.7 12.6 8.1 15.5

Magneto coupler connection 11.2 4.6 11.1 4.4

TOTAL TIME 18.9 17.2 19.2 19.9

Engine fr. Bkt. Insertion with 12mm 3 bolt. 8.2 4.9 10.8 9.2

Clutch wire bracket connection 7.7 8.2 6.7 5.7

Declamp fix.5.4 3.7 3.2 3.3

Move back

TOTAL TIME 21.3 16.8 20.7 18.2

LH. Fender 2bolt prefitment & tightening 3.9 6.7 6.8 4.5

Clutch wire bkt. Tightening 4 4.6 4.5 6.1

Engine rr. Bkt. 2 bolt tightening 6 5.3 4.2 6

Shari Guard bkt. Bolt tightening 6.5 5.1 5.2 4.2

TOTAL TIME 20.4 21.7 20.7 20.8

Picking & inserting 2 bolts in front fork & Engine holding LH. Side 5.1 6.5 13.7 4.5

Chain routing9 8.9 4.5 10.8

Chain adjustmentMove back 1 2 1 1.5

TOTAL TIME 15.1 17.4 19.2 16.8

Chaincase from trolley to vehicle

10.5 16.7 10.3 11.9Lower chaincase fitment and 2 bolts prefit



Upper chaincase fitment

Stick barcode on head pipe 5.2 4.5 4.6 3.9

Move back & collect bolts 1.6 2.4 2.8 2.6

TOTAL TIME 17.3 23.6 17.7 18.4

tighten 4 bolts 11.3 6.1 6.2 4.8

Rr. Axle holding 4.8 9 11.2 7.3

Move back & collect bolts 2.2 2.4 2.1 3.2

TOTAL TIME 18.3 17.5 19.5 15.3

silencer gaskit fitment 4.2 3.6 6 5.2

brither pipe connection 7.4 5.6 6.7 3.5

TPS coupling 6.7 6.9 7.9 7.2

handle holder on frame 4.7 4.1 2.1 3.3

TOTAL TIME 23 20.2 22.7 19.2

Stem nut and fork upper bolts (2) tightening 7.6 7.2 7.4 6.7

Stem nut torque check

Silencer front prefitment 7.6 7.9 7.7 8.2

Move back 3.2 2.5 3.1 3.4

TOTAL TIME

tightening of silencer with gun 3.5 3.2 3.8 4

Thermal sensor connection 11.3 12.7 13.5 13.6

Move back 2.8 2 2.1 2.2

TOTAL TIME 17.6 17.9 19.4 19.8

Handle bar from trolley to frame 5.2 5.3 5.5 5.9Fork rotation

Handle holder on handle bar from frame 6.6 4.6 5.9 4.1

Handle bar bolts tightening (4) 4 5.3 4.7 4.9

Move back 1.50 1.50 1.40 1.50

TOTAL TIME 17.30 16.7 17.5 16.4



battery fitment 7.8 7.5 6.5

R.R cover tightening 10.7 5.3 7.7

Move back 1.5 2.5 2.2

TOTAL TIME 20.00 15.3 16.4

seat cowl from flag & spark plug connection

19.2 19.9 18.8 20.2seat cowl fitment

tail lamp coupler connection

TOTAL TIME 19.2 19.9 18.8 20.2

GSL fitment 8.4 8.1 8.8

arrester & flasher fitment 9.8 8.8 9.9

MOVE back 2 1.8 2.2

TOTAL TIME 20.2 18.7 20.9

tie band 4.4 3.9 3.5 4.4

SPM cable routing 13.5 14.5 13.2 11.2

3 coupler connection 3.9 3.4 2.5 3.1

TOTAL TIME21.8 21.8 19.2 20.4

Throttal cap tightening 2.4 2.1 1.9 1.8

GSL tightening 5.7 3.4 3.2 3

bellow insertion & clamping 7.2 7.6 10.4 8.3

clutch cable routing 2.1 4 2.4 5

move back 3.5 2.5 4.1 2.4

TOTAL TIME 20.9 19.6 22 20.5

CDI connection & fitment 3.4 3.4 4 2.5

carburetter tightening 16.2 14.1 13.3 14.6

Move back 2.3 2.9 2.6 2.3

TOTAL TIME 21.9 20.4 19.9 19.4



reflector tightening 4.3 5.9 3.9 4.2

insertion of SPM wire 2.8 6 3.4 3.2

petrol tank fitment 12.9 7.1 13.1 13.4

Move back 1.6 1.5 1.2 1.1

TOTAL TIME 21.6 20.5 21.6 21.9

front no. plate tightening 9.6 9 5.4 7.8

Cable clamping 2.7 3.4 2.7 2.8

petrol tank lock fitment 7.6 5.8 7 5

Move back 1.5 1.9 1.1 1.6

TOTAL TIME 21.4 20.1 16.2 17.2

Picking lock from fairy and unpacking it 3.6 3.7 3.9 3.5

putting lock washer chromate in side panel 10.8 10.5 11.7 9.8

lock fitment in side panel & P.T. 5.3 4.7 5.7 5

move back 1.5 1.8 1 1.9

TOTAL TIME 21.2 20.7 22.3 20.3

Fr. Br. Connection 11.6 13.3 12.2

flag unloading 4.3 3.5 3.7

Move back 2.1 1.9 1.4

TOTAL TIME 18 18.7 17.3

15.9 16.3 21.2 15.6

Scanning 3.9 4.2 4.6 5.1

S P M Screw tightening 2.8 3.1 2.6 3

TOTAL TIME 6.7 7.3 7.2 8.1

R. H.

Rear wheel loading 4.69 6.39 3.41

kitbin loading 4.21 4.47 6.44



Rear wheel panel on wheel 1.6 2.81 3.15

Move back 3.1 1.45 2.3

TOTAL TIME 13.6 15.12 15.3

rear wheel matching 4.8 4.6 7 6.6

adjuster fitment 4.8 4.8 6.5 3.6

nut & washer fitment8.4 8.2 3.8 6.6

move back

TOTAL TIME 18.1 17.7 17.3 16.8

To put carburator in kitbin 2 2.7 2.1

bearing cage in upper bearing of head pipe 1.3 1 0.9 1.2

carburator clip 4.2 4.8 2.2

rear brake fitment 13.8 13.4 14.6

Move back 1.5 2.2 2.3

TOTAL TIME 22.8 24.1 22.1

Collect fork from trolley to frame

Collect lug nut, dust cap and bearing cone from kitbin

Insert fork in head pipe 21.6 20.9 21.9 21.8

Prefit nut, tighten and torque reset by torque wrench

Move back

fuel pipe in carburetter 2.5 1.7 2.6 1.9

front fender to frame & Insertion of fender in fork 6.9 8.6 8.2 6.9

Prefit bolts (2) 4.1 6.9 4.7 4.4

Carburator positionning on ac box bellow

6.7 4.6 3.8 7.6Rr. Wheel nut washer prefitment

Move back

TOTAL TIME 20.2 21.8 19.3 20.8

Engine from trolley to vehicle and carburetor clip isert in engine bello

18.3 18.2 20.1 18.6Engine insertion with matching to carburetor

Move back to trolley



Engine Fr. Bkt. Match with LH. Bkt.11.9 16.5 13 13.5

3 nut prefitment

Torque rod bolt insert in pannel & torque rod 8.4 6.3 6.2 6.5

TOTAL TIME 20.3 22.8 19.2 20

Fr. Wheel from trolly 5.4 4 4.1 3

match brake pannel & speser 9 9.9 9.1 9.8

axle insertion & nut washer prefitment 6.5 8.6 5.6 6.5

move back 1.9 1.4 3.7 1.2

TOTAL TIME 22.8 23.9 22.5 20.5

Engine Tightening complete 17.8 17.7 19.2 18.4

focus bolt insertion 4.9 3.1 5.1

nut washer prefitment 3.2 2.5 3.1

torque rod bolt nut washer prefitment 5 4.7 7.3

TOTAL TIME 13.1 10.3 15.5

Fr. Wheel tightening 1.5 1.9 2 1.3Rider step 2 bolt prefitment & tightening 19 15.3 17.8 16

TOTAL TIME 20.5 17.2 19.8 17.3

right side reflector 6.1 3.4 5.3 3.7

Rr.wheel alignment & tightening 8.2 10.3 7.9 8.4

Torque rod tightening 3.9 3.3 3.6 4.7

Rr. Br. Play adjusment 1.9 1.4 2.2 2.8

move back 1.5 1.3 1.2 1.3TOTAL TIME 21.6 19.7 20.2 20.9

Silencer front matching with engine stud 6.6 7.1 7.1

Silencer Rr.bolt , nut & washer prefitment & clamp fix.& move back 14.4 13.5 13.5



TOTAL TIME 21 20.6 20.6

2 bolt tightening of fender 6.3 6.8 5.6

3 coupler connection & move back 16.4 15.9 16.2

TOTAL TIME 22.7 22.7 21.8

insulator insertion 7.7 12.4 7.5 8.9

Carburator clip Tightening & carburator tightening 10.9 6.7 10.9 9.6

TOTAL TIME 18.6 19.1 18.4 18.5

RH. Cable routing 17.1 15.9 14.7

silencer rear bolt tightening 3.7 3.4 3.8move back 1.5 2 2.2

TOTAL TIME 22.3 21.3 20.7

2 coupler connection 5.8 6.5 6.5

bellow insertion 11 12.1 11.2

auto-choke coupler connection 5.9 3.6 4.2

move back 1.5 1.2 1.3

TOTAL TIME 24.2 23.4 23.2

tie band of accelerator wire 2.4 2.6 2.8 3.4

Throttel connection 15.4 15.3 13.2 13.2

move back 2.3 3.2 1.9 2.1

TOTAL TIME 20.1 21.1 17.9 18.7

throttel lock pin fitment 4 6.3 6 5.7

Throttel cap prefitment 11.9 14 13.1 13.6

move back 2.9 2.4 2.5 2.2

TOTAL TIME 18.8 22.7 21.6 21.5

Starter motor connection 7.60 7.5 8.90



over flow pipe from carburator to frame 4.60 3.4 3.20

Earthing connection with engine 2.90 3.5 4.00

move back 3.50 2.9 2.60

TOTAL TIME 18.60 17.3 18.7

Seat cowl prefitment & tightening 9.2 11.6 13 11

RH. Adjuster tightening 4 3.2 6 3.8

focus bolt tightening 8.2 6 4.3 9.4

move back 1.9 1.5 1.2 1.2

TOTAL TIME 23.3 22.3 24.5 25.4

RH reflector tightening 2 2.2 2.3

Grab handle pre fitment & tightening with RH. S/P clip insertion 20.2 19.2 20.1

TOTAL TIME 22.2 21.4 22.4

clutch cable routing from outside with clutch play adjustment 19.1 18.2 18.3

move back 2.2 2.5 2.8

TOTAL TIME 21.3 20.7 21.1

RH. S/P fitment & tightening

kick fitment & tightening

Rr. Br. Light adjusment

18.2 17.8 17.3 17.2



MAN/P

AVG.

6.6

2.7

2.8

5.4

3.5 1

21

1

9

5.2

5.5 1

19.6

5.1

4.4

6



4 1

19.5

7.7

5.5

3

3 1

19.2

11

7.8

18.8

8.3

7

3.9 1

19.2

5.5

4.8

5.4

5.2

21 1

7.4

8.3

1.4 1

17

12.4



4.6

2.4 1

19.4

7.1

8

2.5 1

17.6

4.7

5.8

7.2

3.6

21.2

7.3

7.9

3.1

18.3 1

3.6

12.8

2.3 1

18.7

5.5

5.3

4.7

1.50

17.0



7.3

7.9

2

17.2 1

19.5

19.5

8.4

9.5

2

19.9

4

13.1

3.2 1

20.3

2

3.8

8.3

3.4 1

3.1

20.6

3.3

14.5

2.5 1

20.3



4.5

3.8

11.6

1.4

21.2

7.9

2.9 1

6.3

1.5

18.6

3.7

10.7

5.2

1.6

21.1

12.4

3.8

1.8 1

18

17.3 1

4.5

2.9 1

7.6

27

4.8

5



2.5

2.3 1

14.5

5.7

5

6.8

17.5

2.3

1.1

3.8

14

2

23.2 1

21.6

1

2.1

7.6

5

5.7 1

20.3

18.8 1



13.7

6.8 1

20.5

4.1

9.5

6.8

2 1

22.4

18.3 1

4.4

2.9 1

5.7

13

1.6 117

18.6

4.6

8.7

3.8

2 1

1.320.4

7 1

13.8



20.8

6.2

16.2

22.4

9.2

9.5 1

18.7

15.9 1

3.71.9

21.5

6.3 1

11.4

4.5

1.3

23.5

2.8

14.2

2.4 1

19.4

5.5 1

13.2

2.5

21.2

8.0



3.7

3.4

3.0

18.1 1

11.2

4.3

7

1.4 1

23.9

2.1

19.8 1

21.9

18.5 1

2.5

21

1

1

18

25

balancing sheet

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