presented by- tamal mukherjee

Indus Business Academy

(FPG/1012/025)

PRESENTATION ON-“OPERATION PROCESSING STANDARD OF PRESS PARTS PACKING

IN TRANSPORTATION TROLLEYS”

HONDA SIEL CARS INDIA LTD.

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

continued….

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Learning Conclusion References

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley

3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

After GNU, 2nd facility was set up in 2008Spread over 600 acres with investment of 1000cr.Annual capacity- 60000 units Inaugurated in- Sept’2008Press parts & PT parts manufactured Parts supplied to GNU for final assemblyEvery scope of producing Brio in this facility

About HSCI, TKR plant

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart allied with press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

Project associated with PLC Dept. of HSCI, TKR plant To ensure ideal & accurate delivery of press parts to GNU To establish checking standards for each transportation trolley

used for 2PY, 2AZ & 2CV Setting check points of the transportation trolleys in 3 stages-

1) Trolleys in dismantled condition

2) Trolleys in assembled condition

3) Trolleys packed with press parts To avoid any damages like scratches, dent, flange bend over the

parts Newly set up plant, preparing OPS with respect to PLC Dept.

Project Premise

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart allied with press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

Delivers the right quantity, right quality of material on the line at right time & right place to meet the required production target

Responsible for supplying all the necessary material for production

In PLC team, few private companies are-

Introduction of PLC Dept.

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart allied with press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

PLC Responsibilities

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

Press parts Identification

continued….

HONDA CITY (2PY) HONDA JAZZ (2AZ) HONDA BRIO (2CV) 1) HOOD SKIN 1) HOOD SKIN 1) HOOD SKIN 2) TRUNK LID SKIN 2) TAIL GATE SKIN 2) SPOILER 3) FR. DOOR SKIN (R) 3) FR. DOOR SKIN (R) 3) FR. DOOR SKIN (R) 4) FR. DOOR SKIN (L) 4) FR. DOOR SKIN (L) 4) FR. DOOR SKIN (L) 5) RR. DOOR SKIN (R) 5) RR. DOOR SKIN (R) 5) RR. DOOR SKIN (R) 6) RR. DOOR SKIN (L) 6) RR. DOOR SKIN (L) 6) RR. DOOR SKIN (L) 7) FR.FENDER (R) 7) FR.FENDER (R) 7) FR.FENDER (R) 8) FR.FENDER (L) 8) FR.FENDER (L) 8) FR.FENDER (L) 9) ROOF PANEL 9) ROOF PANEL 9) ROOF PANEL 10) SPO (RH) 10) SPO (RH) 10) SPO (RH) 11) SPO (LH) 11) SPO (LH) 11) SPO (LH) 12) FRONT FLOOR 12) FRONT FLOOR 12) FRONT FLOOR 13) REAR FLOOR 13) REAR FLOOR 13) REAR FLOOR 14) TRUNK LID FRAME 14) TAIL GATE FRAME 14) SPOILER FRAME 15) HOOD FRAME 15) HOOD FRAME 15) HOOD FRAME 16) FR. DOOR PANEL(R) 16) FR. DOOR PANEL(R) 16) FR. DOOR

PANEL(R) 17) FR. DOOR PANEL(L) 17) FR. DOOR PANEL(L) 17) FR. DOOR

PANEL(L) 18) RR. DOOR PANEL(R) 18) RR. DOOR PANEL(R) 18) RR. DOOR

PANEL(R) 19) RR. DOOR PANEL(L) 19) RR. DOOR PANEL(L) 19) RR. DOOR

PANEL(L) 20) PANEL RR. INSIDE(RH) 20) PANEL RR.

INSIDE(RH) 20) PANEL RR. INSIDE(RH)

21) PANEL RR. INSIDE(LH) 21) PANEL RR. INSIDE(LH) 21) PANEL RR. INSIDE(LH)

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

Process flow chart with allied press parts

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

Two or four wheeled carriageUsed to carry goodsUsed to move according to needs In HSCI, TKR plant trolleys are used for dispatching

good to GNU

Trolley Introduction

continued….

Pictorial form

2PY TROLLEY 2AZ TROLLEY 2CV TROLLEY

CONROD TROLLEY CRANKSHFT TROLLEYPRESS TROLLEY

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

Classification of Trolley

TROLLEYS

Transportation Trolleys

Trolleys for press parts

Trolleys for PT parts

Press Trolleys

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

Specialty of transportation trolley

To absorb shocks during transportation, appropriate absorbers are used in each trolleyTo avoid part damages and scratches, few special materials like style foam, EVA sheet, PU sheet, PVC pipe are usedTo avoid jerks during transportation, shock absorbing wheel are used in the trolley which is known as caster wheel. These wheel are of two type- a) fixed wheel b) movable wheelFor toeing so many trolleys together, toeing bar with toeing hook is used in each of the trolley

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

Classification of transportation trolley

Transportation trolleys

Unique/Different trolleys(Trolleys in which press

parts of a single model is packed)

Common trolleys(Trolleys in which press

parts of each of the three models can be packed)

FR. FENDER (R & L)ROOF PANELSPO (R & L)PANEL RR. INSIDE (R & L)FRONT FLOORREAR FLOORTRUNK LID/TAIL GATE SKIN/SPOILERTRUNK LID/TAIL GATE/SPOILER FRAME

HOOD SKINHOOD FRAMEFR. DOOR SKIN (R & L)RR. DOOR SKIN (R & L)FR. DOOR PANEL (R & L)RR. DOOR PANEL (R & L)

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

Identification of common trolley

This location in trolley (blue color) is used for packing 2PY parts

This location is common for 2AZ & 2CV in a single trolley. Yellow color is for 2AZ & Red color is for 2CV parts

FR.DOOR SKIN(R & L) TROLLEY:

About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

AGENDA

2PY Unique trolleys

2AZ Unique trolleys

2CV Unique trolleys

Common trolleys for 2PY, 2AZ & 2CV

Model wise trolley identification

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

AGENDA

Checking standards in two stages

For 2PY, 2AZ & 2CV Transportation trolleys:

Stage- I: Observing the trolleys in dismantled condition while the parts of the trolley are not attached to it

a) Must not be any welding defects

b) Should not be any bending

c) Must not be any sharp edges or corners in the trolley

d) Presence of PVC pipe, EVA sheet, PU sheet, Absorbers, Style foam, cable tie, superlon tube is must in the trolley

f) Any partition or separating or supporting bracket used in the trolley, must be equally spaced

continued….

Stage- II: Observing the trolleys in assembled condition while the parts of the trolley are attached to it but the press parts are not packed in the trolley

All the welding joints should be checked in assembled condition, that whether joints are welded properly or not.There should not be dust or rust on the part rest area in the trolley.Wheels of the trolley should move at ease, very freely.It must be ensured that Toeing bar & Toeing hook are available in proper way in the trolley.In each of the assembled trolley, none of the accessories should be in broken condition.Trolley, in which wire mesh is used, must be in a uniform manner. It must not be in ragged condition.Locking arrangement available in each trolley must be easily operable.

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

AGENDA

Checking standards at 3rd stage

2CV PANEL RR. INSIDE TROLLEY (L & R)

1

2

34

5

6

1) SIDE LOCKING BAR

2) PART GUIDE ROD

3) DUMMY PART (right)

4) PART RESTING FRAME

5) FLAT SUPPORTING GAUGE

6) DUMMY PART (left)

continued….

Packed RR. Inside Trolley

PART GUIDE ROD MUST BE SUPPORTING THE PART IN PROPER WAY WHILE BEING WELDED

PART MUST BE SUPPORTED TIGHTLY WITH FOAM

LASHING BELT MUST CLAMPED TIGHT TO FIX FOAM WITH THE PART

SIDE LOCKING BAR HINGED TIGHTLY WITH THE LOCK PIN PROVIDED

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

AGENDA

Any deviation found in the trolley, from the above checking standards is not permissible & packing of the parts is not allowed in that trolley

At the time of unloading the trolleys from the trucks, which comes back from GNU, if any deviation from the standard checking items are found in the trolley, it’s considered as NG (not good) trolley

Routine repairing and maintenance activities are followed upon the NG trolleys

Findings

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

AGENDA

Before finalizing the dispatch, if these standards are followed, chances of damages like scratches, dents, flange bend on the parts can be depleted to a significant level

Result

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings ResultObservation Conclusion References

AGENDA

HONDA is the synonym of qualityPraiseworthy management policies towards the

employees which enable them to think, learn, evaluate & analyze problems while working with complete freedom without any domination

Admirable healthy culture is prevalent throughout the organization

Proper consumables are allocated to every HONDA employees to ensure safety while working

Observation

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings ResultObservation Conclusion References

AGENDA

Usage of spring lock system over the side locking bar, must be incorporated in each trolley

Total trolley making cost can be reduced to some extent while depleting the usage of cable tie, wire locking & reinforcement sheet attached to the trolley

Conclusion

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings ResultObservation Conclusion References

AGENDA

http://www.hondacarindia.com/http://docs.google.com/viewer?

a=v&q=cache:b5XZZyFuylYJ:www.autonews.com

http://www.siamindia.com/scripts/market-share.aspx

References

“Only One Life, Why Not Get Thrilled”