project
TRANSCRIPT
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 2
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]
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 3
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 4
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to Maintenance Department
Project
Bibliography
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 5
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 6
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 7
Time Line of Honda and Its
History
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 8
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 9
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 10
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 11
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
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7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 2
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]
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 3
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 4
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to Maintenance Department
Project
Bibliography
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 5
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 6
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 7
Time Line of Honda and Its
History
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 8
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 9
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 10
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 11
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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]
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 4
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to Maintenance Department
Project
Bibliography
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 5
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 6
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 7
Time Line of Honda and Its
History
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 8
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 9
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 10
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 11
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
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3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
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Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
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7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 4
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to Maintenance Department
Project
Bibliography
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 5
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 6
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 7
Time Line of Honda and Its
History
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 8
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 9
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 10
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 11
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to Maintenance Department
Project
Bibliography
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 5
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 6
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
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Time Line of Honda and Its
History
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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
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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
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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
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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
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3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
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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
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Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
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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
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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
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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
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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
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OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
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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
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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
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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-
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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
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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
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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
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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
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7ORGANISATION STRUCTURE
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
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Pan Cover
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 6
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 7
Time Line of Honda and Its
History
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 8
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 9
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 10
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 11
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 7
Time Line of Honda and Its
History
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 8
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 9
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 10
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 11
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Time Line of Honda and Its
History
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 8
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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
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12 Hondarsquos Products Around The World
Jet Engine
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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
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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
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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
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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
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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
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3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
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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
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Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
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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
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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
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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
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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
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OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
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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
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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
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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-
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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
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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
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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
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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
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7ORGANISATION STRUCTURE
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
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Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 9
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 10
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 11
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 10
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 11
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 11
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
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3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
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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
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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 12
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
12 Hondarsquos Products Around The World
Jet Engine
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 13
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 14
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 15
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 16
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 17
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
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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
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OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
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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
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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
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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-
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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
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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
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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
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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
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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
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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
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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
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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
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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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 19
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 20
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
4 FLOW CHART
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 21
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 22
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 23
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
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Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 25
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
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Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 26
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 27
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 28
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-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 29
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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-
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
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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
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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
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7ORGANISATION STRUCTURE
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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
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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
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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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 30
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 31
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 33
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 32
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
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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 34
7ORGANISATION STRUCTURE
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 35
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 36
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 37
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
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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
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7ORGANISATION STRUCTURE
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
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7ORGANISATION STRUCTURE
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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7ORGANISATION STRUCTURE
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
7ORGANISATION STRUCTURE
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
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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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
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17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
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21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
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- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
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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
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Pan Cover
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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
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Preventive Maintenance Procedure
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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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 38
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 39
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
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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
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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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
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Pan Cover
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
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7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
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25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 40
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
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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
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ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
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Pan Cover
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
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31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
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37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 41
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 42
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 43
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 44
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 45
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
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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
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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
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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
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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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 46
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 47
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 48
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 49
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 50
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 51
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
ED Collector
ED collector is used to collect current during ED process and transmits it through the cables to the body parts
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 52
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 53
Pan Cover
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 54
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 55
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 56
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Preventive Maintenance Procedure
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 57
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
Time Taken approx 2 min
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
Time Taken approx 2 min
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)
Time Taken approx 10 min
Procedure Open the bolts with the specified tool which fasten the post with the big sprocket
5) CLEAN THE ARM
Tool Used Scrapper
Time Taken approx 5 min
Procedure Clean the arm of the carrier by removing the paint deposited with a scrapper
6) CLEAN THE BIG SPROCKET
Tool Used Scrapper
Time Taken approx 12 min
Procedure Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 58
7) CLEAN THE BIG SPROCKET DOGS
Tool Used Scrapper
Time Taken approx 5 min
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)
Time Taken approx 5 min
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
Time Taken approx 1 min
Procedure Lift the big sprocket from spindle shaft panel
10) OPEN THE SPLIT PIN OF ARM ROLLER
Tool Used Long nose plier
Time Taken approx 2 min
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
Tool Used Long nose plier
Time Taken approx 2 min
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
Time Taken approx 2 min
Procedure Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 59
17) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 5 min
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
Time Taken approx 5 min
Procedure Insert new split pins and cross them up
13) OPEN THE CASTLE NUT OF ARM ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
14) OPEN THE CASTLE NUT OF LOCKING ROLLER
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
15) OPEN THE CASTLE NUT OF ARM PIN
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
Time Taken approx 2 min
Procedure Open the castle nut by giving support from the D spanner
16) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL
Tool Used Long Nose Pliers
Time Taken approx 5 min
Procedure Straighten up the crossed pins and pull them out by using long nose pliers
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 60
21) CLEAN THE FRONT TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
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
Time Taken approx 15 min
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
Time Taken approx 2 min
Procedure Insert the new pin by hammering it with a hammer
24) CLEAN THE ARM PIN
Tool Used Amery Paper
Time Taken approx 2 min
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
Time Taken approx 3 min
Procedure Clean the small sprocket of the carrier by using a scrapper
20) CLEAN THE BACK TROLLEY
Tool Used Scrapper
Time Taken approx 10 min
Procedure Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 61
25) GREASE THE LARGE ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
26) GREASE THE SMALL ROLLER
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
27) GREASE THE PIN HOLES OF ARM
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the holes of arm with high temperature grease
28) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
29) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 20-22 mm)
(size 30-32 mm)
Long nose pliers
Time Taken approx 10 min
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
Tool Used Ring spanner (size 18-19 mm)
D spanner (size 24-27 mm)
Time Taken approx 4 min
Procedure The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 62
31) GREASE THE SPINDLE SHAFT
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the spindle shaft with high temperature grease
32) GREASE THE BIG SPROCKET HOLE
Tool Used High Temp Grease
Time Taken approx 1 min
Procedure Grease the roller with high temperature grease
33) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT
Tool Used
Time Taken approx 1 min
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
Time Taken approx 2 min
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)
Time Taken approx 1 min
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
Time Taken approx 3 min
Procedure Collect the old lubrication oil in a bin with proper handling
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 63
37) REASSEMBLE GRUB SCREW
Tool Used Allen Wrench (size 6 mm)
Time Taken approx 4 min
Procedure The grub screw is fitted back in the gear box using Allen wrench
38) OPEN THE GEAR BOX OIL CAP
Tool Used
Time Taken approx 2 min
Procedure Open the gear box oil cap
39) POUR NEW OIL IN GEAR BOX
Tool Used Mug and Grade 220 oil
Time Taken approx 2 min
Procedure Pour new lubrication oil in the gear box
40) GREASE THE FLANGE BEARING OF SMALL SPROCKET
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
41) GREASE ROLLER BEARING OF GUIDE ROLLER
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
42) GREASE THE TROLLEY BEARING
Tool Used High Temp Grease
Time Taken approx1 min
Procedure Grease the bearing with high temperature grease
43) GREASE THE ROLLER BEARING
Tool Used High Temp Grease
Time Taken approx1 min
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
Time Taken approx1 min
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 64
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 65
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 66
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 67
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 68
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 69
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
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
NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 70
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
- Utility
- K K CHAUHAN
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-